Manual TD GDS
Manual TD GDS
Training Manual
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G D M 5 0 0 / 6 5 0 T O P D R I V E
Table of Contents
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G D M 650 / T O P D R I V E
1
Section
T he GDM (Global Drilling Machine) line of Top Drives solves many of the problems that
reduce the performance and reliability of conventional Top Drive models. The GDM line of
Top Drives offers a simple, robust mechanical design that minimizes failure points, provides
improved torque and RPM for increased performance, and allows easier access to maintenance
zones.
General
Contents
Using this Manual......................................................5
Top Drive Specifications..........................................6
Torque Data................................................................9
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G D M 5 6 5 0 T O P D R I V E
Section Description
Contains an outline of this manual and defines precautionary terms; also describes
1 – General
Top Drive specifications, and how to find information.
2 – Operations Instructions for operating the Top Drive Console and HMI Touch Screens.
3 – Maintenance and
Describes maintenance and inspection requirements and routines.
Inspection
Contains assembly drawings and electrical, gear lube, and hydraulic schematics.
4 – Drawings and
Parts shown in drawings are outlined in their respectively allocated Bills of
Parts
Material.
CAUTION – This term refers to any technique or procedure which, if not properly adhered to,
poses the potential to cause damage to parts or equipment—up to and including catastrophic
failure.
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G D M 6 5 0 T O P D R I V E
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G D M 6 5 0 T O P D R I V E
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G D M 6 5 0 T O P D R I V E
Torque Data
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G D M 650 / T O P D R I V E
Section
Operations
2
Contents
Top Drive Console..............................................................11
Figure 1-Top Drive Console
LED Indicator Lights (L1-L4)
Alarm Reset (PB1)
Top Drive Lockout (PB2)
Handler Bypass (PB3)
E-Stop (PB4)
Backup Wrench/BUW (PB5)
Hydraulic Power Unit Selection Switch (SW1)
Brake Switch (SW2)
Top Drive Enable Selection Switch (SW3)
Stand Jump Switch (SW4)
IBOP Switch (SW5)
Top Drive Mode Selection Switch (SW6)
Limit Selection Switch (SW7)
Limit Adjustment Switch (SW8)
Top Drive Handler Joystick (JS1).......................................19
Figure 2 – Top Drive Handler Joystick (JS1)
Link Tilt Joystick (JS2).......................................................19
Figure 3 – Link Tilt Joystick (JS2)
Top Drive Motor Control Joystick (JS3) ..........................20
Figure 4 – Top Drive Motor Control Joystick (JS3)
Top Drive Console Analog Gauges...................................20
Directional Controls ..........................................................21
Drill Mode
Torque Mode
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G D M 650 / T O P D R I V E
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G D M 650 / T O P D R I V E
Following is a description of the Top Drive Console and its functional controls:
Green lamp illuminates when TD Enable switch is placed from OFF to the
Drill Enabled (L1)
DRILL position.
HPU Alarm (L2) Amber lamp illuminates when the HPU fluid level is low.
Lube Oil Alarm (L3) Red lamp illuminates when gear oil pressure drops below acceptable limit.
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G D M 650 / T O P D R I V E
Indicates that an alarm exists. PB1 is a spring-return, red translucent push button
Illuminated over an indicator lamp. Depressing the button will reset Top Drive alarms to
determine whether any faults still exist.
Indicates that there are no current Top Drive alarms. This can also be verified in
Extinguished the Active Status Summary block at the top right-hand corner of any HMI screen.
PB1 is also a tool that the Top Drive Console operator should use before
assuming ownership of the Top Drive. Push and hold the button for five
CAUTION seconds to test all indicator lamps and gauges for functionality. Failure to do so
may result in—for example—overlooking an inoperative lamp bulb that would
otherwise warn of potential equipment damage.
Shuts off all electrical power to the Top Drive and disables all Top Drive
Depressed functions. PB2 is a red spring-return push button with a mechanical depression
device that allows a physical lock to be inserted so that button cannot be released.
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G D M 650 / T O P D R I V E
E-Stop (PB4)
PB4 is a 2-position (in/out) translucent red button with a steel shroud. When
depressed, the button illuminates and shuts off all electrical power to the Top
Drive—disabling all Top Drive functions by:
Depressed
► Tripping the VFD breaker on GDS supplied VFD units
► Tripping the feeder breaker at the GDP panel
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G D M 650 / T O P D R I V E
PB5 is a black spring-return push button, activated when the Mode Select switch
Depressed on the Top Drive console is in the TORQUE position. Push and hold PB5 to
engage the BUW clamp.
Off De-energizes HPU 1 and 2 motor starters, removing available hydraulic power.
Only one HPU motor will run at a time. If HPU 2 is selected while HPU 1 is
Note running, HPU 1 will first shutdown before HPU 2 starts. Either HPU may run
continuously.
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G D M 650 / T O P D R I V E
Brakes will remain released during Torque and Spin operations; Brake
Note position is indicated on the HMI as ON or OFF in the Drill, Trip, and
Remote Operation screens.
The HMI’s Drill, Trip, and Remote Operation screens will indicate that
Trip Top Drive tripping is enabled; allows the operator to actuate all
hydraulic functions. Enables tripping and hydraulic functions.
The HMI’s Drill, Trip, and Remote Operation screens will indicate that
Top Drive drilling is enabled; allows the operator to utilize Drilling and
Drill Torque functions. Lube Pump motor will start. Top Drive Status
display will indicate Top Drive Enable Faulted if all drill enable
conditions are not met. Enables all Console functions.
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G D M 650 / T O P D R I V E
SW4 is a black 2-position maintained switch (OFF / ON) with a white position-
Off indicating stripe across the knob. In the OFF position, the Stand Jump function is
disabled.
Valve status is indicated as OPEN or CLOSED on the HMI Drill and Trip
screens. Indicated valve status is based on both the IBOP switch position and the
Note HPU status. There is no positive feedback on actual valve status and visual
verification of valve position is recommended.
WARNING Do not start Mud Pumps with the IBOP in CLOSED position.
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While holding the Limit Selection switch (SW7) in either RPM or TORQUE
Increase mode, the operator can toggle or ‘bump’ SW8 between neutral center and the INC
position repeatedly to increase desired speed or torque limits by increments of 10.
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The Top Drive Console RPM gauge may be one of two types:
► Traditional analog gauge, RPM from 0 – 250 in two-revolution increments,
with large tic marks in 10 RPM intervals and numerical values printed in
Tachometer increments of 20.
► Optimized analog gauge with backlit scale and a small digital display window,
RPM from 0 – 250 in five-revolution increments, with large tic marks and
numerical values in increments of 25.
The Top Drive Console Torque gauge may be one of two types:
► Traditional analog gauge, torque range from 0 – 100,000 Ft. Lbs. in 1,000#
Torque Meter increments, with bold tic marks in 5,000# intervals and numerical values printed
in increments of 10,000.
► Optimized analog gauge with backlit scale and a small digital display window,
torque range from 0 – 100,000 Ft. Lbs. in 1,000# increments, with large tic marks
in 5,000# intervals and numerical values displayed in increments of 10,000.
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GDM 650 TON TOP DRIVE
Directional Controls
Drill Mode
Bumping the joystick UP will increase speed in increments of 1 RPM. Holding the
joystick in the upward position will increase speed until the maximum RPM limit is
reached.
Up
(Increase Releasing the joystick will not decrease speed. If the joystick is released, the speed
Speed) will be maintained at the value it was at before it was released.
With the Top Drive mode in Drill Reverse, the operation will be the same, but
rotation will be in the Reverse direction and limited to a maximum of 100 RPM.
Bumping the joystick DOWN will decrease speed in increments of 1 RPM. Holding
the joystick in the downward position will decrease speed until Zero speed is
reached.
Down
(Decrease If the joystick is released, the speed will be maintained at the value it was at before it
Speed) was released.
With the Top Drive mode in Drill Reverse, the operation will be the same, but
rotation will be in the reverse (counterclockwise) direction.
Moving the joystick RIGHT will enter the preset speed value (preset value is
Right displayed and modified on HMI) into the speed reference. The Top Drive speed
(Preset will ramp up or down, as applicable, until its preset value is achieved.
Speed)
When the joystick is released, speed will be maintained at its preset value.
Left Toggling the joystick LEFT will ramp the Top Drive speed down to Zero speed.
(Zero Operation is the same in both forward and reverse.
Speed)
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GDM6 50 TON TOP DRIVE
Torque Mode
Make up should only be used once the joint is shouldered up with Spin In first.
Holding the Top Drive Motor Control Joystick UP (Make Up) with DRILL
Up enabled (SW3) and TORQUE mode selected (SW6) will rotate the Top Drive
(Make Up) forward at a maximum 5 RPM as long as you are holding the joystick UP.
The torque will be limited to the set Make Up limit, which is adjusted on the HMI
or console.
Proper sequence should be: (1) Hold the joystick DOWN (Break Out) until the
joint breaks, and then (2) move the joystick right (Spin Out or Spin Out Maintain)
until the joint has spun out.
Holding the Top Drive Motor Control Joystick DOWN (Breakout) with DRILL
Down enabled (SW3) and TORQUE mode selected (SW6) will rotate the Top Drive
(Break Out) reverse at a maximum 5 RPM as long as you are holding the joystick .
The torque will be limited to 80,000 Ft. Lbs.
There is no preset value available for Break Out Torque. The torque will continue
to ramp up until the connection breaks or the capacity of the equipment has
reached its limit.
Holding the joystick RIGHT (Spin Out) with DRILL enabled (SW3) and
TORQUE mode selected (SW6) will rotate the Top Drive at the preset spin speed
in the reverse direction (Spin Speed value is displayed and modified on HMI or
console).
Right When the joystick is released, the Top Drive will stop rotating.
(Spin Out)
Tap the joystick twice to the RIGHT within 2 seconds to maintain Spin Out. Top
Drive will be in Spin Out Maintain when joystick is released. Move joystick to
opposite position (spin in) to stop spin maintain rotation and allow the shaft to
coast to a stop.
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GDM6 50 TON TOP DRIVE
Upon power up of the system, the Main Screen (see Figure 5) appears first.
In the top right-hand of the screen, the date and time appear under the GDS logo, and an active
status summary is highlighted in green. Any active alarm lock-outs or interlocks would display here,
highlighted in red. This feature appears on every screen.
The Main Screen serves as a dashboard to the functional operation and troubleshooting of the Top
Drive.
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GDM6 50 TON TOP DRIVE
The Hydraulic Power Unit (HPU) supplies hydraulic pressure to the Top Drive.
The HPU has two pumps; only one pump runs at any given time.
Either pump can be run continuously or on-demand (as hydraulic power is needed).
HPU 1 will stop when the button is toggled. If HPU 1 is running and HPU
HPU 1 OFF 2 is started, HPU 1 will shut off first.
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GDM6 50 TON TOP DRIVE
Additional Features
Starts a 30-second timer after button has been depressed for 2 seconds. This
30- second window will allow TORQUE mode functions to be permitted,
even if the system cannot determine that the Handler is positively locked.
Normally this feature would only be used in the event of a Handler Lock
sensor failure. The Handler Lock HMI Fault indicator will turn on for 30
Bypass Pipe seconds. Normal Handler Lock operation will resume after 30 seconds. Use
Handler Lock of the Bypass is logged in case of incident.
WARNING: USE EXTREME CAUTION WHEN USING THIS
FEATURE TO ENSURE THAT THE HANDLER IS
PHYSICALLY LOCKED, OR DAMAGE, SEVERE INJURY OR
DEATH MAY RESULT.
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GDM6 50 TON TOP DRIVE
This feature is normally used when the Top Drive is stalled. Press the
Torque Ramp Down push button to unwind the torque.
When you first press this push button, the speed will be reduced to 15 RPM
and the torque will unwind (ramp down) to zero as long as the button
Torque Ramp remains pushed.
Down
When you release the push button, the torque will remain at the current
level.
You have two options now: 1) you can zero the speed reference and begin
normal drilling, or 2) you can press the Torque Restore push button.
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GDM6 50 TON TOP DRIVE
This is intended to allow the driller to automatically move the Pipe Handler
to any one of four preset Pipe Handler positions, depending on which
positions are activated.
Automatic Mode can be turned on/off from the Drill, Trip, and Remote
Operation screens.
The Automatic Pipe Handler can be operated from the Drill, Trip, and
Remote Operation screens as well as from the Pipe Handler Joystick.
Set points can only be changed from the Trip screen, but all positions can
be activated or de-activated from the Drill or Trip screens.
Auto Mode
At 0, the Elevators should be pointing directly at the racking board. At
180, the Pipe Handler will be in Drill mode (Elevator handles pointed
towards the Drawworks).
To set the Pipe Handler position, use the joystick with the Pipe Handler in
Manual mode. Rotate the Pipe Handler to the Trip position (Elevators
pointed directly at the racking board) and press and hold the Zero PH
position PB for 2 seconds.
See the Pipe Handler Help Screen on the HMI for a detailed description of
each PB and display.
When the Automatic Pipe Handler is in Automatic mode, the Joystick Pipe
Joystick Operation Handler Unlock push button and LEFT and Right joystick movements
work the same as the HMI LEFT and RIGHT push buttons.
When the Automatic Pipe Handler is in Automatic mode, the Remote Pipe
Remote Operation Handler Unlock push button and LEFT and RIGHT Joystick push buttons
work the same as the HMI LEFT and RIGHT push buttons.
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GDM6 50 TON TOP DRIVE
Activate
Activating Remote Motor Control will enable the HMI Remote Operation and
Remote Motor
disable the joystick from functioning.
Joystick
Toggling the Top Drive Motor Control Joystick Drill Reverse push button will
toggle the Top Drive Motor direction between Forward and Reverse; this button
PB1 is active only if the Top Drive Mode is selected to DRILL mode.
(Black -Drill
Reverse) The Top Drive Mode Indication on the HMI - Drill, Trip, and Remote
Operation Screens will indicate Top Drive In DRILL mode or Top Drive in
DRILL REVERSE.
Toggling the Top Drive Remote Motor Control BUW Close push button will
activate the BUW to Close. To lock the BUW, depress twice within one second.
PB2
(Red -BUW
Once the BUW is Closed, perform Torque function. When torque ft-lbs reaches
Close)
0, manually release BUW by depressing button again twice within one second.
Toggling the Top Drive Remote Motor Control Spin Maintain push button with
DRILL enabled and selected to TORQUE mode will give you a 2 second
PB3
window to toggle the joystick left or right (Spin In or Spin Out).
(Yellow -Spin
Maintain)
Spin In or Spin Out will be latched on to rotate the Top Drive in SPIN Mode
indefinitely until the joystick is moved in the opposite direction again.
Toggling the Top Drive Motor Control Joystick Torque/Drill push button will
toggle the Top Drive Motor Control Joystick Between DRILL and TORQUE
PB4 modes.
(Green -
Torque/Drill) This will change the functionality of the joystick. The Top Drive Mode
Indication on the HMI Drill, Trip, and Remote Operation Screens will indicate
Top Drive In TORQUE mode or Top Drive in DRILL mode.
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GDM6 50 TON TOP DRIVE
Drill Mode
Pressing the Joystick UP will increase speed, as long as you keep the joystick button
pressed until maximum speed is reached.
Up
If the Joystick UP push button is released at any time, the speed will be maintained at
(Increase
the value it was at prior to release.
Speed)
With the Top Drive Mode in DRILL REVERSE, the operation will be the same but
rotation will be in the Reverse direction and limited to a maximum of 100 RPM.
Pressing the Joystick DOWN push button will decrease speed, as long as you keep the
joystick button pressed until Zero speed is reached.
Down
If the joystick is released at any time, the speed will be maintained at the value it was at
(Decrease
prior to release.
Speed)
With the Top Drive Mode in DRILL REVERSE, the operation will be the same but
rotation will be in the Reverse direction.
Pressing the Joystick RIGHT push button will enter the preset speed value into the
speed reference, and the Top Drive will ramp up speed until the preset value is
achieved.
Right
(Preset Speed)
If the preset value is lower than the actual speed when the Joystick RIGHT push
button is pressed to the right, the speed will ramp down to the preset value.
When the joystick is released, the speed will be maintained at the preset value.
Left Toggling the Joystick LEFT push button will ramp the Top Drive speed down to Zero
(Zero Speed) speed.
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GDM6 50 TON TOP DRIVE
Torque Mode
Make Up should only be used once the joint is shouldered up with Spin in first.
Holding the Top Drive Motor Control Joystick UP PB (Make Up) with DRILL
Up enabled and selected to TORQUE mode will rotate the Top Drive forward at a
(Make Up) maximum 5 RPM as long as you are holding the Joystick UP PB.
The torque will be limited to the set Make Up limit, which is adjusted on the HMI
and Console Gauge.
Proper sequence should be: Break Out until the joint breaks, press the Joystick
RIGHT PB (Spin Out or Spin Out Maintain) until the joint has spun out.
Down Holding the Top Drive Motor Control Joystick DOWN PB (Breakout) with
(Breakout) DRILL Enabled and selected to TORQUE mode will rotate the Top Drive
Reverse at the Spin Speed as long as you are holding the joystick DOWN.
The torque will be limited to the maximum connection torque listed in the specs.
Holding the Top Drive Motor Control Joystick RIGHT PB (Spin Out) with
DRILL enabled and selected to TORQUE mode will rotate the Top Drive at the
Preset Spin Speed in the reverse direction (Spin speed value is displayed and
Left modified on HMI).
(Spin In)
When the Joystick PB is released, the Top Drive will stop rotating. If the Spin
Maintain push button is toggled first, and Spin Out is toggled within 2 seconds, the
Top Drive will be in Spin Out Maintain when Joystick PB is released.
Holding the Top Drive Motor Control Joystick LEFT PB (Spin in) with DRILL
enabled and selected to TORQUE mode will rotate the Top Drive at the Preset
Spin Speed in the forward direction (Spin speed value is displayed and modified on
Right HMI).
(Spin Out)
When the Joystick PB is released, the Top Drive will stop rotating. If the Spin
Maintain push button is toggled first, and Spin In is toggled within 2 seconds, the
Top Drive will be in Spin In Maintain when Joystick PB is released.
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GDM6 50 TON TOP DRIVE
Activate
Activating Remote Pipe Handler will enable the HMI Remote Operation and
Remote Pipe
disable the joystick from functioning.
Handler
Toggling the Top Drive Remote Pipe Handler Pipe Handler Unlock push button will
activate the Pipe Handler Lock to UNLOCK.
PB3
(Yellow -
The Pipe Handler will stay unlocked for 3 seconds, unless the Pipe Handler is
Pipe Handler
rotated, in which case the Pipe Handler will remain unlocked as long as the
Unlock)
Handler is rotated.
When rotation has stopped, the Handler will automatically lock after 3 seconds.
Toggling the Top Drive Remote Pipe Handler Link Tilt Float push button will
PB4 activate the Link Tilt Cylinders to FLOAT if in Maintain, and MAINTAIN if in
(Green - Link Float.
Tilt Float)
Activating either EXTEND or RETRACT will unlatch Float.
UP
Pressing the Top Drive Remote Pipe Handler in the UP direction will activate the
(Link Tilt
Link Tilt Cylinders to EXTEND.
Extend)
Down
Pressing the Top Drive Remote Pipe Handler in the DOWN direction will activate
(Link Tilt
the Link Tilt Cylinders to RETRACT.
Retract
Left
(Pipe Toggle the Pipe Handler Unlock (PB3) first. Pressing the Top Drive Remote Pipe
Handler Handler in the LEFT direction will move the Pipe Handler in the Forward
Rotate (clockwise) direction.
Forward)
Right
(Pipe Toggle the Pipe Handler Unlock (PB3) first. Pressing the Top Drive Remote Pipe
Handler Handler in the RIGHT direction will move the Pipe Handler in the Reverse
Rotate (counter clockwise) direction.
Reverse)
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GDM650 TON TOP DRIVE
Switches
Under normal conditions, the VFD uses encoder feedback for better torque
control. However, the Top Drive can be operating in Encoder Bypass mode,
in which the encoder feedback is ignored by the VFD.
At power up, the Bypass is deactivated. The Top Drive must be in OFF
position in order to switch between the two modes.
Encoder Bypass
The button must be held for 2 seconds before it will become functional.
WARNING: When in Bypass mode, the Top Drive torque will not be
accurate. If the Top Drive stalls while drilling, unexpected results may
occur.
Push Buttons
This feature is used for testing the third party RPM and Torque outputs.
In order to utilize this mode, the Top Drive must be in the OFF position.
Meter Test Mode When activated, whatever is entered in the Drill Limit will display on the
Torque Meter and be sent to the third party PLC Torque Analog Output.
Whatever is entered in the Drill Speed Preset will display on the RPM Meter
and be sent to the third party PLC RPM Analog Output.
Blower Restart If the Blower Motor trips while in in Auto mode, it can be restarted by this
push button, provided the OL has reset.
Lube Pump
If the Lube Pump Motor trips while in Auto mode, it can be restarted by this
Restart push button, provided the OL has reset.
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G D M 650 / T O P D R I V E
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NOTE:
See Maintenance
Checklist on Page
3-17
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GDM500650 Rev. 2 35
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GDM500650 Rev. 2 36
G D M 650 / T O P DRIVE
Maintenance
Lubrication
Hydraulic Oil
Hydraulic oil that is of exceptional quality is vital to ensure acceptable performance of the GDM
500/650 Top Drive and promote long life of hydraulic system components.
Satisfactory results will be achieved in normal operating conditions when the oil in use has a
viscosity index of 100 or greater. A high viscosity index oil product will reduce cold-start issues and
minimize warm-up time. A high viscosity index will also minimize changes to viscosity that appears
with changes in temperature. Cold weather start-up viscosity should not exceed a maximum of 5000
SUS with a pour point of at least 20°F lower than the minimum ambient temperature.
It is recommended that anti-wear type hydraulic oils be utilized. These oils are generally developed
and evaluated on the basis of pump wear tests, such as ASTM-D2882. They offer superior
protection against pump and motor wear, provide resistance to emulsification, and offer corrosion
protection.
Ambient Temperature
ISO Grade of Oil
(°C)
-45° to -15° 15
-20° to 15° 22
10° to 35° 32
20° to 45° 46
25° to 55° 68
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G D M 650 / T O P DRIVE
Filtration
Filtration is the key to overall purity of the hydraulic oil and helps extend the life of components.
To ensure optimal operation of the hydraulic system, maintain a minimum cleanliness level of:
9 To NAS 1638
6 To SAE
18/15 to ISO/DIS 4406
Check the bypass indicators daily. If indicator is RED, change the filter element.
The hydraulic element should be changed every 6 months. The lube oil element should be changed
during each oil change.
GDM500650 Rev. 2 38
G D M 650 / T O P DRIVE
Grease
Use multi-purpose lithium complex grease complying with N.L.G.I. classification No.1 or No.2 at
the following:
No. of
Location Application Frequency
Fittings
Washpipe 1 To excess Every 12 hours
Elevator Tilt Plate
8 To excess Daily
Pins
Load Collar 1 10 pumps per fitting Weekly
Back-up Wrench
2 10 pumps per fitting Weekly
Grabber Cylinder
Slewing Gear 2 10 pumps per fitting Daily
3 to 4 pumps per
Actuator 4 Every 12 hours
fitting
Back Up Wrench
1 To excess Weekly
Pin
Refer to the Top Drive Maintenance Diagram on page 3-2 for the locations of grease points.
Motor
GE Motor See manufacturer’s documentation.
Use manufacturer recommended
Motor Coupling Kop-Flex High Performance Gear Coupling Grease
Frequency: 3-years
Motor Coupling Grease Procedure
Remove 2 set screws – Install grease zerk in one,
Pump grease until grease exits open set screw hole,
If grease appears dirty – Keep pumping until clean grease appears,
Remove grease zerk and reinstall 2 set screws.
GDM500650 Rev. 2 39
G D M 650 / T O P DRIVE
Ambient
A.G.M.A
Temperature GDS Top Drive Gear Oil
Number
(°C)
Comparable products are available in the USA from the Exxon Corporation.
Oils meeting AGMA specifications and grades shown in the above chart could be used in the GDM
500/650 Top Drive.
For approval of specific oil, contact GDS Engineering Department.
Oil should be changed at planned intervals of 90 days.
Oil should never be permitted to become visibly contaminated with mud or water, which rapidly
causes bearing failure. If there is any doubt about the oil quality, it should be changed even if a
change is not due according to the maintenance schedule.
GDM500650 Rev. 2 40
G D M 650 / T O P DRIVE
The GDM 500/650 Top Drive Gearbox has a gear oil capacity of approximately 20 US Gallons.
When operating a GDM 500/650 Top Drive in humid climates, or when corrosive drilling fluids are
in use (e.g., high brine content), ensure that the lube oil is checked on a weekly basis for water
contamination. Samples should also be taken for a visual confirmation.
The gearbox can be drained by removing the drain plug in the bottom of the gearbox. The magnetic
plug is located in the Y-strainer to catch small metallic wear particles. A substantial accumulation of
such particles is often an indicator of an impending bearing failure. There is also a hose that drains
the remaining oil from the lower bearing. This will remove any contamination from the bearing.
Check the breather (located on the gearbox) on a daily basis to ensure that it is not plugged; replace
the breather as required. Seal damage may occur if pressure is permitted to build up in the gearbox.
Figure 9 – Y Strainer
Figure 10 - Breather
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G D M 650 / T O P DRIVE
Inspection
Recommended Inspection Program
General Inspection
Pressure test the circulating path from the Lower Well Control Valve (LWCV) to 200psi to detect
obvious leaks before testing at rated pressure. The test intervals may be specified by regulatory
authorities, operator policies or contractor policies.
Monthly Inspection
1. Remove the LWCV and inspect the connections (including the quill rotary shoulder pin
connection) using magnetic particle techniques according to API RP7G.
2. Visually inspect the following for hoisting integrity:
Bail Adapter
Block Interface Beam
Block Interface Pins
Gearbox
Side Load Plates
Load Pins
Load Collar
Quill
Landing Collar
Elevator links
Elevators (if applicable)
3. Visually check the welds on the Top Drive frame, guard, mounts and supports for cracks or
damage.
4. Visually check the Top Drive unit for loose bolts.
5. Visually inspect the electrical cables on the Top Drive Unit.
NOTE: Items 2, 3, 4, and 5 from the above list should also be checked after first week of
operation on a new Top Drive installation.
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G D M 650 / T O P DRIVE
1. Visually check the complete track for any damage (i.e. bending or cracking).
2. Visually check all welds on the track system. If suspicious cracks are found, a full Dry
Magnetic Particle Inspection must be performed on all welds.
3. Check for loose bolts and mountings for the blower, mast junction box, cable trays and
hydraulic lines.
4. Visually check the service loop and service supports/mounts in the mast.
Check the pre-load in the main Top Drive bearings and re-shim, if necessary, according to
the schedule and instructions in this manual.
Check the gap between the brake disk and the caliper. The disc should be centered in the
caliper.
2. Inspect all of the following load path components using magnetic particle methods, as
specified on the Load Path Inspection Drawings at the end of this section:
GDM500650 Rev. 2 43
G D M 650 / T O P DRIVE
Load Collar
Quill
Landing Collar (2)
Landing Collar Retainer
3. Inspect all bearings, seals, seal running surfaces, gears and splines. Refurbish or replace as
necessary.
4. Remove the mudline and inspect the wall thickness using ultrasonic methods; check for
internal wear. Contact GDS for wall thickness tolerances.
5. Remove the motor and send to a qualified repair shop for inspection and repair, if necessary.
Check all safety wires on bolts for damage. If broken wires are discovered, ensure bolts are
tight and re-wire / replace damaged wires. Be sure to torque all capscrews to their
recommended torque values.
Check all external bolts that are not wired for tightness.
Ensure that all safety cables are attached properly and securely.
Visually check the welds on the Top Drive guard and frame, blower frame and torque guide
system.
If the brake disk is approximately in the center of the caliper, then this may be an
indication that the armature did not drop.
If the brake disk is rubbing on the bottom of the caliper, this may be an indication
that the armature did drop.
44
G D M 650 / T O P DRIVE
Wear Limits
The load path components on the GDM 500/650 Top Drive are designed using safety factor
calculations described in API Specification 8C for particular load capacities.
As these components wear, the equipment may be subject to de-rating to sustain the proper API 8C
safety factors.
The following are the wear limits for the load path components:
The nominal load rating is sustained if the wear is less than 5% for all load path components
of the Top Drive, with the exception of the load collar.
The nominal load rating must be reduced by 5% if the wear is between 5% and 10% for all
load path components of the Top Drive, with the exception of the load collar.
The wear limit for the load collar is 10% without the necessity to reduce the nominal load
rating. The load collar load rating must be reduced by 5% if the wear is found to be between
10% and 15%.
GDS engineering must be contacted if the wear is above 10% for all load path components,
and above 15% on the load collar to obtain the correct load rating.
Conduct a Category IV inspection per API RP 8B to determine wear. Contact GDS Engineering
for baseline dimensions.
45
G D M 650 / T O P DRIVE
End play + 0.010 inches = Shim to be added. *Note* preload not to exceed 0.005 inches
End play + 0.010 inches = Shim to be added. *Note* preload not to exceed 0.005 inches
46
G D M 650 / T O P DRIVE
Packing Assembly
Instructions
2. Rotate sleeve 360° and record total indicator reading (TIR) at indicator positions A, B, C.
Recommended Tolerances
Maximum allowable washpipe misalignment after complete assembly = 0.010 inches TIR
47
G D M 650 / T O P DRIVE
In addition to premature wear, dragging brake pads can also cause excessive heat build-up in
the brake compartment.
If the brake pads are dragging, the system may require bleeding to eliminate any trapped air.
See Brake Bleeding Procedure.
1. Activate brakes.
4. Re-tighten bleeder.
48
G D M 650 / T O P DRIVE
Maintenance Checklist
GDM 500/650 Maintenance Checklist
For Week Ending: ________________
49
G D M 650 / T O P DRIVE
50
Section
4
650/850 T O N T O P D R I V E MANUAL REV 0
Rig Up Procedure
Rig Up Procedure
Estimated Weights :
Top Drive Package 50,000 LBS (22,700 KG)
Top Drive with Slide Frame 37,300 LBS (19,900 KG)
Top Section of Track 4,500 LBS (2,040 KG)
Travel Stand 8,600 LBS (3,900 KG)
63
LIFT TOP DRIVE TO DRILL FLOOR. ENSURE ALL LIFTING
EQUIPMENT IS SUITIBLE FOR 50,000 LB (22,700 KG)
WORKING LOAD
BACKUP LINE
SHACKLES
1. WHILE RAISING TOP DRIVE TO FLOOR, USE
BACKUP LINE TO ASSIST IN CONTROLLING TOP
DRIVE FROM HORIZONTAL TO VERTICAL
POSITION.
2. PULL TOP DRIVE PACKAGE INTO POSITION
AND PREPARE TO REMOVE TOP DRIVE FROM
STAND.
1. WITH THE TOP DRIVE PACKAGE UPRIGHT ON
FLOOR, BRING TRAVELING BLOCK TO FLOOR
REMOVE SLINGS.
2. CONNECT TRAVELING BLOCK TO BAIL.
1. PUT A LITTLE TENSION ON TRAVELING
ASSEMBLY AND REMOVE LOWER TOP
DRIVE SHIPPING PINS FROM
TRACK/RUNNER AREA.
2. REMOVE BOLTS FROM SKID TO TRACK
THEN UNBOLT THE TRAVEL STAND GUIDES.
3. WITH UPPER TOP DRIVE SHIPPING PINS
REMAINING, LIFT TOP DRIVE AND TOP
PIECE OF TRACK OUT OF THE TRAVEL/RIG
UP STAND.
1. LIFT TOP DRIVE CLEAR OF THE TRAVEL STAND.
2. REMOVE TRAVEL STAND FROM THE DRILL FLOOR.
NOTES:
• IDENTIFY BOTTOM SECTION AND INSTALL LAST
• TOP TRACK WEIGHT 4,500 LBS (2,040 KG)
• MID TRACK WEIGHT 5,450 LBS (2,470 KG)
• BOTTOM TRACK WEIGHT 4,500 LBS (2,040 KG)
TRACK HOOK
PIVOT PIN
ENGAGE
LOCKING PIN
LOCKING PIN
74
650/850 T O N T O P D R I V E MANUAL REV 0
5A Assembly Drawings
75
G D M 5 0 0 / 6 5 0 T O P D R I V E
5A – Assembly Drawings
Assembly Drawing Index
GDM500650 Rev. 8 76
G D M 5 0 0 / 6 5 0 T O P D R I V E
GDM500650 Rev. 8 77
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GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
GDM500, 6-5/8 SINGLE
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV
B A500373
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 3/25/14 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
24 55 24 18 8 30 18 51 52 56 57 64 12 31 27 73 9 72 15 58
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37
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GDS International
TITLE:
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D D
48
C C
50
50
74
B B
4
43 32
49
GDS International
TITLE:
A GEARBOX ASSY, A
B A500373 01
SCALE: 1:18 WEIGHT: SHEET 3 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
D D
69 34 40 56 33 43 60 21 59 28 29
59
29 28
65 66
36
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43 32
B B
42 44
GDS International
TITLE:
A GEARBOX ASSY, A
B A500373 01
SCALE: 1:12 WEIGHT: SHEET 4 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
45 29 28 54 20 28 29 45
D 76 75 D
60
60
C C
B B
SECTION G-G
59 28 29 28 29 59 SCALE 1 : 12
19 19
GDS International
SECTION F-F TITLE:
A GEARBOX ASSY, A
B A500373 01
SCALE: 1:6 WEIGHT: SHEET 5 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY.
1 M100967 DOWEL PIN, 1/2'' x 2'' LONG 4 46 S101530 O RING, 6 1/4 X 6 1/2 X 1/8, 2- 259, 70 DUROMETER 1
2 M500024 PINION 1 47 S100079 O-RING, 8 3/4 x 9 x 1/8, NITRILE 1
3 M500243 FLANGE, IDLER GEARS, TOP 2 48 S100081 O-RING, 9 x 9 1/4 x 1/8,2-270 70 DUR 2
4 M500240 FLANGE, IDLER GEARS, BOTTOM 2 49 S500003 O-RING, 9.50 X 9.75 X .125, N-70 2
D D
5 M500245 COVER, IDLER GEARS, BOTTOM 2 50 S101439 O-RING,NITRILE,2-278 4
6 M500242 RETAINER, FLANGE, BOTTOM 1 51 S100123 O-RING, 10 1/2 x 11 x 1/4 1
7 A500239 IDLER GEARS ASSY 1 52 S500004 O-RING, 13.5 X 14.0 X .250, N-70 1
8 A500010 QUILL ASSY 1 53 S100129 O-RING, 15 x 15 1/2 x 1/4 1
9 M500305 13" DIA ROUND BAR 1 54 M500295 FLANGE, LUBE PIPE, GDM 500 1
10 M500239 FLINGER, LOWER BEARING, GEARBOX 1 55 M500297 SPACER CAGE SEAL, GEARBOX 1
11 230101.1000 WASHER,LOCK,HI COLLAR 5/8 36 56 A500011 GEARBOX ASSEMBLY MACHINING FINIAL 1
12 M500246 FLANGE, SEAL, PINION, TOP 1 57 S500005 ORING, 70 NITRILE, 2-276 1
13 M500247 FLANGE, PINION, BOTTOM 1 58 M500290 RE-WORK RENOLDS COUPLING, HUB COUPLING ASSY. 1
14 M500248 FLANGE, PINION, TOP 1 59 M500498 FLANGE, SUCTION DRAIN, GDM 500 2
15 M500249 COUPLING, RETAINER 1 60 A500095 KIT, GEARBOX VIEWPORTS, GDM 500 1
C
16 M500254 SPACER, SHAFT, PINION 1 61 M500257 SLEEVE, TAPER 1
C
17 M500255 FLANGE, QUILL, BOTTOM 1 62 026211.1028DH2 CAPSCREW,SOCKET HEAD, 5/8-11UNC X 1.75, DH2 28
18 M500256 SEAL, CAGE, TOP 1 63 M500294 LUBE PIPE GEAR BOX 1
19 S500014 O-RING, 2.406 ID x .139 4 64 026211.1032DH2 CAPSCREW,SOCKET HEAD, 5/8-11UNC X 2.00, DH2 8
20 M500259 FLANGE, FILLER CAP 1 65 220102.0400 WASHER,LOCK,NORDLOCK,1 PAIR 1/4 12
21 M500260 COVER, FLANGE, PINION, BOTTOM 1 66 026211.0412DH CAPSCREW,SOCKET HEAD, 1/4-20UNC X 0.75, DH 12
22 M500262 SHIMS, SET, PINION 1
67 A500272 RETAINER, MOTOR COUPLING ASSEMBLY 1
23 M102888 BEARING, TAPERED ROLLER 130X230X67.75MM 2
68 S101448 SEAL,ROUND EXTRUDED SILICONE CLOSED CELL FOAM 1
24 S101566 SEAL, OIL SEAL 8.5 X 10 X .625 2
69 M500611 BRACKET - LINK TILT CYLINDER HOSE 1
25 S101567 SEAL, OIL SEAL 10.5 X 12.5 X .625 2
70 M500261 SHIMS, KIT, QUILL 1
26 026211.1656DH2 CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2 15
71 H100728 PLUG, HOLLOW HEX, 3/4'' NPT 1
27 208201.1200 WASHER,FLAT,Gr8, 3/4 1
72 S100124 O-RING, 11 1/2 X 12 X 1/4 1
B 28 026211.0824DH2 CAPSCREW,SOCKET HEAD, 1/2-13UNC X 1.50, DH2 26 B
73 S500008 O-RING, 11.375 X .250, N-70 1
29 230101.0800 WASHER,LOCK,HI COLLAR 1/2'' 26
74 M500264-250 SHIM, IDLER, 0.250 1
30 026211.0716DH2 CAPSCREW, SOCKETHEAD, 7/16-14UNC X 1 8
75 M500703 OIL RING, GDM 650, NEW 1
31 008122.1228DH2 CAPSCREW, HEXHEAD, 3/4-16UNF X 1-3/4 1
76 026211.0828DH2 CAPSCREW,SOCKET HEAD, 1/2-13UNC X 1.75, DH2 8
32 008121.1236DH2 CAPSCREW,HEX HEAD, 3/4-10UNC X 2.25,DH2 20
33 008121.1232DH2 CAPSCREW,HEX HEAD, 3/4-10UNC X 2.00,DH2 10
34 008121.0616DH2 HEX HEAD, 3/8-16 UNC x 1 IN, GR 8 WIRED 8
35 026211.1232DH2 CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.00, DH2 10
36 H102597 CLAMP, SADDLE, LUBE PIPE 6
37 M500253 FLINGER, BEARING, TOP, GEARBOX 1
38 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 10 GDS International
39 008121.0822DH2 SCREW, HEX HEAD, 1/2-13 X 1-3/8, GR8 10 TITLE:
A 40 220102.0600 WASHER,LOCK,NORDLOCK,1 PAIR 3/8 8 GEARBOX ASSY, A
41 M500059 FLANGE TOP QUILL, LOAD COLLAR ASSY 1 GDM500, 6 5/8 SINGLE
42 008121.1440DH2 CAPSCREW,HEX HEAD, 7/8-9UNC X 2.50,DH2 12
43 220102.1200 WASHER,LOCK,NORDLOCK,1 PAIR 3/4 30 SIZE DWG. NO. REV
44 220102.1400 WASHER,LOCK,NORDLOCK,1 PAIR 7/8 12 B A500373 01
45 S100419 O-RING,2-224,NITRILE, N70, 1.75 X 2.00 X 1/8 2 SCALE: 1:24 WEIGHT: SHEET 6 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
D
4 M500315 SLEEVE, WITHDRAWAL 2 D
5 026221.0824DH2 CAPSCREW,SOCKET HEAD, 1/2-20-UNF X 1.50, DH2 12
C
4 4
C C
SECTION C-C
5 2 3 1 3 2 5
B B
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500239
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/3/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
1 2 E 3
C C
1
16 4 "
3
3
26 16 " E
B B
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500226
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR MANUFACTURE 10/31/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 517.53 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
13 14 18 6 7 1 10 9 1
D D
DETAIL C
SCALE 1 : 4
A
DETAIL B
SCALE 1 : 4
3 4 12
13
C C
B C
15
2
1
B 1 B
ITEM 16 APPLY BLUE LOCTITE
17
ITEM 15
APPLY WHITE ASSEMBLY GREASE (LUBRIPLATE) 6 11 5 15 2 8 10 16 9 1
TORQUE TO 1750 FT/LBS
SECTION A-A
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500010
DRAWING IS THE SOLE PROPERTY OF
02 UPDATED DRAWING TO REFLECT E2 1/7/15 DF
02
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/4/13 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1482.34 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
B B
GDS International
TITLE:
A QUILL ASSY A
B A500010 02
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
13 14 1 18 6 18 10 9 1
D D
DETAIL C
SCALE 1 : 4
A
DETAIL B
SCALE 1 : 4
3 4 12
13
C C
C
B
A
2
1
1
B 15 ITEM 16 APPLY BLUE LOCTITE
B
17
6 7 11 5 15 2 8 10 16
ITEM 15 1
APPLY WHITE ASSEMBLY GREASE (LUBRIPLATE)
TORQUE TO 1325 FT/LBS SECTION A-A
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A600003
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/21/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1476.31 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
B B
GDS International
TITLE:
A QUILL ASSY A
B A600003 01
SCALE: 1:12 WEIGHT: SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
C C
5
6
5
10
88.09
12
9 13
B 1 B
3 3
11
2 4
7 GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
8
A SECTION A-A DIMENSIONS ARE IN INCHES DRAWN DGW 12/18/13
TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/20/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/20/15
ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
MOTOR
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION GDM 500
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV
B A500279
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/20/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 974.05 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
D D
C C
16 2 SECTION B-B 1 14 13
30.00
14 15 7
6
8
11 12
B B
14.13
B B
10 11 5 4
GDS International
NAME DATE
4 16 9 3 2
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES DRAWN DGW 12/18/13
TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/21/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/21/14
ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
MOTOR
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION DISC BRAKES
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV
B A500231
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/21/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 480.13 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
GDS International
TITLE:
A ASSY A
MOTOR
DISC BRAKES
SIZE PART/DWG NO. REV
B A500231 01
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
1 7
36 8 " 34 8 "
8
C 1 C
7 9 10
1
49 16 "
B B
6 10 9 1
3 4 5
2
2
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
-
REPRODUCTION IN PART OR AS A WHOLE MATERIAL
- - - - SIZE PART/DWG NO. REV
B A500252
WITHOUT THE WRITTEN PERMISSION OF
01
GLOBAL DRILLING SUPPORT INTL. IS
01
FINISH
RELEASE FOR MANUFACTURE DGW 10/14/14 - PROHIBITED.
125AA Unless stated otherwise
REV. DESCRIPTION INITIAL DATE ECN # DO NOT SCALE DRAWING SCALE: DNS WEIGHT: 161.78 SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
C 14X 6 C
3 1 5 16X
B B
11 4X 12 16X 13 14X
UNLESS OTHERWISE SPECIFIED: NAME DATE
9
41.00
D D
11
1 12
10
D
E
57.05
10 12
A
8 3
C C
5 5 11
12 10
1 14 15
F DETAIL D
SCALE 1 : 8
1
13
4
K
16
C
7
B 13 B
11 2 91.88
B
H H 12 5
9 8 12
DETAIL E
6 DETAIL K SCALE 1 : 8
SCALE 1 : 4
SECTION H-H
6 SCALE 1 : 24
1
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
GDM 500
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 MFG APPR. XXX XX/XX/XX
PROPRIETARY AND CONFIDENTIAL INTERPRET GEOMETRIC Q.A.
TOLERANCING PER: ASME Y14.5M XXX XX/XX/XX
THE INFORMATION CONTAINED IN THIS
02
MATERIAL
ADDED WELDED HINGE PIN, PAGE 2 JP 9/24/14 DRAWING IS THE SOLE PROPERTY OF SIZE DWG. NO. REV
B A500277
GLOBAL DRILLING SUPPORT INTL. ANY
1
3
17
5
D D
4
8
AA
7
8
8
16
9
6 8
DETAIL A
G 8 G SCALE 1 : 4
C 1 C
DETAIL C
SCALE 1 : 4 1/2 ROUND BAR TYP
1/4
2 .25
CAGE HINGE
8
B DETAIL B 5 B
SCALE 1 : 12
1 DETAIL AA
2 7 SCALE 1 : 6
11 11
9
GDS International
DETAIL F TITLE:
A SCALE 1 : 8 GUARD ASSEMBLY, A
GDM 500
41.00 SIZE DWG. NO. REV
B B
GDS International
TITLE:
A
GUARD ASSEMBLY, A
GDM 500
SIZE DWG. NO. REV
B A500277 01
SCALE: 1:1 WEIGHT: SHEET 3 OF 3
8 7 6 5 4 3 2 1
1 of 2
2 of 2
8 7 6 5 4 3 2 1
1
58"
C C
1
B B
5 4
3
28"
1
88"
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500101
DRAWING IS THE SOLE PROPERTY OF
02 MODIFIED FROM ORIGINAL VERSION 9/5/13 JAV
02
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 REFER TO TD125146 - ORIGINAL VERSION 7/18/12 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1.32 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
1 of 2
2 of 2
1 of 2
2 of 2
8 7 6 5 4 3 2 1
6
12
1
B B
1
92 8 "
5 9 10 11 8
7
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500355
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/21/2015 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 3398.33 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
23 25 24 13 12
D D
21
DETAIL A 15 17
26
19 SCALE 1 : 2
DETAIL C
SCALE 1 : 1.5
C C
2
5 4 9 8
42"
3
B 37 16 " 3
7 20 21 22
10
18
B B
11
36 16 "
C
16 SECTION B-B
SCALE 1 : 12
14
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500015
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/22/2015 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 2834.84 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
GDS International
TITLE:
A LINK COLLAR ASSEMBLY A
GDM 650/500
B A500015 01
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
12 11 10 8
B B
5 9
13 13
DETAIL A
SCALE 1 : 4
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500160
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/22/15 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 151.42 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
C C
B B
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500348
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTUE 1/22/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
8
C C
C
2
3 6
B B
DETAIL C
SCALE 1 : 4
4 5
DETAIL B
SCALE 1 : 4
DETAIL A
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
-
REPRODUCTION IN PART OR AS A WHOLE MATERIAL
- - - - SIZE PART/DWG NO. REV
B A500347
WITHOUT THE WRITTEN PERMISSION OF
01
GLOBAL DRILLING SUPPORT INTL. IS
01
FINISH
RELEASE FOR PRODUCTION MH 9/25/14 - PROHIBITED.
125AA Unless stated otherwise
REV. DESCRIPTION INITIAL DATE ECN # DO NOT SCALE DRAWING SCALE: DNS WEIGHT: SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
1
30 2 "
B B
13 5
8 16 "
6
9
5 1 9 1
6
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500349
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 9/23/14 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
5.50
4 3
C C
17.00
B B
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500162
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
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01 RELEASE FOR MANUFACTURE 6/17/14 DF 125AA UNLESS STATED OTHERWISE
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REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 71.06 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
2
1 1
2
A A
C C
1.00
3
15.00
2
1 3
B
B B
3
SECTION A-A
SCALE 1 : 2
1
ASSEMBLY, GDM
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 MFG APPR. XXX XX/XX/XX
PROPRIETARY AND CONFIDENTIAL INTERPRET GEOMETRIC Q.A.
TOLERANCING PER: ASME Y14.5M XXX XX/XX/XX
THE INFORMATION CONTAINED IN THIS
MATERIAL
DRAWING IS THE SOLE PROPERTY OF SIZE DWG. NO. REV
B A500411
GLOBAL DRILLING SUPPORT INTL. ANY
14 15 16 17 29 11 19 12 1 12 13
11
24
D D
13
11
A A
29 10
14
C 12 C
21 29 10 3 4 12
B
14
B B
30 22
B 30 23
SECTION B-B
20
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500345
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/18/13 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1094.47 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
GDS International
TITLE:
A GRABBER ASSEMBLY A
500T
B A500345 01
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
4 5 6
2 3 1
C C
7
68"
B B
5"
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500102
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
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01 RELEASE FOR MANUFACTURE 11/4/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 21.93 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
4
7 5 2
A 7
C C
3
8 6
1
7 16 "
B B
3
A 38"
SECTION A-A
15
10 16 "
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500103
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURING 1/27/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
2 3 6 8 1 4
A
C C
15 7 8
6 16 "
B B
A
SECTION A-A
15
10 16 "
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500105
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/4/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 21.30 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
BOM Table
1 2 ITEM NO. PART NUMBER DESCRIPTION QTY.
1 M500585 BLOCK, DIE, GRABBER, 6.625" - 8.500" 1
2 M500568 PLATE, RETAINER, DIE, GATE SIDE FOR 6-5/8" - 8-1/2" OD 2
3 R100030 TONG DIE, 1/2 x 1 1/4 x 5 LONG 2
D
4 M500553 PIN, BLOCK, DIE, GATE, GRABBER 500T 1 D
5 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 4
6 008121.0816DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2 4
7 M100559 WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE 2
8 M100482 1/16" ALUMINUM OVAL, WIRE ROPE CLIP 4
5"
3
2 16 "
A 6 5
C 4 C
15
6 16 "
B B
NOTE:
LOWER WELL CONTOL VALVE (LWCV) USE ONLY.
2
A
SECTION A-A
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500353
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/28/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
7 2
SECTION A-A
SCALE 1 : 3 INSERT OPTIONS
M500322 STANDARD
4 11
5 10 M500724 LARGE
4 7 6
4
3 A A
B B
10 11
3
2
1
9
8
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500254
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/28/2015 JP 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
1 of 1
8 7 6 5 4 3 2 1
1
C C
2
A 4 5
B
35.50 B
6 7
A 34.27
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
SECTION A-A
DIMENSIONS ARE IN INCHES DRAWN DF 1/27/15
TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 1/27/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/27/15
BONNET ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
GDM
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV
B A500370
DRAWING IS THE SOLE PROPERTY OF
01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/27/15 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1000.93 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
D D
C C
B B
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500230
DRAWING IS THE SOLE PROPERTY OF
1
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR DATABOOK 1/22/2015 WJB 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
8 7
C C
6
A
B B
DETAIL A
B SCALE 1 : 4
5 4
DETAIL B
SCALE 1 : 4
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500329
DRAWING IS THE SOLE PROPERTY OF
2 REDRAWN 1/21/2015 WJB
2
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE 1/2/14 JAV 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 3347.37 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
C C
5 6
1 4
2
B B
3
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500240
DRAWING IS THE SOLE PROPERTY OF
1
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR MANUFACTURE 1/21/2015 WJB 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 995.16 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
1 2 3 5 6
C C
B B
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
B A500024
DRAWING IS THE SOLE PROPERTY OF
1
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR MANUFACTURE 1/21/2015 WJB 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 3393.46 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
650/850 T O N T O P D R I V E MANUAL REV 0
5B Electrical Schematics
134
G D M / 6 5 0 T O P D R I V E
5B Electrical Schematics
Electrical Schematics Index
522 M
L2 T2 L2 T2 T2
523
HPU1
TB3
524 120 V (L) 650
L3 T3 L3 T3 T3 20 HP
1 TB20:1 907 1760 RPM
THERMAL TRIP: 25A
525 120 V (N)
2
651
TB21:1 924 MAGNETIC TRIP: 400A 19.3 A - 575V
526 3
CAB 20
527 GREEN
L1 T1 L1 T1 T1
MTR6
528 WHITE
M
BLACK L2 T2 L2 T2 T2
529
HPU2
530 CB ** TB4 L3 T3 L3 T3 T3 20 HP
120 V (L) BLACK L1 L1
1 SOLA THERMAL TRIP: 25A 1760 RPM
531 120 V (N) WHITE N UPS N MAGNETIC TRIP: 400A 19.3 A - 575V
2
532 GREEN G G
3
533 L2
L1 T1 L1 T1 HPU COOLER
534 M 2 HP
L2 T1 L1 T1 1750 RPM
535 L3 T1 L1
2.7 Amp
T1
536
537
901
902
903
904
905
TB 20
906 120V AC
10A
650 1F 600
TB3-1 120V AC (L) / 523 TB 20:1 / 1027 PLC PS1
907 1A POWER SUPPLY TB 22
#12 AWG 2F
120 VAC/24 VDC 24VDC(+)
908 3F 726 10A
700
C 1F
TD 24V PS1 / 1804
RDY
909 #12 AWG
10A
4F 606 606
L AC(L) NO
106
3027
10A
2F 702 TD 24V PS2 / 1805
10A
608 740 5A
910 5F
N AC(N) 24VDC + 746 3F
1A 10A
6F
G 24VDC - 741 4F
911 5A
2A
7F
744 5F 708 TB 22:5 /3102 HPU SENSORS
912 3027
5A
8F 2A
740 6F 710 TB 22:6 / 3151 HPU1 STATUS
2A
913 650 656 9F PS2 742
5A
7F 712
TB 22:7 / 3021 CONSOLE PLC
2A POWER SUPPLY 2A
10F
914 120 VAC/24 VDC #14 AWG 8F 714 TB 22:8 / 3163 HPU2 STATUS
#12 AWG #12 AWG 728
5A
11F C 1A
9F 716 TB 22:9 / 1735 ENCODER SELECT
915 5A 608
RDY
107 2A
12F L AC(L) NO
10F 718
TB 22:10 / 3269 LUBE STATUS
916 626
609
N AC(N) 24VDC + 742 2A
720
13 11F
TB 22:11 / 3369 BLOWER STATUS/ CT
743
917 658
G 24VDC - 2A
12F F12
TB 22:12 / MICROBOX
14 2A
142
918 13F
TB 22:13 / 3416 HEATER OPTION
5A
14F 730
15 E-STOP POWER
919 5A
15F
1003 753
ETHERNET PIN-OUT
1 - WHITE / GREEN
1004 M L+
MANAGED ETHERNET
SWITCH 2 - GREEN
3 - WHITE / ORANGE
CAB 30
1005 CAB 31
2119 4 - BLUE
5 - WHITE / BLUE
2119
6 - ORANGE
1006 1928 7 - WHITE / BROWN
1 8
6GK5310-0BA00-2AA3 8 - BROWN
1007
1008 754 754 754
24 VDC
1113
1009
RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP
1015
PORT
I-1/0.2 4 115 AUTO SLIDER REV O-1/0.2 4 139 LUBE PUMP START O-2/2.2 4 SPARE
C 4 (+) CH 1
AO-1/0
6
(-)
165A
TD TORQUE SIGNAL
THIRD PARTY 0
4202 3262 SPARE 3522
AI-1/2
1016 I-1/0.3 5 114 SLIDER ENABLE O/P O-1/0.3 5 137 HPU COOLER START O-2/2.3 5 SPARE 5
(-)
7 (+)164B
CH 1
4205 3162 149
AO-1/2 TD RPM SIGNAL
(-)
1017 I-1/0.4 6 112 BLOWER CT O-1/0.4 6 132 HPU #1 START O-2/2.4 6 SPARE 6 (+)
CH 2
SLIDER RPM SP
10 165B
THIRD PARTY 0
752 3369 3145 3529
L+ AI-1/4 3107
1018 I-1/0.5 7 105 HPU COOLER RUN O-1/0.5 7 133 HPU #2 START O-2/2.5 7 SPARE
(-)
11 (+)164C
SIEMENS 6ES7315-2EH14-0AB0
SIEMENS 6ES7307-1KA02-0AA0
7 CH 2
753 3164 3157 149
1019
M
ETHERNET
PORT I-1/0.6 8 100 TD HPU E-STOP O-1/0.6 8 138 SLIDER ENABLE O-2/2.6 8 SPARE
C 8 (+)
AO-1/4
14
(-)
165C
TD TORQUE SIGNAL
THIRD PARTY 1
3119 3422 CH 3 3522
AI-1/6 SLIDER TORQUE
1020 I-1/0.7 9 101 TD LUBE PUMP RUN O-1/0.7 9 136 HORN O-2/2.7 9 SPARE 9
(-) LIMIT 3107 15 (+)164D CH 3
3269 L1+ 3413 L1+ 149 TD RPM SIGNAL
754 754 AO-1/6
(-)
1021 L+ 10 10 10 11 18 165D
THIRD PARTY 1
3529
149
Comp + M - ana
I-1/1.0 12 102 TD BLOWER RUN O-1/1.0 12 900 SCR FORWARD O-2/3.0 12 SPARE
1022 M 3369 754
11
754
11 12 (+) CH 4
23 (+)
CH 4
AO-1/8 TD TORQUE SIGNAL
AI-1/8 INCLINEOMETER (-)
I-1/1.1 13 108 TD HPU OIL LEVEL O-1/1.1 13 901 SCR REVERSE O-2/3.1 13 SPARE THIRD PARTY 2
1023 3104 13
(-) 3107 26
149
1024 750
I-1/1.2 14 103 TD HPU#1 RUN
3150
O-1/1.2 14 902 SCR 40 AMP FIELD O-2/3.2 14 SPARE C 14 (+) CH 5
27 (+) CH 5
L+ L+ SPARE TD RPM SIGNAL
AO-1/10
SCR 15 AMP FIELD SPARE AI-1/10 (-) THIRD PARTY 2
1025 I-1/1.3 15 104 TD HPU#2 RUN
3162
O-1/1.3 15 903 O-2/3.3 15
(-) 30
SIEMENS 6ES7322-1BH01-0AA0
SIEMENS 6ES7322-1HH01-0AA0
SIEMENS 6ES7321-1BH02-0AA0
SIEMENS 6ES7322-5HF00-0AB0
751 15
SIEMENS 6ES7331-7KF02-0AB0
M M 149
149
1030 M 20 M 20 M 20 M 20 M 20
1031
1032 755 755 755 755 755
0 VDC
1132
1033
1034
1035
1036
1037
1037
1001
1002
1003
1004
1005
1006
1007
1008
1009
RACK 0 GDP
1010 GDP-6
1011
#6
1012
754 L1+
24 VDC 21
1013 1009 3 197 WHITE
4844
1014 CH 0
GRID TEMP 1
4 196 RED
4842
1015 5 197
1019 9 200
1021
SIEMENS 6ES7311-7PF01-0AB0
11 203 WHITE
1022 4854
CH 2 12 202 RED
1023 ROOM TEMP 4852
1024 13 203
RED
1025 14 204
4853
1027 CH 3
HPU TEMP
16 557 RED
1028 17
1030 M 40
1031
1032 0 VDC
755
1033
1033
1034
1035
1036
1037
1037
1700
1701
1702
1703
GDP
1704
1705 TD TB1
1 TB2:1
1706
2 TB2:2
1707
1708 3 TB2:3
1709 4 TB2:4
1710 5 TB2:5
1711
6 TB2:6
1712
7 TB2:7
1713
8 TB2:8
1714
1715 9 TB2:9
1716 10 TB2:10
1717
1718
VFD GDP TB2 MAST J BOX TD AUX BOX
1719 TD 309TB8 TD TB2 TD TB2 TD TB2
800
+VDC 1 1 1 1 RED
1720
+VDC CAB 33
801
1721 0VDC 2 2 2 2 BLACK
1722 3 3 3
1723 SIG(A)
802
YELLOW
11 4 4 4
TO VFD DRIVE
1724 CHANNEL A CHANNEL A
803
SIG(A\) 12 5 5 5 YELLOW/WHITE
TD ENCODER
1725 CAB 33
6 6 6
1726
804
1727 SIG(B) 13 7 7 7 BLUE
CHANNEL B CHANNEL B
805
1728 SIG(B\) 14 8 8 8 BLUE/WHITE
1729 9 9
1730
10 10
1731
1732
NOTE:
715A
1809 6
BLUE
TB70 / 517 6
7
1810
8
1811
9 0 VDC
1812 7
WHT-BLK
7
WHT-BLK
10
1813 RED-BLK RED-BLK
8 8
1814
9 GRN-BLK 9 GRN-BLK
1815
ORN-BLK ORN-BLK
10 10G
1816
1817 11
1818 12
1819
1820
1821
1822
1823
1824
1825
1826
1827
1828
1829
1830
1831
1832
1833
1834
1835
1836
1837
1838
MODULE #1 MODULE #2 MODULE #3 MODULE #4 MODULE #5 MODULE #6 MODULE #7
2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC
1900 RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE
1901
1902
ETHERNET
1903 24V 0V DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2
1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5
1904 HNDLR ROTATE
FORWARD
HNDLR ROTATE
REVERSE HNDLR UNLOCK STAND JUMP IBOP CLOSE IBOP OPEN BUW CLOSE BUW OPEN
LINK TILT
EXTEND
LINK TILT
RETRACT
LINK TILT
FLOAT
HYDRAULIC
OIL COOLER BRAKE BRAKE DUMP
Q8.0 Q8.1 Q9.0 Q9.1 Q10.0 Q10.1 Q11.0 Q11.1 Q12.0 Q12.1 Q13.0 Q13.1 Q14.0 Q14.1
320 322 334 316 314 312 310 308 326 328 324 332 304 306
1905
1906
+ + 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V
1907 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6
1908
1909
1910 - - 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V
3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7
1911
321 323 335 317 315 313 311 309 327 329 325 333 305 307
1912
1913
PE PE PE PE PE PE PE PE PE PE PE PE PE PE PE PE
1914 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8
1915
1916
1917
WAGO 750-375 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508
1918
1919 TB30:7
0V MODULE #8 MODULE #9 MODULE #10 MODULE #11 MODULE #12 MODULE #13 MODULE #14
24V 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 16-DI 24V DC 4-AI 4-20mA
TB30:1 RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE
1920 DI1 DI2
1 2
1921 24V POWER 24V POWER
SUPPLY #1 SUPPLY #2
2 6 2 6 2 6 2 6 2 6 DI7 DI8 2 6
1927 7 8
PURGE PRESSURE
1928 SWITCH SPARE
9 10
0V 0V 0V 0V 0V 0V 0V 0V 0V 0V AI3 AI4
1930 3 7 3 7 3 7 3 7 3 7
SPARE SPARE
3 7
HYDRAULIC
1931 DI11 DI12 SPARE SYS PRESS
0V
1935 DI15 DI16
1936 15 16
SPARE SPARE
1937 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 750-1405 WAGO 753-455
1938
1939
1940
1941
MODULE #15 MODULE #16 MODULE #17 MODULE #18 MODULE #19 MODULE #20 MODULE #21
4-AI 4-20mA 4-AI 4-20mA 2/4 CHANNEL RTD 2/4 CHANNEL RTD INCREMENTAL ENCODER INTERFACE INCREMENTAL ENCODER INTERFACE END MODULE
2000 RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE
2001
2002
2003 AI1 AI2 AI1 AI2 AI1 AI2 AI1 AI2 A A/ 24V 0V A A/ 24V 0V
1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5
2004 HYD RETURN
PRESS HYD TEMP
LUBE OIL
FLOW
ELEVATOR
SIGNAL CLOSED
LUBE OIL
TEMP
BRAKE
TEMP
MOTOR
RTD 1
MOTOR
RTD 3
PIPE HANDLER
ENCODER
TOP DRIVE
MOTOR RPM PROX
411 407 401 956 432 434 417 423 440 441 346 347
2005
2006
M M M M M M M M B B/ N1 N2 B B/ N1 N2
2007 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6
2009
2010 AI3 AI4 AI3 AI4 AI3 AI4 AI3 AI4 LTCH GATE LTCH GATE
3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7
2011 LUBE PRESS
AFTER FILTER
LUBE PRESS
B4 FILTER SPARE SPARE
AMBIENT
TEMP SPARE
MOTOR
RTD 2 SPARE
2015 0V 0V
428 421
2016
2017
WAGO 753-455 WAGO 753-455 WAGO 750-464 WAGO 750-464 WAGO 750-637-000-0001 WAGO 750-637-000-0001 WAGO 750-600
2018
(DC Only)
2019 24V 24V
0V 0V
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
2032
2033
2034
2035
2036
2037
2101
2102 OPERATOR INTERFACE PANEL
2103
2104
2105
2106
2107
2108 SIEMENS HMI
2109 SIMATIC PANEL PC
2110 IPC 677C
2111
2112
2113 ETHERNET PROFI_BUS CDL DB15 L N G
2114
2115
2116
2117
2118
2119 ETHERNET / 1005
2120
ETHERNET / 1005
2121
2122
2123
2124
2125
2126 120V AC (L)
2128
2129
2130
2131
2132
2133
2134
2135
2136
2137
2138
MODULE #1 MODULE #2 MODULE #3 MODULE #4 MODULE #5 MODULE #6
16-DI 24V DC 16-DI 24V DC 16-DI 24V DC 4-DO 24VDC 4-DO 24VDC 4-DO 24VDC
2200 RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE
1 2 1 2 1 2
2201 1 2 1 2 1 2
SLIDER SLIDER
E-STOP PRESSURE SW DRILL ENABLED TRIP ENABLED FORWARD REVERSE
2202 I2.0
3213 3211
I2.1 I4.0
3404 3215 3214
I4.1 I4.0
3404 8705 8706
I4.1
ETHERNET 3 4 3 4 4
2203 24V 0V
3 4 3 4 3 4
DO1 DO2 DO1 DO2 DO1 DO2
1 5 1 5 1 5 1 5
2204 ALARM RESET
I2.2
HNDLR BYPASS
I2.3
TORQUE / DRILL
I4.2
BUW CLOSE
I4.3
SPARE
I4.2
SPARE
I4.3 ALARM PL DRILL ENABLED PL HPU ON PL IBOP CLOSE PL BRAKE PL
ELEVATOR
CLOSED
3200 3203 3111 3107 Q4.0 Q4.1 Q5.0 Q5.1 Q6.0 Q6.1
3400 3300 3401 3500 3403 3650
2205 5 6 5 6 5 6
5 6 5 6 5 6
BRK-OUT / DEC MK-UP / INC
2206 HPU1 START
I2.4
HPU2 START
I2.5
JOYSTICK - DN
I4.4
JOYSTICK - UP
I4.5
SPARE
I4.4
SPARE
I4.5
+ + 3201 3202 3105 3104 24V 24V 24V 24V 24V 24V
2207 2 6 7 8 7 8 7 8 2 6 2 6 2 6
7 8 7 8 7 8
2208 IBOP CLOSE TD IBOP OPEN
SPIN-OUT / PRE
JOYSTICK - RT
SPIN-IN / ZERO
JOYSTICK - LT SPARE SPARE
I2.6 I2.7 I4.6 I4.7 I4.6 I4.7
3100 3216 3103 3102
2209 9 10 9 10 9 10
9 10 9 10 9 10
2210 - - LINK TILT EXT
JOYSTICK 3 - UP
LINK TILT FLOAT
JOYSTICK 3 - RT
REV / FWD
SWITCH 7 - LT RPM LIMIT SPARE SPARE
0V 0V 0V 0V 0V 0V
WAGO 750-375 WAGO 750-1405 WAGO 750-1405 WAGO 750-1405 WAGO 750-504 WAGO 750-504 WAGO 750-504
2218
2219 0V MODULE #7 MODULE #8 MODULE #9 MODULE #10 MODULE #11
24V 4-DO 24VDC 4-AO 0-10V DC 4-AO 0-10V DC 4-AI 4-20mA END MODULE
RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE
2220
2221
2222
DO1 DO2 AO1 AO2 AO1 AO2 AI1 AI2
2223 1 5 1 5 1 5 1 5
RPM OUTPUT RPM OUTPUT SLIDER SLIDER
2224 SPARE
Q20.0
SPARE
Q20.1
RPM OUTPUT
PQW272
RPM SETPOINT
PQW274
3RD PARTY
PQW280
3RD PARTY
PQW282
RPM SETPOINT
PIW288
TORQUE SETPOINT
PIW290
3700+ 3701+ 3600+ 3602+ 8700 8702
2225
2226 24V 24V M M M M M M
2 6 2 6 2 6 2 6
2227
2228 3700- 3701- 3600- 3602+ 8702 8704
2229
0V 0V AO3 AO4 AO3 AO4 AI3 AI4
2230 3 7 3 7 3 7 3 7
TORQUE OUTPUT TORQUE OUTPUT
2231 TORQUE OUTPUT
PQW276
TORQUE SETPOINT
PQW278
3RD PARTY
PQW284
3RD PARTY
PQW286
SPARE
PIW292
SPARE
PIW294
3702+ 3703+ 3601+ 3603+
2232
2233 DO3 DO4 M M M M M M
4 8 4 8 4 8 4 8
2234 SPARE
Q20.2
SPARE
Q20.3
0V 0V 0V
2236
2237 WAGO 750-504 WAGO 750-559 WAGO 750-559 WAGO 750-455 WAGO 750-600
2238
2239
2240
2241
2400 CONSOLE - TD MOTOR CONTROL JS 2441
2401 2442
DC R3 M4 DC R3 M8 RPM ANALOG
2402 3300 3300 0010 2443 3700+ WHITE
O-0.1 5 G 3005 O-7/0+ 1 A
DRILL ENABLED PL RPM OUTPUT
2403 2444 2211
DC R3 M4 Channel 0
2404 3301 3301 0010 2445 DC R3 M8 RPM ANALOG
O-0.3 8 A O-7/0- 2
3700- BLACK
B
2405 HPU ALARM PL 2446
RPM OUTPUT
2212
2406 DC R3 M5
3302 3302 0010
2447
2407
O-0.2 4 A 2448
LUBE OIL PL
2427 2468
RPM GAUGE
2428 2469 F5 WHITE
24V 3032 A
2429 2470
2430 2471 0005 BLACK
OV 3037 B
2431 2472
2432 2473 TORQUE GAUGE
F5 WHITE
24V 3032 A
2433 2474
2434 2475 OV 3037
0006 BLACK
B
2435 2476
2436 2477
2437 2478
CONSOLE - 3RD PARTY RPM / TORQUE
4-20mA RPM
DC R3 M9 ISOLATOR 1
3600+ BLACK
O-7/0+ 1 1
RPM OUTPUT 0-10VDC
Channel 0
DC R3 M9
3600- BLACK
O-7/0- 2 2
RPM OUTPUT 0-10VDC
4-20mA TRQ
DC R3 M9 ISOLATOR 2
3601+ BLACK
O-7/0+ 3 1
TRQ OUTPUT 0-10VDC
Channel 2
DC R3 M9
3601- BLACK
O-7/0- 4 2
TRQ OUTPUT 0-10VDC
4-20mA TRQ
ISOLATOR 1
F6 BLACK
24V 24V 7
0V BLACK
OV 0V 8
4-20mA
ISOLATOR 2
F6 BLACK
24V 24V 7
0V BLACK
OV 0V 8
641 BLACK -
4 2
642 BLACK +
5 3
643 BLACK -
6 4
4-20mA TRQ
ISOLATOR 2
644 BLACK +
3 5
645 BLACK -
4 6
646 BLACK +
5 7
647 BLACK -
6 8
OPTIONAL
3000 GDP
DRIVE LOCKOUT
3001 GDP PLC M0
RL12
135 705
O-0.0 2
3002 3162
1025 E-STOP / L.O. SIGNAL A1 A2
24VDC
3003 CONSOLE
3004
E-STOP 0010
2402
3005 TD TB11 TB40 PB2
732 CAB 32 BLACK 732 734 0010
516 1 1 R 3034
3006 1 2 CP 3 4
DC ONLY E-STOP LIGHT
3007 SCR E-Stop CP 1 2 1 2 1 2
RL1 3 4 3033
3008 705B 734A WHITE 734
TB23:4 / 935 2 2
3009 A2 A1
TOP DRIVE LOCK-OUT
TD TB14 TD TB14 PB2 PB1
3010 LOCKOUT RELAY 3
205 206
4
744 742 740
RL3
DC R3 M1 1 2 1 2
3011 TB23:7 / 933
713 111A
3
RED
3
3213
1 I-2.0
111
CP 13 14 23 24 A2 A1 TD LOCKOUT/E-STOP
3012 24VDC
744
901 901 3 4
CP 33 34 43 44 GDP PLC M1
3013 901 901 I-1/1.4 16
111
3016 24V DC
712 ORANGE 740
TB22:1 / 912 5 5
740
3017
3018 AC ONLY 6 BLUE
6
3019
FAULT RELAY WHITE/BLACK
7 7
3020 CR2A
3022
GREEN/BLACK
TD TB12 9 9
3023 3
850
11 14
3024 851 10G ORANGE/BLACK
10G
4
3025
3026
3027 1F 2A FUSE F1 PLC 24V
2216
F2 ETHERNET
3028 2F
2A FUSE
3029
3030 3F 2A FUSE F3 INPUT 24V
3531
2A FUSE F4 INPUT 24V
3031 4F
3402
2A FUSE F5 GUAGE 24V
5F
3032 2470,2474
2A FUSE F6 SPARE
6F
3033
0002 0038
3034 0V DC
17
0010
PLC 0V 21 RPM METER 0V
3005 2218 3571
0011 0039
3035 18
0034
2413 22 TORQUE METER 0V
2225 3575
0035 0040
3036 19
0036
2225 23 ETHERNET SWITCH 0V
2225 3575
0037
3037 20 2225
GDP HPU J-BOX HPU
3100 3141 GDP PANEL
GDP PLC M2
3112 6
BLUE
6
3153 133 A1 A2 705
HPU2 START 7 O -0.5 RL6 A2 / 3146
705
3113 3154 1014 RL7 RL8 A2 / 3363
HPU2 HPU1
556 WHT-BLK
BREAKER STARTER
3114 GDP PLC
7 7
HPU OIL TEMP 3155 714 714A 104 104
GDP PLC M1
WHT 24 Vdc TB22:8F / 914 33 34 13 14
15 I -1.3 HPU2 RUNNING STATUS
15
3115 557 RED-BLK RED 3156 1017
HPU TEMP M6 16 8 8
RED
3116 18 3157
557 GRN-BLK
3117 9 9 3158 RL11
HPU COOLER HPU COOLER
STARTER
3118 3159 905
RELAY
910 705E
ORG-BLK 24 Vdc 3152 0 Vdc TB23:2 / 935
10 10 11 14 A1 A2
3119 3160
3120 3161 GDP PLC M2
137 A1 A2 705
HPU COOLER START 5 O -0.3 RL10 A2 / 1736
705
3121 3162 1013 RL11 ISO 1 A
HPU COOLER HPU COOLER
3122 3163 BREAKER STARTER GDP PLC M1
710 710E 105 105
24 Vdc TB22:6F / 912 33 13
7 I -0.5 HPU COOLER STATUS
3123 3164 34 14
1018
MCC BUS
3124 3165 CAB 19
MTR5
L1 T1 L1 T1 T1
3125 TOPDRIVE 3166
TD PLC J-BOX M
3126 3167 L2 T2 L2 T2 T2
TD R1 M15 CH1
407 WHITE HPU1
3127 HYDRAULIC
- 5 SIGNAL - 3168 L3 T3 L3 T3 T3 20 HP
PT1 408 BROWN 24V
TEMPERATURE + TB30:3 1760 RPM
THERMAL TRIP: 25A
3128 3169 MAGNETIC TRIP: 400A 19.3 A - 575V
GND1
GND
3129 3170
CAB 20
TD R1 M14 CH3 MTR6
3130 409 BLK 3171 L1 T1 L1 T1 T1
HYDRAULIC - 7 SIGNAL -
SYSTEM PT1
3131 PRESSURE +
410 RED 24V
TB30:3 3172 L2
M
L2 T2 T2 T2
GND1
3132 GND 3173 HPU2
L3 T3 L3 T3 T3 20 HP
3133 TD R1 M15 CH0 3174 THERMAL TRIP: 25A 1760 RPM
411 BLK MAGNETIC TRIP: 400A 19.3 A - 575V
HYDRAULIC - 1 SIGNAL -
3134 RETURN PT1 3175
412 RED 24V
PRESSURE + TB30:3
3135 GND1
3176
L1 T1 L1 T1 HPU COOLER
GND
3136 3177 L2 T1 L1
M 2 HP
T1 1750 RPM
2.7 Amp
3137 3178 L3 T1 L1 T1
3200 3241
3201 3242
TOP DRIVE
3202 3243
3203 GEARCASE JBOX 3244
3204 3245
TD R1 M17 CH 0
3205 WHT
3246
WHT CAB 76 432
1 MEAS LEAD (-)
3206 LUBE OIL 3247
TEMP
3207 RED 431 RED
2 MEAS LEAD (+)
3248
RTD7
3208 3249
RED 433 LUBE OIL
3209 TEMP 3250
3210 3251
3211 3252
3212 3253
3213 TOPDRIVE 3254
3214 3255
3215 3256
TD R1 M16 CH0
3216 401 BLK 3257 GDP PANEL
- 1 SIGNAL -
LUBE OIL PT1
3217 +
402 RED 24V
TB30:4 3258 RL3 RL9
FLOW
L.O. AUX. LUBE LUBE PUMP
3218 GND1 3259 BLOCK RELAY STARTER
GND 705D
906 907 907 907A
3219 3260 24 Vdc TB20:18 / 920 0 Vdc / TB23:3 936
53 54 11 14 A1 A2
TD R1 M15 CH3
403 BLK
3220 LUBE PRESS - 7 SIGNAL - 3261
BEFORE PT2 404 RED 24V
3221 FILTER + TB30:4 3262 GDP PLC M2
GND2 139 A1 A2 705
3222 3263 LUBE START 4 O-2/0.2 RL8 / 3363
GND
1020 705
RL9 RL10/ 1736
3223 TD R1 M15 CH2 3264
405 BLK
LUBE PRESS - 3 SIGNAL -
3224 AFTER PT3 3265 LUBE PUMP LUBE PUMP
406 RED 24V BREAKER STARTER
FILTER + TB30:4 GDP PLC M1
3225 3266 718 718A 718A 101
9 I-1/0.7
GND3 24 V TB22:10F / 914 33 34 11 14 LUBE RUNNING STATUS
GND
3226 3267 1014
3227 3268
3228 3269
3229 3270
3230 3271
3231 3272
3232 3273
3233 3274
3234 3275
3235 3276
3236 3277
3237 3278
3300 3341
3301 3342
3302 3343
3303 3344
3304 3345
3305 3346
3306 3347
3307 3348
3308 OPTIONAL (SCR) 3349
3309 3350
FOR A DIFFERENTIAL
3310 TOPDRIVE PRESSURE SWITCH SET AT 4.5" OF
3351
WATER DECREASING
PLC J-BOX
3311 3352
FOR A PRESSURE SWITCH SET AT
3312 6" OF WATER DECREASING
TD R1 M13
3353
T.D LOW AIR PURGE
3313 PS2 352 WHITE 3354
3 I-0.2
3 4
3314 3355
3315 351 BLACK
24V 3356
3316 SWITCH OPENS ON T.D AIR PRESSURE PS 3357 GDP PANEL
LOW PRESSURE
3317 3358 RL3 RL8
L.O. AUX. BLOWER BLOWER
3318 3359 BLOCK RELAY STARTER
908 909 909 909A 705C
3319 3360 24 Vdc TB20:19 / 918 0 Vdc / TB23:4 / 935
63 64 11 14 A1 A2
3320 3361
3321 3362 GDP PLC M2
134 A1 A2 705
3322 3363 BLOWER START 3 O-0.1 RL7 A2 / 3154
1015 705
RL8 RL9 A2 / 3263
3323 3364
3324 3365 BLOWER BLOWER
BREAKER STARTER GDP PLC M1
3325 3366 720 720A 720A 102
12 I-1.0
24 Vdc TB22:11 / 915 33 34 13 14 BLOWER RUNNING STATUS
3326 3367 1015
3330 3371
3331 3372
3332 3373
3333 3374
3334 3375
3335 3376
3336 3377
3337 3378
3400 CONSOLE SW4 3441
TRIP
3401 3442
OFF DRILL
DC R3 M2
3402 3031
F4 3214 3214
2 I-0.1 3443
TRIP 1922
3403 DC R3 M2
3444
F4 3215 3215
3404 3543 1 I-0.0 3445
DRILL 1923
3405 3446
3406 3447
3407 3448
3408 3449
3409 3450
3410 3451
3411 3452
3412 3453
3413 3454
3414 3455
3415 3456
3416 3457
3417 3458
3418 3459
3419 3460
3420 3461
PLC_GDP_M3
3421 O - 0.0 2
181 621 HM A2 / 932 3462
A1 A2
1013 HOUR METER
3422 HOUR METER
3463
3423 3464
3424 3465
3425 3466
3426 3467
3427 3468
3428 3469
3429 3470
3430 3471
3431 3472
3432 3473
3433 3474
3434 3475
3435 3476
3436 3477
3437 3478
CONSOLE - TD MOTOR CONTROL JS
JS1-LEFT DC R3 M2 DC R3 M1
F4 F4 1 3 3102 3102 F4 1 3 3204 3204
3519 8 I-4.7 3404 8 I-3.6
SPIN-IN / DRILL ZERO STANDJUMP
F4 2212
3513
JS1-RIGHT DC R3 M2
F4 1 3 3103 3103
7 I-4.6
SPIN-OUT / PRESET
JS1-UP DC R3 M2
F4 1 3 3104 3104
6 I-4.5
MAKE-UP / INCREASE
JS1-DOWN DC R3 M2 GDP
F4 F4 1 3 3105 3105
5 I-4.4
BREAK-OUT / DECREASE
SW7-LEFT
DC R3 M2
4247
F4 F4 3106 3106
9 I-5.0 TD TB 13
TO DRILLING / MUDLOGGER
RECORDER RIG
GDP PLC M5
DRILL REV / FWD 164A MUDLOGGER +
F4 O-0+ 3 1
SW 5
DC R3 M2 TORQUE
F4 F4 3107 3107 Channel 0
3544 4 I-4.3
BUW CLOSE GDP PLC M5
F4 165A MUDLOGGER -
4242 O-0 - 6 2
TORQUE SUPPLIED BY CUSTOMER
SW 7
DC R3 M2
F4 F4 3111 3111 TD TB 13 RECORDER / MUDLOGGER RIG
3 I-4.2 GDP PLC M5
164B MUDLOGGER +
TORQUE / DRILL O-2+ 7 3
F4
3502 RPM
Channel 1
GDP PLC M5
165B MUDLOGGER -
SW 7 O-2 - 10 4
DC R3 M2 RPM SUPPLIED BY CUSTOMER
F4 F4 3205 3205
10 I-5.1
RPM LIMIT SELECT
SW 7 221
DC R3 M2
F4 3206 3206 TD TB 13
TO DRILLING / MUDLOGGER
RECORDER RIG
11 I-5.2 GDP PLC M5
164C MUDLOGGER +
TORQUE LIMIT SELECT O-4+ 11 5
SW 7 TORQUE
DC R3 M2 Channel 2
F4 3207 3207
12 I-5.3
GDP PLC M5
LIMIT DECREASE 165C MUDLOGGER -
SW 7 O-4 - 14 6
DC R3 M2 TORQUE SUPPLIED BY CUSTOMER
F4 3208 3208
13 I-5.4
LIMIT INCREASE
SW X
DC R3 M1
TD TB 13 RECORDER / MUDLOGGER RIG
F3 F3 3200 3200 GDP PLC M5
3028 3 I-2.2 164D MUDLOGGER +
O-6+ 15 7
ALARM RESET
SW 7 RPM
DC R3 M1 Channel 3
F3 3201 3201
5 I-2.4 GDP PLC M5
HPU1 START 165D MUDLOGGER -
O-6 - 18 8
SW 7 RPM
DC R3 M1 SUPPLIED BY CUSTOMER
F3 F3 3202 3202
4000 6 I-2.5
HPU2 START
CONSOLE
3900 BUW 3941
3901 CLOSED 3942
877 0VDC
3902 R3 MOD7 DO/1 TB 23 3943
3903 A1+ A2- 3944
3904 3945
3905 11 14 3946
3906 DRY CONTACTS 3947
3907 3948
3908 3949
3909 3950
3910 3951
3911 3952
3912 3953
3913 3954
3914 3955
3915 3956
3916 3957
3917 3958
3918 3959
3919 3960
3920 3961
3921 3962
3922 3963
3923 3964
3924 3965
3925 3966
TOPDRIVE
3926 PLC J-BOX 3967
BUW GRIPPER OPEN
3927 TD R1 M4 SOL10A 3968
308 CAB 54 BLACK 2-H
O-0.1 5
3928 + - 3969
309 WHITE
O-0.1 7
3929 GREEN 3970
3930 3971
BUW GRIPPER CLOSE
SOL10B
3931 310
3972
O-0.0 1 CAB 55 BLACK 2-H
+ -
3932 O-0.0
311 WHITE 3973
3
3933 GREEN 3974
3934 3975
3935 3976
3936 3977
3937 3978
CONSOLE - TD PIPE HANDLER CONTROL JOYSTICK
JS2-LEFT PLC J-BOX
4000 DC R3 M1 4041 PIPE HANDLER ENCODER
F3 3112 3112 24V
3536 12 I-1.3 TD R1 M18B
4001 PH LEFT
4042 346 CAB 74 RED 1024 PPR
I-5 1 + DUAL OUTPUT
4002 JS2-RIGHT DC R3 M1
4043 347 BLK
I-5 5 -
F3 3113 3113
4003 13 I-1.4 4044 0V
PH RIGHT TD R1 M18A
4004 4045 440 YEL
JS2-UP I-5 1 A
DC R3 M1
4005 F3 3116 3116
14 I-1.5
4046 441 YEL/WHT
I-5 5 /A
4006 UNLOCK 4047
4007 JS3-UP 4048 TD R1 M18A
DC R3 M1 BLU
442
F3 3114 3114 I-5 2 B
4302 9 I-1.0
4008 S1-1 S1-2 4049 443 BLU/WHT
ENCODER
LT EXTEND I-5 6 /B
4009 4050
JS3-DOWN DC R3 M1
4010 F3 3115 3115 4051
11 I-1.2
S2-1 S2-2 Z
LT RETRACT
4011 4052
JS3 - RIGHT /Z
DC R3 M1
4012 F3 3117 3117
4053
10 I-1.1
4013 LT FLOAT 4054 TD R1 M18B
13G
4014 DC R3 M1 4055 SHIELD 8 GND
F3 3203 3203 4
4015 I-0.3 4056
HANDLER BYPASS +
4016 4057
TOP DRIVE -
4017 PLC J-BOX 4058
TD R1 M13 HANDLER LOCK SENSOR
4018 HANDLER LOCK STATUS I-0.3 4 355 PROX2 4059
A
4019 TB30:9
356 0V 4060
BLK BRWN /A
354 24V
4020 TB30:3 4061
4021 4062
BLU B
4022 4063
/B
4023 4064
4024 TD R1 M2
HANDLER UNLOCK
SOL02B 4065
334 CAB 53 BLACK 2-H Z
HANDLER UNLOCK O-0.0 1
4025 - + 4066
/Z
4026 335 WHITE 4067
O-0.0 3
4027 GREEN 4068
4028 4069
HANDLER ROTATE FORWARD
4029 TD R1 M1 SOL09A
4070
320 CAB 60 BLACK 2-H
HANDLER ROTATE FORWARD O-0.0 1 +
-
4030 4071
321 WHITE
O-0.0 3
4031 4072
GREEN
4032 4073
HANDLER ROTATE REVERSE
4033 TD R1 M1 SOL09B 4074
5 322 CAB 61 BLACK 2-H
HANDLER ROTATE REVERSE O-0.1
4034 - + 4075
323 WHITE
4035 O-0.1 7 4076
GREEN
4036 4077
4037 4078
4100
4101
4102
CONSOLE
4103 CONSOLE - TD PIPE HANDLER CONTROL JS
LINK TILT
4104 FLOAT ENGAGED
4105 879 0VDC
JS3-UP DC R3 M1 R3 MOD7 DO/4 CONSOLE
4106 F3 1 3 3114 3114
4302 9 I-3.0 A1+ A2-
LINK TILT EXTEND
4107
JS3-DOWN DC R3 M1
4108 F3 1 3 3115 3115 11 14
11 I-3.2
4109 LINK TILT RETRACT
JS1-RIGHT
DRY CONTACTS
4110 1 3
DC R3 M1
F3 3117 3117
10 I-3.1
4111 LINK TILT FLOAT
4112
4113
4114
4115
4116
4117
4118 TOPDRIVE
PLC J-BOX
4119 TD R1 M5
LINK TILT RETRACT
SOL03B
328 CAB 64 BLACK 2-H
O-0.1 5
4120 + -
7
329 WHITE
0V DC
4121 GREEN
LINK TILT RETRACT
LINK TILT EXTEND
4122
TD R1 M5 SOL03A
326 CAB 63 BLACK 2-H
4123 O-0.1 1 + -
4128
325 WHITE
0V DC 3
4129 LINK TILT FLOAT GREEN
4130
4131
4132
4133
4134
4135
4136
4137
CONSOLE IBOP CONTROL VALVE
SW3
4200 4241
DC R3 M1
4201 4242 3514 F3 OPEN CLOSE 3216
8 I-2.7
A1 A2
4202 4243 IBOP OPEN SW
4203 4244
4204 4245
4205 4246
DC R3 M1
4206 4247 3511 F3 3100
7 I-2.6
B1 B2
4207 4248 IBOP CLOSE SW
4208 4249
4209 4250
4210 4251
4211 4252
4212 4253
4213 4254
4214 4255
4215 4256
4216 4257
4217 4258
4218 4259
4219 4260
4220 4261
4221 4262
4222 4263 TOPDRIVE
4223 4264
PLC J-BOX IBOP CONTROL VALVE
OPEN
4224 4265
SOLENOID "A"
TD R1 M3
4225 4266 5 312 CAB 56 BLACK 2-H (OPTIONAL)
O-0.2 + -
4226 4267 313
0V DC 7 WHITE
4227 4268 IBOP OPEN GREEN
IBOP CONTROL VALVE
4228 4269 CLOSE
SOLENOID "B" (OPTIONAL)
4229 4270 O-0.3 1 314 CAB 57 BLACK 2-H
+ -
TD R1 M7 SOL01B
4314 304 BLACK 2-H
O-0.0 1
+ -
4315
305 WHITE
4316 0V DC 3
TOP DRIVE BRAKE GREEN
4317
4318
4319
4320 TOP DRIVE BRAKE DUMP
TD R1 M7 SOL01C
4321 306 BLACK 2-H
O-1/0.3 5
+ -
4322
307 WHITE
4323 0V DC 7
TOP DRIVE BRAKE GREEN
4324 DUMP VALVE
4325
4326
4327
TD R1 M17
4328 MEAS LEAD (-) 6
CAB 78 WHT 434
BRAKE
4329 TEMP
RED 435
4330 MEAS LEAD (+) 5
4331 BRAKE
TEMP
4332
4333
4334
4335
4336
4337
4800 4841
4801 PLC J-BOX MOTOR AC 5GEB20 4842
4802 4843
4803 TD R1 M18 CH0 WHT 4844
417
+AI 1 1
4804 WHT 4845
A
4805 TD R1 M18 CH0 RTD 4846
418 RED
-AI 1 2
4806 4847
4807 4848
WHT
4808 4849
4809 WHT
SPARE 4850
RTD
4810 RED 4851
4811 4852
4812 4853
TD R1 M18 CH1 WHT
4813 420 4854
+AI 3 3
WHT
4814 B 4855
TD R1 M18 CH1 RTD2
421 RED
4815 -AI 3 4 4856
4816 4857
4817 4858
WHT
4818 4859
WHT
SPARE
4819 4860
RTD
RED
4820 4861
4821 4862
4822 TD R1 M18 CH2 WHT 4863
423
+AI 2 5
4823 WHT 4864
C
TD R1 M18 CH2
4824 424 RED
RTD2 4865
-AI 2 6
4825 4866
4826 4867
WHT
4827 4868
4828 WHT 4869
SPARE
RTD
4829 RED 4870
4830 4871
4831 4872
4832 4873
4833 4874
4834 4875
4835 4876
4836 4877
4837 4878
CONSOLE ELEVATOR CONTROL VALVE
SW
4200 4241
TOPDRIVE DC R3 M2
4201 4242 F3 OPEN CLOSE 3550
15 I-5.6
A1 A2
4202 4243 ELEVATOR OPEN SW
4203 4244
TD R1 M13 WEIGHT SENSOR
4204 WEIGHT SENSOR SW I-0.5 6
375 LIMIT SWITCH 4245
4205 GND 376 GND 4246
BLU BLK
374 24V DC R3 M2
TB30:4
4206 4247 F3 3551
16 I-5.7
B1 B2
4207 4248 ELEVATOR CLOSE SW
GRN
4208 4249
4209 4250
4210 4251
4211 4252
4212 4253
4213 4254
4214 4255
4215 4256
4216 4257
4217 4258
4218 4259
4219 4260
4220 4261
4221 4262
4222 4263 TOPDRIVE
4223 4264
PLC J-BOX ELEVATOR CONTROL VALVE
OPEN
4224 4265
SOLENOID "A"
TD R1 M10
4225 4266 330 BLACK 2-H (OPTIONAL)
O-17.0 1 + -
4226 4267 331
0V DC 3 WHITE
4227 4268 ELEVATOR OPEN GREEN
4228 4269
4229 4270
4230 4271
4231 4272
4232 4273
4233 4274
4234 4275
4235 4276
4236 4277
4237 4278
2000
2001
2002
2003 MODULE #1 MODULE #2 MODULE #3 MODULE #4 MODULE #5
16-DI 24V DC 4-DO 24VDC 4-AI 4-20mA INCREMENTAL ENCODER INTERFACE END MODULE
2004 RACK 4 CONSOLE RACK 4 CONSOLE RACK 4 CONSOLE RACK 4 CONSOLE RACK 4 CONSOLE
1 2
2005 1 2
MUD PUMP DW ANTI COLLISON
RUN STATUS PROX SW
2006 3750 3751
ETHERNET 3 4
2007 24V 0V
3 4
DO1 DO2 AI1 AI2 A A/ 24V 0V
2008 SW
3752 3753
OVER RIDE ANTI COLLISION
RELAY
CUT AND SLIP LT BAILS
INCLINOMETER
DRAWORKS
ENCODER 955
950 951
5 6
2009 5 6 954
ZONE MNGMT
2010 BYPASS
+ + 3754 0V 0V M M B B/ N1 N2
2011 2 6 7 8 2 6 2 6 2 6 2 6
7 8
2013 9 10
9 10
2014 - - DO3 DO4 AI3 AI4 LTCH GATE
3 7 3 7 3 7 3 7 3 7
2015 11 12
UPPER LIMIT
INDICATION PL
11 12
2016
2017
PE PE 13 14 0V 0V M M REF SHLD
2018 4 8 13 14 4 8 4 8 4 8 4 8
2019 0V
15 16
2020 15 16
2021
WAGO 750-375 WAGO 750-1405 WAGO 750-504 WAGO 750-455 WAGO 750-637-000-0001 WAGO 750-600
2022 (OPTION)
2023 TB24/0V
2A FUSE F7
7F
2024
2025
954
2026 +VDC MOD1-B
955
0VDC MOD1-B
2027 RED
WHITE 24V
TB30:2 ZONE MNGMNT
TD R4 M3 CH0 BLACK BYPASS
WHITE SW
2028 DRAWORKS
SIG(A)
950
MOD1-A
SIGNAL 1
GREEN INCLINOMETER
W/ GATEWAY
F4 F4 3754 3754
DC R4 M1
5 I-0.5
ENCODER CHANNEL A BLACK
951 ZONE MGMT BYPASS
SIG(A\) MOD1-A
2029 YELLOW
BLUE
F4
2030 SIG(B)
952
MOD1-A
CHANNEL B
953
SIG(B\) MOD1-A
2031
2032
2033
2034
2035
2036
2037
CONSOLE - SLIDER RPM / TORQUE CONSOLE - TD MOTOR CONTROL JS SLIDER
JS1-LEFT DC R3 M2
4-20mA RPM 3RD PARTY 1 3 3102 3102
8 I-4.7
ISOLATOR 1 TB
SPIN-IN / DRILL ZERO
SLIDER TB
642 BLACK JS1-RIGHT 3900 3900
5 3 1
1 3
647 BLACK
6 8 SW7-LEFT
DC R3 M2
3106 3106
9 I-5.0
DRILL REV / FWD
3902
791
0VDC 2 2
SHIELD 3 3
820
SIG(A) 4 4
CHANNEL A
821
SIG(A\) 5 5
SHIELD 6 6
822
SIG(B) 7 7
CHANNEL B
823
SIG(B\) 8 8
SHIELD 9 9
734
10 10 LOCK-OUT
CR1A
0V TB 23
A1+ A2-
INPUT CUBICLE
TD TB3 TD TB6 TD TB12
852 852 BLK 852
1 1 1
11 14
853 853 WHT 853
2 2 2
744
TB12:3
FAULT RELAY
CR2A
A1+ A2-
TD TB5
850 850 RED 850
8 3 3
GDP CPU PROFIBUS PLUG
PROFIBUS PLUG VFD DRIVE 11 14
(NODE 3) 851 851 GRN 851
9 4 4
RED RED
SH RTD01
WHT ORG
GRN 5 5
ON SH OFF
1015 CAB006 GRN
SIEMENS CPU RED BLU
SH 6 6
RED
PROFIBUS PLUG
GRN BRAKING MODULE RED WHT/BLK
(NODE 4) 7 7
RTD02
RED WHT BLK/RED
8 8
RED BLK/GRN
SH ON 9 9
RED BLK/GRN
10 10
GRN
GDP (IDS) SCR HOUSE
Forward
RL13
900 0VDC
R0 MOD2 DO/12 TB 23
TB14 TB6
A1+ A2- BLACK H1 L1
1 1 39 PC1-44
3010 SCR ONLINE WHITE
2 2 40 TB8-5 600V CT
11 14
205 RED
3 3 41 PC1-38
H2 L2
Reverse E-STOP 206 GREEN
RL14 4 4 42 C-6
901 0VDC ORANGE
R0 MOD2 DO/13 5 5 730 PC1-36
A1+ A2- FORWARD 865 BLUE 708 FORWARD
6 6
REVERSE 866 WHITE-BLK 709 REVERSE FIELD SUPPLY
7 7
11 14 TB1 TB2
882 RED-BLK
TRQ LIMIT R0 MOD5 AO/31 8 8 128 128
200
40 Amp 15 5
883 GREEN-BLK
RL15 RPM REF R0 MOD5 AO/35 9 9 130 130
902 0VDC 880 ORANGE-BLK 0
R0 MOD2 DO/14 TRQ FDBK R0 MOD4 AI/16 10 10 161 PC1-7 (2.66V/1000A) 14 4
21 21
GDP
LOCK-OUT
TD TB1 POWER PLC 1 CR1A TD TB3
+VDC 1 TD TB9 003 853
BLK 700 2
+VDC 1 TD 24V S1 / 907 LOCKOUT A2- A1+
0VDC 2 TD TB12
WHT 702 TD 24V S2 / 908 BLK 734 852
2 1 1
3 14 11
RED 701 WHT
3 TD RET S1 / 928 2 FAULT RELAY
PR2 BLK / 1826 820 CR2A TD TB5
4
GRN 703 RED 0001 851
TO TOP DRIVE CHANNEL A 4 TD RET S2 / 929 3 9
PR2 WHT / 1827 821
5 A2- A1+
ORG GRN
5 4
744 850
6 8
BLU ORG 14 11
6 5
PR3 BLK / 1829 822
7
WHT/BLK BLU
CHANNEL B 7 6
823
PR3 WHT / 1830 8
RED/BLK WHT/BLK
8 7
9
GRN/BLK RED/BLK
9 8
PR4 BLK / 1832 10
ORG/BLK GRN/BLK
CHANNEL Z 10 9
NOT CONNECTED PR4 WHT / 1833 11
ORG/BLK
10
12
13 E-STOP
TD TB 10
14 BLK 708
1 RL5 +24VDC TB22:5F / 910 3rd Party
HPU TD TB13
15 E-STOP BLK 164A
WHT 100A A1 A2 705 1 3 O-4/0+
2 3153
1014 TORQUE
705 WHT 165A
TB23:2 / 931 2 6 O-4/0 -
***NOTE : GDP TO ENCODER SHIELDS GROUNDED AT GDP / ISOLATED AT TD***
GDP PLC M1
100 1015 TORQUE
2 I-1/0.0 HPU E-STOP RED 164B
3 7 O-4/2+
ENCODER VFD 1013
1016 RPM
TD TB2 GRN 165B
4 10 O-4/2 -
+VDC RED
1 3 1017 RPM
+VDC ORG 164C
5 11 O-4/4+
0VDC 2 1019 TORQUE
GDP PLC M1 BLU 165C
GRN 108 6 14 O-4/4 -
4 12 I-1/1.0 HPU LEVEL
3 1020 TORQUE
1021 SWITCH WHT/BLK 164D
7 15 O-4/6+
SIG(A) 4 ORG 1021 RPM
TO VFD DRIVE RED/BLK 165D
CHANNEL A 5 18
CAB 25 8 O-4/6 -
SIG(A\) 5 1022 RPM
BLU GRN/BLK
6 9
6
ORG/BLK
10
SIG(B) 7 WHT/BLK 556
7
CHANNEL B GDP PLC
SIG(B\) 8 15
RED/BLK 557
16 HPU TEMP
8 M6
Forward
9 18 RL10
0VDC 900
GRN/BLK 557 TB 23 MOD2 DO/12 R0
10 9 TB14
BLACK
A2- A1+
1
WHITE 3010
ORG/BLK 2
10 14 11
RED 205
3
GREEN 206 Reverse
4 RL11
TB3 ORANGE 0VDC 901
120 V (L) 650 5 MOD2 DO/13 R0
1 TB20:1 907
BLUE 865 FORWARD A2- A1+
120 V (N) 651 6
2 TB21:1 924
WHITE-BLK 866 REVERSE
7
3 POWER PLC 2 14 11
RED-BLK 882
TD TB11 8 MOD4 AO/3 R0 TRQ LIMIT
GREEN BLK 732 40 Amp
1 GREEN-BLK 883
9 MOD4 AO/7 R0 RPM REF RL12
WHITE
WHT 732 ORANGE-BLK 880 0VDC 902
2 10 MOD3 AI/16 R0 TRQ FDBK MOD2 DO/14 R0
BLACK
LOCKOUT RELAY BLUE-BLK A2- A1+
RL3 11
RED 111A
3 BLACK-WHT 881
744 12 MOD3 AI/18 R0 RPM FDBK
TB12:3
GRN 711 RED-WHT 734 14 11
4 TB23:6 / 931 0V DC 13 TB 11:2
TB4 0001
BLACK L1 L1 TB12:4 GREEN-WHT 873 40AMP 15 Amp
1 SOLA ORG 712 14 RL13
UPS 5 TB22:1 / 912 24V DC 15AMP
2
WHITE N N BLUE-WHT 874 0VDC 903
15 MOD2 DO/15 R0
GREEN G G BLU BLACK-RED A2- A1+
3 6 16
L2 WHITE-RED 120V
WHT/BLK 17
7
ORANGE-RED 113 14 11
18 MOD1 DI/17 R0 SCR FIELD LOSS
RED/BLK
GDP CPU 8
PROFIBUS PLUG
PROFIBUS PLUG VFD DRIVE BLUE-RED 120N
GRN/BLK 19 TB 21:4
HMI (NODE 3) 9
RED RED-GREEN
RED ORG/BLK 20
10
SH 21
GRN
ON SH OFF
1015 CAB006 GRN
SIEMENS CPU SH
RED
PROFIBUS PLUG
GRN BRAKING MODULE
(NODE 4)
RED
SH ON
GRN
6
650/850 T O N T O P D R I V E MANUAL REV 0
Section
OMRON
166
1
Drawing Package Index
Project Number 159105
Project Description 800HP Top Drive House
Drawing Package Version 11
Customer Name Global Drilling Support
Page Total Revision
No. Pages Name Description 1 Description 2 Doc Class Revision Description Number
1 1 Index Drawing Package
2 1 159105E020 DIAGRAM ‐ POWER SYSTEM ONE‐LINE ELECTRICAL INITIAL RELEASE A
3 1 159105E200 DIAGRAM ‐ LIGHTING PANEL ELECTRICAL Swaped 30 amp breaker to 15 amp breaker. B
4 14 159105E308 DIAGRAM ‐ STANDALONE A1000 VFD WITHOUT GEN CONTROLS ELECTRICAL REMOVED TB32 1,2 FROM SH 10 E
CHANGED CUSTOMER RTD CONNECTIONS TO
18 4 159105E309 DIAGRAM ‐ TOP DRIVE ELECTRICAL INTERNAL, 309TB8 TO TB8 C
22 1 159105M001 EQUIPMENT OUTLINE ‐ POWER CONTROL HOUSE MECHANICAL INITIAL RELEASE A
23 1 159105M002 ELEVATION ‐ LINE UP, 800HP TOP DRIVE MECHANICAL INITIAL RELEASE A
UPDATED DRAWING TO REFLECT CHANGES TO
24 3 001.028.112 HOUSE ‐ ACCESSORIES, TOP DRIVE MECHANICAL PLATE C
27 5 001.052.117. PLUG PANEL MAIN LEFT MECHANICAL INITIAL RELEASE A
32 2 001.029.006. PLUG PANEL ‐ TOP DRIVE, PRECABLE ASSEMBLY MECHANICAL INITIAL RELEASE A
34 3 001.039.194 CUBICLE ‐ MODEL 07010 INPUT, STAND ALONE DRIVE, 86.0 HIGH X 24.0 WIDE X 34.0 DEEP MECHANICAL REMOVED ITEM 321 E
37 2 001.039.195 CUBICLE ‐ MODEL 07103 CONVERTER/INVERTER, 3 POLE (1 FUTURE), SAD, 86.0 HIGH X 50.0 WIDE X 34.0 DEEP MECHANICAL REMOVED ITEM 266 AND ITEM 267 D
NOTES:
2. THE LINE-UP SHALL BE SECURED BY WELDING THE BASE OF THE UNIT TO THE DECK
PLATE. THE TOP OF THE EQUIPMENT SHALL BE SECURED TO THE HOUSE WALL USING
AN ANGLE, 2 PLACES PER CABINET.
4. THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.
B 8/14/2013 STD-AC-ECN-20130814-02 BROWN,K BRAATZ,J FRENCH,J This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159105 SHEET NO:
1/ 3
A 7/16/2013 STD-AC-ERO-20130716-03 BROWN,K BRAATZ,J FRENCH,J of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:
61 X2
62 LF1 60 60 LF2
63 320 X2 61 321
5 344 1 10LDP1
PLAN VIEW
C B A D
100
320 321
120 10T1
C 64 343 B A D 64 343
EAST ELEVATION
WEST ELEVATION SOUTH ELEVATION
(LESS CUST. EQUIP.)
702 600
200
CONVERTER/ 240
INVERTER
323
100
INPUT CONVERTER/
INVERTER
120
201
200
10DISC1,2 2X 80
321 320
INPUT 323 2X 340
2X 342 1
201
10RECPT1,2 2X 260
SECTION B-B SECTION D-D
2X 340
2X 341
700 700
701
SEE PLUG
PANEL DETAIL
ROW G
ROW F
ROW A
ROW D
ROW C
ROW B
ROW E
21
1
300
1
1
708
1
2
711
23
1
303 708
2
1 20
3
707
301 711
2
709
2
23
4
3
2
303 709
22 711
2
5
302
3
710
3
23
3
303
3
4
4
40 40
50 50
NOTES:
2. THE LINE-UP SHALL BE SECURED BY WELDING THE BASE OF THE UNIT TO THE DECK
PLATE. THE TOP OF THE EQUIPMENT SHALL BE SECURED TO THE HOUSE WALL USING
AN ANGLE, 2 PLACES PER CABINET.
4. THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.
B 8/14/2013 STD-AC-ECN-20130814-02 BROWN,K BRAATZ,J FRENCH,J This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159105 SHEET NO:
1/ 3
A 7/16/2013 STD-AC-ERO-20130716-03 BROWN,K BRAATZ,J FRENCH,J of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:
61 X2
62 LF1 60 60 LF2
63 320 X2 61 321
5 344 1 10LDP1
PLAN VIEW
C B A D
100
320 321
120 10T1
C 64 343 B A D 64 343
EAST ELEVATION
WEST ELEVATION SOUTH ELEVATION
(LESS CUST. EQUIP.)
702 600
200
CONVERTER/ 240
INVERTER
323
100
INPUT CONVERTER/
INVERTER
120
201
200
10DISC1,2 2X 80
321 320
INPUT 323 2X 340
2X 342 1
201
10RECPT1,2 2X 260
SECTION B-B SECTION D-D
2X 340
2X 341
700 700
701
SEE PLUG
PANEL DETAIL
ROW G
ROW F
ROW A
ROW D
ROW C
ROW B
ROW E
21
1
300
1
1
708
1
2
711
23
1
303 708
2
1 20
3
707
301 711
2
709
2
23
4
3
2
303 709
22 711
2
5
302
3
710
3
23
3
303
3
4
4
40 40
50 50
18 4 159286E309. DIAGRAM‐TOP DRIVE ELECTRICAL (Sheet 4) RTD dashed wires were changed to solid D
22 1 159105M001. EQUIPMENT OUTLINE ‐ POWER CONTROL HOUSE MECHANICAL INITIAL RELEASE A
23 3 001.034.527. HOUSE ‐ ACCESSORIES, TOP DRIVE, 1200 HP MECHANICAL ADDING ITEM 800 B
26 2 001.034.525. PLUG PANEL ‐ TOP DRIVE, PRECABLE ASSEMBLY MECHANICAL INITIAL RELEASE A
28 5 001.052.117. PLUG PANEL MAIN LEFT MECHANICAL INITIAL RELEASE A
33 3 001.039.194. CUBICLE ‐ MODEL 07010 INPUT, STAND ALONE DRIVE, 86.0 HIGH X 24.0 WIDE X 34.0 DEEP MECHANICAL REMOVED ITEM 321 E
36 2 001.024.995. CUBICLE ‐ MODEL 07103 CONVERTER/INVERTER, 3 POLE, SAD, 86.0 HIGH X 50.0 WIDE X 34.0 DEEP MECHANICAL ADDING LEXAN COVER D
NOTES:
2. THE LINE-UP SHALL BE SECURED BY WELDING THE BASE OF THE UNIT TO THE DECK
PLATE. THE TOP OF THE EQUIPMENT SHALL BE SECURED TO THE HOUSE WALL USING
AN ANGLE, 2 PLACES PER CABINET.
4. THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.
61 X2
62 LF1 60 60 LF2
63 320 X2 61 321
5 344 1
PLAN VIEW
2 10LDP1
C B A D
100
320 321
320 700 321 240
A/C 1 A/C 2 GLAND PLATE
THIS SIDE
A/C 1 A/C 2
120 10T1
C 64 343 B A D 64 343
702 600
200
CONVERTER/ 240
INVERTER
323
100
INPUT CONVERTER/
INVERTER
120
201
200
10DISC1,2 2X 80
321 320
INPUT 323 2X 340
2X 342 1
5
201
10RECPT1,2 2X 260
SECTION B-B SECTION D-D
2X 340
2X 341
700
700
701
SEE PLUG
PANEL DETAIL
R R R R R R R
O O O O O O O
W W W W W W W
G F E D C B A
21
30 1
0
21 1 70
1 71 8
30 1
0 1 2
20 1 70
1 2 8
30 3 70
1 71 7
20 2 1
2 70
30 9
1 4
22 2 3
2 71 70
30 1 9
5
2 22 3
30 3 71
2 0
3
3 40
40
50
50
4 4
70 70 70 70 70
6 5 4 3 2
HPU-WILSON
254
GDS International
7330 W Sam Houston Pkwy N – Houston, Texas 77040 – (832) 467-0001 – Fax (832) 467-0011
832-467-0001
832-467-0011 Fax
WILSON COMPANY
7330 W Sam Houston Pkwy N
Houston, TX 77040
I want to thank you for buying your Fluid Power System from Wilson Company’s
Systems Division. This unit has been designed with high quality materials
With proper installation and maintenance, it should provide you with many
years of service.
If you have any question about this equipment before startup, contact
Products, please contact your local Wilson Company sales associate, or call
Thank you again for electing Wilson Company as your source for
Sincerely,
Gary Hanson
Systems Manager - Houston
DRAWINGS
Parts List, Schematics, & Specifications
LITERATURE
Hydraulic Motors, Pumps, & Valves
LITERATURE
Hydraulic Filters & Strainers
LITERATURE
Hydraulic Fittings & Hose
LITERATURE
Misc. Components
ELECTRIC MOTORS
Maintenance & Installation
WILSON COMPANY
WILSON COMPANY
P1/PD Series: 18cc to 140cc Medium
Pressure Axial Piston Pumps
Variable Displacement – Service Information
Bulletin HY28-2665-02/SVC/EN
Effective: January 1, 2014
The product information, specifications, and descriptions contained in this publication have been compiled for
the use and convenience of our customers from information furnished by the manufacturer; and we can not,
and do not, accept any responsibility for the accuracy or correctness of any description, calculation, specifica-
tion, or information contained herein. No such description, calculation, specification, or information regarding the
products being sold has been made part of the basis of the bargain, nor has same created or amounted to an
express warranty that the products would conform thereto. We are selling the goods and merchandise illustrated
and described on this publication on an “as is” basis, and disclaim any implied warranty, including any warranty of
merchantability or warranty of fitness for any particular purpose whatsoever, with respect to the goods and mer-
chandise sold. All manufacturer warranties shall be passed on to our customers, but we shall not be responsible
for special, indirect, incidental, or consequential damages resulting from the use of any of the products or informa-
tion contained or described on this publication. Further, we reserve the right to revise or otherwise make product
improvements at any time without notification.
The user, through its own analysis and testing, is solely responsible for making the final selection of the system and components and assuring that all performance, endurance,
maintenance, safety and warning requirements of the application are met. The user must analyze all aspects of the application, follow applicable industry standards, and follow
the information concerning the product in the current product catalog and in any other materials provided from Parker or its subsidiaries or authorized distributors.
To the extent that Parker or its subsidiaries or authorized distributors provide component or system options based upon data or specifications provided by the user, the user is
responsible for determining that such data and specifications are suitable and sufficient for all applications and reasonably foreseeable uses of the components or systems.
OFFER OF SALE
The items described in this document are hereby offered for sale by Parker-Hannifin Corporation, its subsidiaries or its authorized distributor. This offer and its accepteance
are governed by the provisions stated in the detailed "Offer of Sale" elsewhere in this document.
2
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
General Information P1/PD Maintenance
MOUNTING These pumps are designed to operate in any position. The pump shaft must be in alignment
with the shaft of the source driver and should be checked with a dial indicator. The mating
pilot bore and coupling must be concentric. This concentricity is particularly important if the
shaft is rigidly connected to the driven load without a flexible coupling.
SHAFT INFORMATION Splined: The shafts will accept a maximum misalignment of 0.15mm, 0.005 inch, total
indicator reading. Angular misalignment at the external and internal spline axis must be less
than ± 0,002 mm per mm of shaft radius, ± 0.002 inches per inch of shaft radius. The coupling
interface must be lubricated. PARKER recommends lithium molydisulfide or similar grease.
The internal coupling should be hardened to Rc 27-34 and must conform to SAE-J498c,
class 5 flat root side fit.
Keyed: High strength heat treated keys must be used. Replacement keys must be hardened
to 27-34 Rc. The key corners must be chamfered 0.81-1.0 mm, 0.032”-0.040”, at 45° to clear
radii that exist in the keyway.
SIDE LOAD CAPABILITY The P1/PD series is designed for inline-drive. Side loading on the shaft is not recommended.
If this is unavoidable consult your nearest PARKER representative.
FLUID CONNECTIONS Connect inlet and outlet lines to the port block of the pump. The maximum case pressure is 2
bar (30 psi) continuous, 4 bar (60 psi) intermittent. The case pressure must never exceed inlet
pressure by more than .5 bar (7 psi). When connecting case drain line make certain that drain
plumbing passes above highest point of the pump before passing to the reservoir. The case
leakage line must be of sufficient size to prevent back pressure in excess of 2 bar (30 psi) and
returned to the reservoir below the surface of the oil as far from the supply inlet as possible.
All fluid lines, whether pipe, tubing, or hose must be adequate size and strength to assure
free flow through the pump. An undersize inlet line will prevent the pump from operating
properly at full rated speed. An undersize outlet line will cause back pressure and cause heat
generation and increased noise. Flexible hose lines are recommended. If rigid piping is used,
the workmanship must be accurate to eliminate strain on the pump port block or to the fluid
connections. Sharp bends in the lines must be eliminated wherever possible. All system piping
must be cleaned and flushed before installing pump. Make sure the entire hydraulic system is
free of dirt, lint, scale, or other foreign material.
Caution: Do not use galvanized pipe. Galvanized coating can flake off with continued use.
SYSTEM RELIEF VALVES Although the P1/PD series pumps have very fast off-stroke compensator response, system
relief valves are recommended in all cases for safety considerations.
RECOMMENDED FLUIDS The fluid recommended for use in these pumps has a petroleum base and contains agents
which provide oxidation inhibition and anti-rust, anti-foam and de-aerating properties as
described in PARKER standard HF-1. Where anti-wear additive fluids are specified, see
PARKER standard HF-0.
VISCOSITY INDEX 90 V. I. minimum. Higher values extend the range of operating temperature but may reduce
the service life of the fluid.
TEMPERATURE Determined by the viscosity characteristics of the fluid used. Because high temperatures
degrade seals, reduce the service life of the fluid and create hazards, fluid temperature
should not exceed 110°C (230°F) at the case drain.
MAINTENANCE The pump is self-lubricating and preventative maintenance is limited to keeping system fluid
clean by changing filters frequently. Keep all fittings and screws tight. Do not operate at
pressures and speeds in excess of the recommended limit. If the pump does not operate
properly, check the troubleshooting chart before attempting to overhaul the unit. Overhauling
may be accomplished by referring to the disassembly, rework limits of wear parts, and
assembly procedures as provided in this service manual.
FLUID CLEANLINESS Fluid must be cleaned before and continuously during operation, by filters that maintain a
cleanliness level of ISO 20/18/14. Better cleanliness levels will significantly extend the life
of the components. As contaminant generation may vary with each application, each must
be analyzed to determine proper filtration to maintain the required cleanliness level.
Typical Ajustment Ranges and Initial Settings (unless customer specified at time of order)
Function Adjustment range Adjustment value Recommended or Initial Setting
Pressure compensators
"C0" 80-280 bar (1160-4060 PSI) 40 bar/turn (580 PSI/turn) Factory supplied at minimum
"C1" 20-80 bar (290-1160 PSI) 18.6 bar/turn (260PSI/turn) Factory supplied at minimum
"AM" 80-280 bar (1160-4060 PSI) 40 bar/turn (580 PSI/turn) Factory supplied at minimum
Load sense pressure
"L0" 8-35 bar (116-500 PSI) 28 bar/turn (410 PSI/turn) 24 bar (350 PSI)
Differential pressure
"AM" 37 bar (540 PSI) Adjustment not recommended Factory Set do not adjust
Maximum Volume stop
018 100-40% 9% per turn (1.6 cc/turn) 100%
028 100-40% 8.2% per turn (2.3 cc/turn) 100%
045 100-20% 7.5% per turn (3.4 cc/turn) 100%
060 100-30% 6.8% per turn (4.1 cc/turn) 100%
075 100-35% 6.2% per turn (4.65 cc/turn) 100%
100 100-50% 5.5% per turn (5.5 cc/turn) 100%
140 100-50% 4.8% per turn (6.72 cc/turn) 100%
Minimum Volume stop
018 0-68% 10% per turn (1.8 cc/turn) 0%
028 0-40% 9% per turn (2.6 cc/turn) 0%
045 0-40% 8.2% per turn (3.7 cc/turn) 0%
060 0-50% 4.6% per turn (2.76 cc/turn) 0%
075 0-45% 4.3% per turn (3.23 cc/turn) 0%
100 0-45% 3.9% per turn (3.9 cc/turn) 0%
140 0-25% 3.3% per turn (4.62 cc/turn) 0%
Component problems and circuit problems are often interrelated. An improper circuit may operate with apparent success but
will cause failure of a particular component within it. The component failure can be the effect, not the cause of the problem.
This general guide is offered to help in locating and eliminating the cause of problems by studying their effects.
028 P S 5 A 00
Pump Open Circuit Shaft Single Shaft Fluorocarbon Additional Adjustable Thru-Drive Special
Series Options Shaft Rotation Seal Material Control Displacement Mounting Features
Seal Design Control Options Stops Pad/Coupling
Displacement Mounting Configuration
Letter Options
28cc/rev. & Ports Port Port
(1.71 in³/rev) Orientation Type Paint
0 No ECU
D Proportional displacement control
Proportional pressure
Y
and displacement control
Technical Data
Model P1/PD 018 P1/PD 028 P1/PD 045 P1/PD 060 P1/PD 075 P1/PD 100 P1/PD 140
Maximum Displacement, cm3/rev 18 28 45 60 75 100 140
cu.in./rev 1.10 1.71 2.75 3.66 4.58 6.01 8.54
Outlet Pressure – Continuous, bar 280
psi 4000
Intermittent*, bar 320
psi 4500
Peak, bar 350
psi 5000
P1 Maximum Speed (1.3 bar abs inlet), rpm 3600 3400 3100 2800 2700 2500 2400
P1 (1.0 bar abs inlet), rpm 3300 3200 2800 2500 2400 2100 2100
P1 (0.8 bar abs inlet), rpm 2900 2900 2400 2200 2100 1900 1800
PD Maximum Speed (1.0 bar abs inlet), rpm 1800
PD (0.8 bar abs inlet), rpm 1800
Minimum Speed, rpm 600
Inlet Pressure – Maximum, bar 10 (gage)
psi 145
Rated, bar 1.0 absolute (0.0 gage)
psia 14.5
Minimum, bar 0.8 absolute (-0.2 gage)
psia 11.6
Case Pressure – Peak, bar 4.0 absolute (3.0 gage)
and less than 0.5 bar above inlet pressure
Rated, bar 2.0 absolute (1.0 gage)
and less than 0.5 bar above inlet pressure
Fluid Temperature Range, °C -40 to +95
°F -40 to +203
Fluid Viscosity – Rated, cSt 6 to 160
Max. Intermittent, cSt 5000 (for cold starting)
Min. Intermittent, cSt 5
Fluid Contamination – Rated, ISO 20/18/14
Maximum, ISO 21/19/16
SAE Mounting – Flange 82-2 (A) 101-2 (B) 101-2 (B) 127-2 (C) or 127-4 (C) 127-4 (C) 152-4 (D)
ISO Mounting - Flange 80 mm 100 mm 100 mm 125 mm 125 mm 125 mm 180 mm
SAE Keyed Shafts 19-1, A 25-1, BB 25-1, BB 32-1, C 32-1, C 38-1, CC 44-1, D
ISO Keyed Shafts 20 mm 25 mm 25 mm 32 mm 32 mm 40 mm 50 mm
SAE Spline Shafts 9T, A 13T, B 13T, B
14T, C 14T, C 17T, CC 13T, D
11T, A 15T, BB 15T, BB
Weight – End Port, kg (lb) 13.4 (29.5) 17.7 (39.0) 23 (50) 29 (64) 30 (66) 51 (112) 66 (145)
Side Port, kg (lb) 14.2 (31.3) 18.1 (40.0) 24 (52) 30 (67) 31 (68) 53 (117) 67 (147)
Thru-Drive, kg (lb) — 22 (48) 27 (59) 34 (75) 35 (77) 55 (121) 82 (180)
Moment of Inertia kg·mm2 760 1555 3208 4548 5041 12027 21400
Moment of Inertia Thru-Drive kg·mm2 NA 1618 3268 4687 5207 12402 22343
*Intermittent pressure is defined as less than 10% of operation time, not exceeding 6 successive seconds.
1
25
3
41 4
26
5
7
8
11 9
27 14
13
42 15
44
45
12 19
28
20
43
21
31 31
22
32
32
33 23
34 35
24
46 47 38
39
40
After engaging
Aftershaft slot toshaft
engaging pin, slot to pin, After engaging
Aftershaft slot toshaft
engaging pin, slot to pin,
hold sensorhold
flushsensor
to pump padto pump pad
flush hold sensorhold
flushsensor
to pump padto pump pad
flush
and rotate toandalign screw slots
rotate to align screw slots and rotate toandalign screw slots
rotate to align screw slots
to screw holes. Secure
to screw withSecure
holes. screwswith screws to screw holes. Secure
to screw withSecure
holes. screwswith screws
& washers, & 2 places.
washers, 2 places. & washers, & 2 places.
washers, 2 places.
198±8 Nm 50 51 52
(146±6 ft-lbs) 53
57 61
60
59 58 57 56
55
54
70
Rotating Group
018 028 045 060 075 100 140
Kits
CW Mobile P1 S2E-18710-0K S2E-19119-0K S2E-19067-0K S2E-18698-0K S2E-18032-0K S2E-18485-0K S2E-18489-0K
CW Mobile P1 with
S2E-19205-0K S2E-19209-0K S2E-19235-0K ** ** ** **
Ripple Chamber
CCW Mobile P1 S2E-18711-0K S2E-19120-0K S2E-19068-0K S2E-18699-0K S2E-18033-0K S2E-18486-0K S2E-18490-0K
CCW Mobile P1 w/
S2E-19206-0K S2E-19210-0K S2E-19236-0K ** ** ** **
Ripple Chamber
CW Industrial PD S2E-18712-0K S2E-19121-0K S2E-19069-0K S2E-18700-0K S2E-18483-0K S2E-18487-0K S2E-18491-0K
CW Industrial PD w/
S2E-19207-0K S2E-19211-0K S2E-19126-0K ** ** ** **
Ripple Chamber
CCW Industrial PD S2E-18713-0K S2E-19122-0K S2E-19070-0K S2E-18701-0K S2E-18484-0K S2E-18488-0k S2E-18492-0K
CCW Industrial PD
S2E-19208-0K S2E-19212-0K S2E-19127-0K ** ** ** **
w/ Ripple Chamber
Rotating Group Kit includes barrel s/a, pistons, retainer, washer, pins, port plate
Item
Quantity Description NOTES / Tightening Torque
no.
Compensator body CW rotation
1 1
Compensator body CCW rotation
2 1 Spool
3 1 Spring seat
4 1 Outer spring C0 versions only
5 1 Inner spring
6 1 Spring seat & piston
7 1 Seal piston o-ring
8 1 Spring cap o-ring
9 1 Spring cap 115 ± 7 N-m (85 ± 5 ft-lbs)
10 1 Adjusting screw
11 1 Adjusting screw locknut 7.9 ± 0.8 N-m (70 ±7 in-lbs)
12 1 Socket set screw (Loctite 242) 3.4 ± 0.4 N-m (30 ± 3 in-lbs)
13 4 Hex mounting screw 5.0 ± 0.3 N-m (45 ± 3 in-lbs)
14 1 SAE #2 o-ring
15 1 Hardened SAE #2 o-ring boss plug 4.0 ± 0.6 N-m (35 ± 5 in-lbs)
17 4 Teflon O-ring
18 1 Roll pin
19 1 Teflon O-ring
Compensator Disassembly:
1. Measure and record the extension of the two pressure adjusting screws.
2. Carefully remove the main compensator spring cap. Remove the two
springs. Remove the seal piston and spring seat. Remove the o-ring
boss access plug on the opposite side of the compensator. Remove the
compensator spool. NOTE: the compensator spool and inner spring are
not interchangeable with the load sense compensator spool and spring.
3. For “L” series compensators: Carefully remove the load sense com-
pensator spring cap with spring seat/seal piston. Remove the spring.
Remove the spring seat. Remove the o-ring boss access plug on the
opposite side of the compensator. Remove the load sense compensa-
tor spool. NOTE: the load sense compensator spool and spring are not
interchangeable with the main compensator spool and inner spring of the
main compensator.
4. Remove all SAE o-ring boss access plugs.
1. Inspect the main compensator spool and the load sense spool for
scratches or other damage.
2. Inspect the springs for proper free extension length (see chart below).
3. Inspect the spool bores for damage. Apply a light oil film on the
appropriate spool and check its fit in the bore. The spool should fit snugly
in housing and not have any radial play.
PUMP DISASSEMBLY Pump disassembly for inspection should be limited to the following cases:
a) Malfunction or oil leakage resulting from damage or wear and tear.
b) Trouble-shooting procedures previously listed do not solve the problem.
For rotation change or shaft conversion, disassembly should be done only as far
as necessary to completePump
conversion.
disassembly for inspection should be limited to the following cases:
a) Malfunction or oil leakage resulting from damage or wear and tear.
b) Trouble-shooting
Disassembly and reassembly procedures previously
should be performed in a clean listed do not solve the problem.
environment.
For rotation change or shaft conversion, disassembly should be done only as far
as necessary to complete conversion.
Caution: Spring assemblies in the pump are normally set under high
compression and bodilyDisassembly
injury mayand reassembly should be performed in a clean environment.
occur if caution is not taken during
disassembly.
Caution: Spring assemblies in the pump are normally set under high
compression and bodily injury may occur if caution is not taken during
disassembly.
It is usually not necessary to replace spring (20) fitted in cylinder barrel. Do not
replace the spring unless absolutely necessary.
It is usually not necessary to replace spring (20) fitted in cylinder barrel. Do not
After disassembly, the internal
replaceparts should
the spring beabsolutely
unless coated with a film of clean oil and
necessary.
protected from dirt and moisture.
After disassembly, the internal parts should be coated with a film of clean oil and
protected from dirt and moisture.
It is recommended that the length of the protruding portion of the compensator
adjusting screws, on the control 40 be measured
It is recommended andofnoted
that the length as thisportion
the protruding information
of the compensator
adjusting screws, on the control 38 be measured and noted as this information
will prove useful during assembly.
will prove useful during assembly.
For complete overhaul, all o-rings and seals should be discarded and replaced.
For complete overhaul, all o-rings and seals should be discarded and replaced.
1. Identify the pump from information on the data tag. Figure 1
1. Identify the pump from information on the data tag. Figure 1
Figure 1
Figure 1
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance
2. Drain fluid from housing. Fluid drained from pump should be disposed of
properly.
PUMP DISASSEMBLY 2. 3.
Drain fluidpump
Mount frominhousing.
fixture toFluid drained
prevent fromwhile
movement pump should main
removing be disposed
housing of
Continued properly.
bolts
3. 4.
Mount pumpbolts
Remove in fixture
holdingtothe
prevent movement
compensator whileonremoving
assembly the pump main housing
housing.
bolts
Additional fluid may drain out of the passages when the compensator is
removed. Set compensator aside for later disassembly and inspection
4. Remove bolts holding the compensator assembly on the pump housing.
Additional
5. Removefluid may attaching
the bolts drain outthe
of port
the passages
block to thewhen the compensator is
main housing.
removed. Set compensator aside for later disassembly and inspection
6. Carefully remove the port block. Use caution to avoid dropping the port
5. Remove
plate. the
Notebolts attaching
the location thebias
of the portspring
block- piston
to theassembly
main housing.
and the control
6. piston assembly.
Carefully remove the The control
port piston,
block. Usebias piston
caution toand biasdropping
avoid spring may
theremain
port
in pump when port block is removed. Remove and discard the three white
plate.
Teflon seals on the port block. These seals should be replaced each timecontrol
Note the location of the bias spring - piston assembly and the
piston
the assembly. The control piston, bias piston and bias spring may remain
pump is disassembled.
in pump when port block is removed. Remove and discard the three white
7. Remove
Teflon sealsthe
oncontrol piston
the port andThese
block. the bias piston
seals - spring
should beassembly.
replaced each time
the NOTE:
pump isFor rotation change only, do not disassemble further, proceed to
disassembled.
step 16.
7. Remove the control piston and the bias piston - spring assembly.
8. Remove
NOTE: the tapered
For rotation roller bearing
change only, docone
not and shim from the
disassemble end of
further, the shaft.
proceed to
step 14.
9. Position the pump horizontally and remove the rotating group. Avoid
8. Position the pump
separating horizontally
the pistons from theand remove
barrel the rotating
if possible. This will group.
assist inAvoid
identifying
separating thedamage
pistonsbetween
from thean barrel
individual piston and
if possible. borewill
This during
assistcomponent
in
inspection.
identifying damage between an individual piston and bore during component
inspection.
10. Remove the drive shaft.
NOTE: Forashaft
8a. If completing sealchange
changeonly, no further disassembly
or complete overhaul onisarequired.
045 pump Proceed
turn housing
to assembly procedure step 5.
over and remove the snap ring and shaft seal from the housing before moving
on to
11. step 9.the cam by rotating it 90 degrees and carefully extracting it from the
Remove
9. pump cam
Remove housing.
fromNote the large
housing. Seepocket under
Figure 2 the cam fits on the pressure
control side of the pump housing (same side as the three seals on the
housing flange). Figure 2
Large Pocket
Pressure control
side of pump
Figure 2
PUMP DISASSEMBLY 10. Remove cam bushing screws and cam bushings from pump.
Continued
11. Remove snap ring in housing and shaft bearing assembly.
12. If completing a seal change or a complete overhaul turn the housing over
and remove the snap ring and shaft seal from the housing.
12a. If you are working on an 045 pump please omit this step as this
has already been completed in step 8a.
12b. Always use a new shaft seal. Do not reuse old shaft seal.
13. If there is excessive wear on the port block bushing; remove the bushing
from the port block.
14. If complete overhaul or rotation change, remove control piston and bias
piston guides. The Control piston and bias piston guides are installed with
Anaerobic thread lock. Place the port block in an oven at 163°C (325°F).
NOTE: to prevent annealing of heat treated surfaces DO NOT USE A TORCH
TO HEAT PISTON GUIDES. (45 Size only)
COMPENSATOR DISASSEMBLY NOTES: Access plugs on end of compensator spool bores are hardened plugs.
Do not interchange with other plugs in the control. For rotation change, the
complete compensator assembly will need to be replaced.
1. Measure and record the extension of the two pressure adjusting screws.
2. Carefully remove the main compensator spring cap. Remove the two
springs. Remove the seal piston and spring seat. Remove the o-ring boss
access plug on the opposite side of the compensator. Remove the
compensator spool. NOTE: the compensator spool and inner spring are not
interchangeable with the load sense compensator spool and spring.
3. Load sense compensator: Carefully remove the load sense compensator
spring cap with spring seat/seal piston. Remove the spring. Remove the
spring seat. Remove the o-ring boss access plug on the opposite side of the
compensator. Remove the load sense compensator spool. NOTE: the load
sense compensator spool and spring are not interchangeable with the main
compensator spool and inner spring of the main compensator.
4. Remove all SAE o-ring boss access plugs.
PUMP INSPECTION PROCEDURES Carefully clean and dry all parts prior to inspection. Refer to chart 1 for dimensional
information regarding allowable tolerances.
1. Examine piston diameters for scratches or gouges. If any piston is severely-
damaged, note which piston bore it came out of. Extra attention should be
given to that bore in step 2. Check end play of piston shoe assembly. Check
the bottom surface of the shoes for damage. The shoe surface should be
square and flat. Measure the depth of the pocket of the shoe. Shoes may be
lapped as a set if the pocket depth is within allowable limits. Confirm pocket
depth after lapping to insure it is still within limits.
2. Examine bores in cylinder for scratches Check diameter of bores in 4different
locations, including near the bottom of the barrel where the piston does not
travel. If the dimensions vary by more than 0.0102 mm (0.0004 in.)or any di-
mension exceeds the allowable limit, the barrel needs to be replaced. Examine
the barrel face for scratches and gouges. The barrel canbe reworked if dimen-
sions are with specifications listed in chart 1.
3. The port plate can be lapped lightly if the face is only lightly scratched,
otherwise it should be replaced.
4. Examine the retainer plate in the area of contact with the piston shoes. Any-
marks beyond light polishing indicate that replacement is necessary. Check the
surface of the spherical area of the retainer plate and the spherical guide ball.
Inspect the back surface of the spherical guide ball where the load pins make
contact. If indentations are present replace the guide ball.
5. Examine cam on top and bottom surface. If scratches or gouges appear to
penetrate the surface treatment, the cam must be replaced.
6. The cam bearings cannot be reworked and should be replaced if worn through
the Teflon surface.
7. Both the bias piston and the compensator piston should move freely in their
respective bores. The pistons and bores should be free of scratches or gouges.
8. The seal area of the drive shaft should be smooth and not have marks due to
seal wear. Keyed shafts should be inspected for signs of brinelling and damage
to the key area. Splined shafts may have a contact wear pattern but should not
show excessive wear on the spline area.
NOTE: Spinning on shaft for P1/PD-018, 028 and 045 the cylindrical bearing
should not have any signs of roller spalling, brinelling or discoloration. The
bearing should be free to rotate without bind or rough feel.
COMPENSATOR INSPECTION NOTE: The compensator is supplied as an assembly. Individual parts are not
available. If there is significant damage to any of the parts, the complete
compensator will need to be replaced.
1. Inspect the main compensator spool and the load sense spool for scratches
or other damage.
2. Inspect the springs for proper free extension length (see chart on page 30).
3. Inspect the spool bores for damage. Apply a light oil film on the appropriate
spool and check its fit in the bore. The spool should fit snugly in housing and
not have any radial play.
Chart 1
Rework Limits
Item Number Component 018 Part No 028 Part No 045 Part No Tolerances
13 03E-94430-0 03E-94393-0 03E-94356-0
Bias Spring Free Height +/- 0.2mm
Page 16 & 17 78.3 mm 87.5 mm 116.4 mm
20 787635 03E-94387-0 03E-94350-0
Barrel Spring
Page 16 & 17 41.4 mm 39.5 mm 48.3 mm Free Height +/- 0.2mm
Measure OD in 3 places,
789519 S2E-18415-0 S2E-184130-0
top, middle and bottom.
Max End Play Max End Play Max End Play
Measurement should
0.10 mm 0.07 mm 0.10 mm
not vary by more than
26
Piston 0.01 mm
Page 16 & 17 Min Shoe Min Shoe Min Shoe
Flange Flange Flange
End Play between piston
Thickness Thickness Thickness
and shoe should not
2.97 mm 3.98 mm 4.98 mm
exceed value shown
Measure piston bore ID
in 3 places , top, middle,
bottom. Measurement
should not vary by more
23
Barrel 03E-94717-0 03E-94375-0 03E-94338-0 than 0.01 mm.
Page 16 & 17
Max material to be
removed by lapping is
.0051 mm
P Max
4 03E-93158-0
Compensator Free Height : +/- 0.7mm
Page 28 & 30 39 mm
Spring-Outer
P Max
5 03E-93159-0
Compensator Free Height : +/- 0.5mm
Page 28 & 30 26 mm
Spring- Inner
17 Load Sense 03E-93825-0
Free Height : +/- 0.4mm
Page 28 Spring 14 mm
PUMP ASSEMBLY PROCEDURES For major overhauls, all plugs should be removed, and the seals replaced. Prior
to assembly, all parts should be thoroughly cleaned. Assembly should be
performed in a clean work environment.
Do not use bearing grease during installation. Grease does not dissolve in
hydraulic oil and may plug orifices or filters in the system. Clean petroleum jelly is
preferred to lubricate o-rings and seals, and to adhere parts for assembly.
NOTE: For fluids other than petroleum based hydraulic oil, insure that petroleum
jelly is compatible with the fluid. If not compatible, another product should be
used instead.
Inspect all bearing surfaces and seal areas to insure that they are free from
nicks, dings, scratches, and rust.
1. Turn housing over. Using installation tool T1, press the shaft seal in the
seal bore. Install the snap ring into the groove in the seal housing bore.
NOTE: Install shaft and bearing on 45 unit before installing shaft seal.
T1 tool not used on 45 unit, use T3 tool to insert shaft seal over input shaft.
2. Install cylindrical bearing on pump shaft (slip fit). Install external retaining ring
ASSEMBLY PROCEDUREto hold bearing in place on the shaft. Insert shaft assembly into the pump
CONTINUED 9. Repeat the procedure three times. Once recorded, take the average of the
housing with thethree
bearing sliding into the bearing diameter in the housing.
measurements.
Install internal retaining ring into the housing. (See drawing)
10. With the average, use chart 2 to determine the correct shim to install in the
3. If barrel hold down spring was removed during disassembly process, install
pump.
three pins to slots in barrel spline (45 Size only). Petroleum jelly can be used
to hold pins in
11.place while
If barrel holdinstalling
down spring remaining
was removedparts. (Figure
during 4) Place
disassembly barrelinstall
process,
on fixture with pinthree
sidepins to slots
down. in barrel
Install spline.washer
backup Petroleumandjelly can down
hold be used to holdand
spring pins in
second back up place
washer.while installing remaining
Compress spring in parts. (Figure
press and4)install
Place snap
barrel ring.
on fixture with
pin side down. Install backup washer and hold down spring. Compress
Caution: Make sure snap
spring ringand
in press is properly seated
install snap in groove
ring. Caution: Makeprior
suretosnap
removing
ring is
barrel from press. properly seated in groove prior to removing barrel from press.
Figure 4
13. Apply a light film of oil into the piston bores. Lightly lubricate the spherical
PUMP ASSEMBLY PROCEDURES 5. Install the surface
locating pin
of the on ball.
guide theInstall
portthe
block face. into the bores in the hold
nine pistons
Continued down plate. Install the spherical guide ball into the hold down plate. While
6. For 045: Apply
holdingLoctite
the guidePrimer Grade
ball against T down
the hold to guide threads
plate, install and allow
the pistons into theto dry.
barrel.
Install unlubricated o-rings on the control guide and bias guide. Apply Loctite
271 to 14.
guide threads.
Install For
the locating pinleft hand
on the rotation
port block face. the bias guide is installed near-
est to the dowel pin (figure 5A.) For right hand rotation the control guide is
15. Apply Loctite Primer Grade T to guide threads and allow to dry. Install
installed nearest to o-rings
the dowel
on the pin (figure 5B.) Torque the Loctite
control and bias
Chart 2 Chart 3
unlubricated control guide and bias guide. Apply 271to
Pump Control and bias
guides as guide
specified
threads.inFor
Chart 2. rotation
left hand For 018, 028:
the bias The
guide guidesnearest
is installed are identical
to the and
Pump Control and bias dowel pin (figure 5A.) For right hand rotation the control guide is installed
guide torque press fit into the holes. (Not shown in picture below)
nearest to the dowel pin (figure 5B.) Torque the control and bias guides as
guide torque045 specified in Chart 3.
Locating pin
018 Press Fit Bias Piston 045 Picture
Guide
028 Press Fit
045 142 Nm (105 ft lbs)
Install the
26. port
Installplate
o-ring on the
seals port
and block,
assembled lining
18. Apply a light layer of petroleum jelly to the backup the ofslot
compensator
surface on on the
theside
port port housing.
of pump
plate. plate
Pumpthe
with the locating
Install rotation
pin. is on
(Refer
port plate indicated
to port
the by arrow
Figure
block, liningon
6) upcompensator housing.
the slot on the port Torque bolts
plate with
the
to 5locating
0.25pin.
Nm (45 3 in-lb).
19. Install the large o-ring in the groove on the pump housing. Install the three
Teflon o-rings in the pressure communication ports on the pump housing.
20. Install the cam bearings in the cradle area of the housing. The chamfer on
the back of the bearing must face the outer wall of the housing. Use Loctite
Primer Grade “T” or other suitable primer on screws and mating threads in
Industrial port plates
housing. Apply Loctite #242 (use sparingly) to screw threads and install
orifice screws to hold bearings in place. Torque screws to 3.4 0.25 Nm (33
3 in-lb).
21. Place thin film of clean oil on cam bearing surfaces. Install cam in housing.
note slot length
The cam must be tilted to permit entry into the housing. (Figure 2) NOTE:
The large pocket on the bottom surface and quantity
of the cam must be on the same
side as the three pressure communication holes on the main housing. Pump
rotation does not affect the assembly of the cam.
Mobile port plates
22. Install the drive shaft into the pump housing. Position pump horizontally.
Install the rotating group over the pump shaft. Rotate the barrel to insure that
it is seated against the cam. Insure that the pump shaft is seated properly in
the front bearing.
CCW CW compensator
CCW CW compensator
Figure 7
CCW pump with CW pump with
compensator compensator
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA 41
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Assembly Tools P1/PD Maintenance
A B C 31.2 mm
DIA DIA DIA (1.250 in)
DIA.
T3 Seal Guard B
C
30˚
D
BLEND RADIUS
& POLISH O.D.
T3 SealModel
Pump Guard A B C D
D EE FF
018 (018 SAE) 76.20 mm 50.80 mm 19.05 mm 28.82 mm 20.45 mm
15°
“01”, “02”, “04” Shafts 3.00 in. 2.00 in. 0.75 in. 1.135 in. 0.805 in.
018 (018 ISO) 76.20 mm 50.80 mm 19.05 mm 28.82 mm 16.76 mm
15°
“06” Shaft 3.00 in. 2.00 in. 0.75 in. 1.135 in. 0.66 in.
(028 SAE)
028 / 045 76.20 mm 50.80 mm 19.05 mm 38.10 mm 26.00 mm
15°
“01”, “02”, “04” Shafts 3.00 in. 2.00 in. 0.75 in. 1.50 in. 1.024 in.
(028 ISO)
018/028/045 76.20 mm 50.80 mm 19.05 mm 28.82 mm 22.50 mm
15°
“08” Shaft
(045 SAE) 3.00 in. 2.00 in. 0.75 in. 1.135 in. 0.885 in.
(045 ISO)
Parker Hannifin Corporation
Hydraulic Pump Division
42 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Assembly Tools P1/PD Maintenance
25.40
(1.00)
T5 Rear
T5Bushing Installation
Rear Bushing Tool
Installation Tool
mmmm
( in )
(in)
101.60
A 38 ( 4.00) 102
(1.5) (4.0)
A
13
38.10
( 1.50)
(.5) Pump Size A B
12.7 3.71 mm 19.9 mm
018
( 0.5) 0.146 in. 0.772 in.
4.00 mm 21.6 mm
028
0.157 in. 0.85 in.
4.00 mm 24.1 mm
045
0.157 in. 0.95 in.
1. 2.Mount pumpwith
Fill case on test fixture.
clean Insure that
oil. Connect shaftdrain
upper alignment
port toisreservoir
within specified
with no
PUMP TEST PROCEDURE Testtolerances.
criteria based on hydraulic
restrictions. oil ISO drain
Insure other 32 per Parker HF-0properly
ports are specifications.
plugged.
Oil temperature: 50°C ± 2°C (120°F ±10°F). NOTE: insure that the hydraulic
2.system does not overheat during this test procedure.
3.FillConnect
case withinlet
clean oil.pressure
Connect upper drain port to reservoir with no
Operating speed: 0 - 2300and
rpm ± 30 rpm. lines. Insure that lines are filled with oil. Refer to
restrictions. Insure
circuit Maximum
Case pressure: below. For other
psidrain
14.5units bar)ports
(1 with are properly plugged.
“L” compensators, connect a suitable pilot line
from port “X” to the pump discharge pressure line, down stream of the
3.1. Connect
Mount pump inlet andfixture.
on test
non-compensating pressure lines.
Insure
flow Insure
that shaft
valve. that lines
alignment arespecified
is within filled with oil. Refer to
tolerances.
circuit below. For units with “L” compensators, connect a suitable pilot line
from port “X” to the pump discharge pressure line, down stream of the
2. 4. Fill Confirm direction
case with clean of rotation
oil. Connect for pump
upper drain and drive
port to reservoir withare
no correct.
non-compensating
restrictions. Insure otherflow valve.
drain ports are properly plugged.
4.3. 5.Confirm
Reduce
Connect inlet
the main
direction compensator
of rotation
and pressure for pump
lines. Insure
setting
andare
that lines
tofilled
drive minimum.
are correct.
with
For units with “L”
oil. Refer to
compensators,
circuit below. For units advance the load sense
with “L” compensators, connectcompensator adjustment
a suitable pilot line until it
5. frombottoms
port “X” toout, and
the pump lock into
discharge position.
pressure line, down stream of the
Reduce the main compensator setting to minimum. For units with “L”
non-compensating flow valve.
compensators, advance the load sense compensator adjustment until it
4. 6.bottoms
Set maximum
Confirm out, and
direction volume
lock into
of rotation stop
pump (if
andincluded)
for position. to full
drive are correct.displacement. If minimum
volume stop is included, back adjustment all of the way out.
Reduce
6.5. Set the main volume
maximum compensator
stopsetting to minimum.
(if included) Fordisplacement.
to full units with “L” If minimum
compensators, advance the load sense compensator
7.volume
If possible,
stop is gradually
included, increase
back adjustment
bottoms out, and lock into position.
all adjustment
pump speed to way
of the 1800until±it30 rpm with no load.
out.
7.6. 8.IfSetpossible,
Screw
maximumingradually increase
compensator
volume stop pump
to fullspeed
adjusting
(if included) screw to 1800
until
displacement. ± 30 rpmout,
itIfbottoms
minimum withwith
no load.
no pressure
on system
volume load-relief
stop is included, valve. all of the way out.
back adjustment
8. Screw in compensator adjusting screw until it bottoms out, with no pressure
7. If possible, gradually increase pump speed to 1800 ± 30 rpm with no load.
9.on Break-in
system load-relief
pump at valve.
times and pressures listed below. Adjust the load-relief
8. valve
Screw to the pressure
in compensator listed
adjusting screwfor
untilthe times out,
it bottoms indicated. After break-in,
with no pressure reduce
9. Break-in
on system pump at setting
load-relief
compensator times
valve. and pressures
to 280 listedpsi),
bar (4060 below.
andAdjust
adjustthe load-relief
system load relief to
valve to the
cause pumppressure
to listed for the
compensate timestimes
three indicated.
to After
verify break-in,
that pump reduce
compensates on
9. compensator
Break-in pump atsetting
times and pressures listed below. Adjust the load-relief
to 280 bar (4060 psi), and adjust system load relief to
and
valve off pressure
to the stroke properly.
listed for the times indicated. After break-in, reduce
cause pump to compensate three times to verify that pump compensates on
compensator setting to 280 bar (4060 psi), and adjust system load relief to
and
causeoff stroke
pump properly. three times to verify that pump compensates on
to compensate
Time 30properly.
and off stroke seconds 30 seconds 30 seconds
Time
Pressure30 seconds 30 seconds 30 seconds 30 seconds
Time 30 seconds 30 seconds
Time
Pressure
Pressure 3062-69
seconds
Bar 30 seconds
200-207 Bar 30 seconds269-276 Bar.
Pressure
TESTCIRCUIT
CIRCUIT 900-1000 psi 2900-3000 psi 3900-4000 psi
TEST
6
TEST CIRCUIT
TEST CIRCUIT
1. Test pump 6 6
1. Test1.pump
2. Test Test pump
stand prime mover 5
2. Test stand prime mover
3. Test
2. Pump pressure
stand prime gauge
mover
3. Pump pressure gauge
5
5
4. Pump
3. Non-compensating
4. pressure gaugeflow
Non-compensating control
flow control 4
4
4.
5. Non-compensating
Load
5. pressure
Load pressure flow
gaugegauge control 4
5.
6. Load 6.pressure
Load Load valve
relief relief valve
gauge
7.relief
Safety bypass relief valve 3
6.
7. Load
Safety valve 3
8. Main flow meter valve
bypass relief 8
3 8
7.
8. Safety
Main bypass
9. flowCasemeter relief
drain valvegauge
pressure 8
8.
9. Main10.flow
Case drain
Casemeter
pressure
drain gauge
flow meter 2 1
9. Case
10. 11. drain
Case Filterpressure
drain assembly
flow meter gauge
with bypass 2 1 7
Circuit 1
13 13
Parker Hannifin Corporation
9 9 10 10 Hydraulic Pump Division
44 Marysville, Ohio USA
Circuit
Circuit 1 1
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Test Procedure P1/PD Maintenance
PERFORMANCE SPECIFICATIONS
PUMP WITH PRESSURE COMPENSATOR
STEP
CONDITION 018 028 045
REFERENCE
1 Rated Speed 1800 1800 1800
32 lpm 49 lpm 80 lpm
4 Output Flow at minimum pressure
minimum minimum minimum
30 lpm 47 lpm 77 lpm
5 Output Flow at rated pressure of 280 bar
minimum minimum minimum
6 Case leakage at rated pressure of 280 bar 1.6 lpm 2.3 lpm 5.3 lpm
9* Case leakage when compensated at 280 bar 5.7 lpm 5.7 lpm 9.5 lpm
10 Input Torque when compensated at 280 bar 17.5 Nm 21.2 Nm 42 Nm
Output Flow when pressure reduced to 273 bar 30 lpm 47 lpm 77 lpm
11
with compensator set at 280 bar minimum minimum minimum
* When using the A series compensators increase compensated case leakage by 2.3 lpm
TEST PROCEDURE
PUMP WITH PRESSURE COMPENSATOR
STEP
CONDITION REQUIRED VALUE MEASURED VALUE
REFERENCE
1 Set the pump speed to 1800 RPM 1800 rpm
Increase pump pressure compensator adjustment to
2 n/a
maximum.
3 Record input oil temperature 43-54 ° C (110 – 130 °F)
Set output load pressure to minimum.
4 see performance chart
Record output flow
Set output load pressure to 280 ± 2 bar
5 see performance chart
(4060 ± 30 psi). Record output flow
6 Record case leakage see performance chart
7 Set output pressure to 290 ± 2 bar (4200 ± 30 psi) n/a
Set pressure compensator to
8 n/a
280 ± 2 bar (4060 ± 30 psi)
9 Record case leakage see performance chart
10 Record input torque see performance chart
Reduce output pressure to 273 ± 2 bar
11 see performance chart
(3960 ± 30 psi). Record output flow
12 Verify no external leaks No leakage permitted
CONVERSION FACTORS
DEFINITION & UNIT
displacement in3/rev x 16.387 = cm3/rev cm3/rev x 0.06102 = in3/rev
flow gpm x 3.78 = L/min L/min x 0.2642 = gpm
power hp x 0.7457 = kW kW x 1.341 = hp
torque lb-ft x 1.3567 = Nm Nm x 0.7376 = lb-ft
pressure lbs/in2 (psi) x 0.06895 = bar bar x 14.50 = lbs/in2 (psi)
lbs/in2 (psi) x 6.895 = kPa kPa x 0.1450 = lbs/in2 (psi)
weight lb x 0.4536 = kg kg x 2.205 = lbs
force lb x 4.448 = N N x 0.2248 = lbs
volume in3 x 16.387 = cm3 cm3 x 0.06102 = in3
area in x 6.452 = cm
2 2
cm2 x 0.1550 = in2
length in x 25.4 = mm mm x 0.03937 = in
temperature degree F-32 = °C 1.8 x C+32 = °F
1.8
viscosity cSt x 1.0 = mm2/sec mm2/sec x 1.0 = cSt
SSU = cSt x 4.25 + 14 20 cSt = 99 SSU
Features
1. All-steel construction–no internal seals or gaskets to wear
out.
2. One-piece body eliminates threads and seals that may be
potential failure or leakage points.
3. Valve seats resist damage from shocks, surges and
contamination.
4. Poppet has an oil retention groove that lubricates the bore
2 3 4 and eliminates galling.
5
5. Poppet spring is isolated from the liquid flow stream,
minimizing turbulence.
6. Poppet is heat treated to help prevent damage from
shocks, surges and galling.
7. Close tolerance fit between poppet and poppet retainer
creates a cushion that protects valve from surge shock
damage.
8. Check valve body is shaped like an arrow to indicate flow
direction.
9. Available in a variety of standard and non-standard
crack pressures.
1 6 7 8 9
Dimensions (In.)
Valve ** Std Crack Max Operating
Part Number Inlet Port Thread Wrench Outlet Port Thread
Size Length Pressure (psi) Pressure (psi)
Flats
1/4” DC-250-** 1/4 - 18 NPSF 2.44 0.81 1/4 - 18 NPSF 1, 5, 65 3000
1/4” DC-250-FOFO-** .438 - 20 UNF 2.44 0.81 .438 - 20 UNF 1, 5 3000
3/8” DC-370-** 3/8 - 18 NPSF 2.75 0.88 3/8 - 18 NPSF 1, 5, 65 3000
3/8” DC-370-FOFO-** .562 - 18 UNF 2.75 0.88 .562 - 18 UNF 5 3000
1/2” DC-500-** 1/2 - 14 NPSF 3.5 1.06 1/2 - 14 NPSF 1, 5, 65 3000
1/2” DC-500-FOFO-** .750 - 16 UNF 3.5 1.06 .750 - 16 UNF 5, 65 3000
3/4” DC-750-** 3/4 - 14 NPSF 3.88 1.37 3/4 - 14 NPSF 1, 5, 65 3000
3/4” DC-750-FOFO-** 1.062 - 12 UN 3.88 1.37 1.062 - 12 UN 5, 65 3000
1” DC-1000-** 1 - 11.5 NPSF 4.88 1.62 1 - 11.5 NPSF 5, 65 3000
1” DC-1000-FOFO-** 1.312 - 12 UN 4.88 1.62 1.312 - 12 UN 5, 65 3000
1-1/4” DC-1250-** 1-1/4 - 11.5 NPTF 5.94 2.00 1-1/4 - 11.5 NPTF 5, 65 3000
1-1/4” DC-1250-FOFO-** 1.625 - 12 UN 5.94 2.00 1.625 - 12 UN 5, 65 3000
1-1/2” DC-1500-** 1-1/2 - 11.5 NPTF 6.37 2.38 1-1/2 - 11.5 NPTF 5, 65 3000
1-1/2” DC-1500-FOFO-** 1.875 - 12 UN 6.37 2.38 1.875 - 12 UN 5, 65 3000
2” DC-2000-** 2 - 11.5 NPTF 7.00 3.00 2 - 11.5 NPTF 5, 65 3000
2” DC-2000-FOFO-** 2.500 - 12 UN 7.00 3.00 2.500 - 12 UN 65 3000
80 120
60
Pressure Drop in PSID
40 60
30
40
20
20
10
0 0
0 2 4 6 8 10 0 10 20 30 40 50 60
120
110
100
90 1-1/2"
Pressure Drop in PSID
1-1/4" DC-1500
80 DC-1250
1"
70 DC-1000 2"
DC-2000
60
50
40
E Valves
30
20
10
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Flow in USGPM
Ordering Information
DC-✱✱✱-✱✱✱✱-✱✱
Crack Pressure:
1 = 1 PSI
5 = 5 PSI
65 = 65 PSI
Other crack pressures up to 100 PSI (in 5 PSI increments)
are available. Contact the Division for price and delivery
on non-standard crack pressures.
Fitting Style:
Size Blank = Female pipe inlet to Female pipe outlet
250 = 1/4” FOFO = Female O-ring Boss inlet to Female O-ring Boss outlet
370 = 3/8”
500 = 1/2”
750 = 3/4”
1000 = 1”
1250 = 1-1/4”
1500 = 1-1/2”
2000 = 2”
Series
ORDERING INFORMATION
ICFT – A – 61 32 (24) – N 015 – RØ
INSERTA®
FLOW CONTROL OPTION
CHECK VALVE R = FIXED RESTRICTIVE ORIFICE
FLANGE TYPE Ø = DIAMETER (INCH) OF THE FIXED
(w/ICT CHECK) ORIFICE. CUSTOMER MUST SPECIFY
THE ORIFICE DIAMETER.
DESIGN CODE SEE “RØ” ON DATA SHEET FOR
ORIFICE DATA.
MOUNTING PATTERN
CRACKING PRESSURE
61 = SAE CODE 61 003 = 3 PSI
62 = SAE CODE 62 007 = 7 PSI
015 = 15 PSI (STANDARD)
NOMINAL SIZE (USED WHEN ICT 030 = 30 PSI
08 = 1/2 24 = 1-1/2 CHECK SIZE IS
12 = 3/4 32 = 2 SMALLER THAN THE SEAL COMPOUND
16 = 1 40 = 2 1/2 NOMINAL SIZE) N = BUNA–N (STANDARD)
20 = 1 1/4 48 = 3 OMIT WHEN THE SAME V = VITON
CHECK VALVE
Inserta Products, Inc. 4-BOLT ø 1 ø 1
Blue Bell, Pa. 19422 FLANGE TYPE
© 2010 ADACONN® + INSERTA® All rights reserved. www.adaconn.com / www.inserta.com
CHECK VALVES
FACE SEAL
*Seal Protector must be retained
by the mating standard SAE Face
Seal groove’s inner support area.
* SEAL PROTECTOR
W H
CODE 61
MOUNTING NOMINAL NOM. FLOW W H L O-RING THREAD-IN
PATTERN– SIZE RATE (GPM) SIZE NO. CHECK VALVE
SIZE PART NO.
CHECK VALVE
Inserta Products, Inc. ø
4-BOLT 1 ø 1
Blue Bell, Pa. 19422
FLANGE TYPE
© 2010 ADACONN® + INSERTA® All rights reserved. www.adaconn.com / www.inserta.com
Catalog HY15-3502/US
Technical Tips Pressure Control Valves
CV
INTRODUCTION
This technical tips section is designed to help familiarize you with the Parker line of Pressure Controls. In this
Valves
Check
section we highlight new products to this catalog as well as some design features of our pressure control line. In
addition we present common options available to help you in selecting products for your application. Finally we
SH
give a brief synopsis of the operation and applications of the various product offered in this section.
Shuttle
Valves
NEW PRODUCTS
LM There are several new additions and product improvements to our Pressure
Controls product line.
Load/Motor
Controls
Variety of Adjustments
Flow
DC
Directional
Controls
“D”-Ring
MV Standard 4301 Polyurethane Seal
High Pressure Design eliminates the need for backup rings
Pilot operated valves are rated providing easier manifold installation.
to 350 Bar (5000 PSI) for use (For more information on “D”-Ring
Manual
Valves
SV
Solenoid
Valves
CE
Electronics
Internal Screen
Coils &
valves are designed with a high rate operated pressure controls reduces
bias spring pressure, enhancing stability. the manifold clearance required.
Data
Valves
Check
Control products. As such, some of the options
mentioned below may not be available on all valves.
SH
Consult the model coding and dimensions for each
valve for specifics. Here are some of the common
Shuttle
Valves
options available.
LM
Load/Motor
Adjustment Types: Parker offers four primary types Tamper Resistant - The tamper
Controls
of adjustments for most of the pressure control pro- resistant option is a screw adjustable
ducts. Samples of these types are shown below. Please valve with a steel cap installed to
note all options may not be available for all valves. conceal the adjustment. The cap is FC
Consult the individual catalog pages for more details. designed so that the internal edges
clamp into the groove of the valve
Controls
adapter. Once the cap is installed,
Flow
Screw Adjustment - Valve can be it cannot be removed without damaging
adjusted with an allen wrench. Lock the cap and the valve. When a valve is ordered with PC
nut included to maintain desired the tamper resistant option, it will be preset at the
Pressure
Controls
setting after adjustment. This is the factory, and the cap will be included in a separate
most common adjustment option plastic bag to allow for fine tuning at the customer site.
available on most Parker products. Parker offers tamper resistant cap conversion kits for LE
most pressure control valves. For kit numbers consult
Elements
individual valve pages.
Logic
Knob Adjustment - An aluminum
knob is added to the standard screw
DC
adjustment. A lock knob is provided Seals: The Winner’s Circle products feature a
Directional
to help maintain the desired setting standard 4301 Polyurethane “D”-Ring. The “D”-Ring
Controls
after adjustment. Parker offers knob eliminates the need for backup rings. The majority of
conversion kits for most pressure the products are available in Nitrile or Fluorocarbon
control valves. For kit numbers consult Seals. You should match the seal compatibility to the MV
individual valve pages. temperature and fluid being used in your application.
Manual
Valves
Pressure Range: Parker offers a range of spring SV
Fixed Style - In most cases, the settings for the Pressure Control product line. You
Fixed Style product is a screw want to choose the setting that best meets the
Solenoid
Valves
adjustable product with a steel collet operating range. The model callout is equivalent to the
threaded over the screw adjustment. maximum setting (in psi) of the spring divided by 100
These valves are preset at the (i.e. 50 = 5000 psi). PV
Proportional
factory.
Valves
CE
Electronics
Coils &
BC
Bodies &
Cavities
TD
Technical
Data
spring force. Inlet pressure on the nose (port 1) of the poppet acts
against the spring force to unseat the poppet at the valve setting and allow flow to pass to tank. Since the
pressure is working directly on the spring, this valve is very fast responding. It is not the best choice for system
FC
pressure regulation as it is slightly noisier than pilot operated relief valves and has higher pressure rise.
Note: Any backpressure on port 2 would be additive to the spring setting.
Controls
Flow
PC
Differential Area Relief Valves
Differential area relief valves also are
Pressure
Controls
Pressure
(2)
also best suited for intermittent appli-
cations where fast response is critical. Tank
(1)
LE These valves are often used as cross-
over relief valves to chop pressure spikes.
Elements
rate and have a lower pressure rise than the standard directing
DC acting relief. The poppet design allows for low leakage.
Directional
OPERATION - Pressure on the inlet (port 2) of the valve acts on the differential area of the poppet (difference
Controls
between the O.D. of the poppet and the seat diameter) to produce a force which is opposed by the spring force.
When pressure reaches the valve setting, the poppet is pushed off its seat, permitting flow to tank.
MV Note: Any backpressure on port 1 would be additive to the spring setting.
Manual
Valves
the valve setting, the pilot ball unseats. The pilot flow creates a pressure
CE
imbalance across the main spool causing the spool to move and allowing flow from
inlet (port) 1 to tank (port 2.) Note: Any backpressure on port 2 would be additive to the spring setting.
Electronics
Coils &
BC
Bodies &
Cavities
TD
Technical
Data
Features
Valves
(2)
PC
(1)
Pressure
Controls
Specifications
LE Rated Flow 45 LPM (12 GPM) Performance Curve
Elements
5000 345
Maximum Tank 350 Bar (5000 PSI)
Pressure 4000 276
Pressure, PSI
MV
Reseat Pressure 75% of crack pressure 3000 207
Manual
Valves
0
LPM 8 15 23 30 38 45 53
Operating Temp. -40°C to +93.3°C (Nitrile) 0
GPM 2 4 6 8 10 12 14
PV Range/Seals (-40°F to +200°F) Flow (Q)
Proportional
Viscosity
Coils &
Cavity C08-2
(See BC Section for more details)
TD
Form Tool Rougher None
Technical
Finisher NFT08-2F
Data
Valves
Check
SH
25.4 (1.00)
Dia. Knob
Shuttle
Valves
LM
72.8 75.3 74.6
71.7
Load/Motor
(2.86) (2.96) (2.94)
(2.82)
Controls
FC
Controls
Flow
* 3/4
16UNF-2A Thread 22.4 (.88) Hex. PC
31 N.m. 27.7
(276 In.-Lbs.) (1.09)
Pressure
Controls
(2) Torque
* For applications over 210 Bar
(3000 PSI), Thread Lock
Compound is recommended.
(1) Ø 12.7 LE
(.50)
Elements
Logic
THIRD-ANGLE Screw/Knob Version Fixed Cap/Tamper Resistant Version
PROJECTION
DC
Directional
Controls
Ordering Information
RDH083 MV
Manual
Valves
Differential Area Style Range Pressure Material Size
Relief Valve Setting
SV
Code Adjustment Style / Kit No. Code Seals / Kit No. Code Body Material
Solenoid
Valves
F Fixed style, preset at factory. Omit Nitrile / (SK08-2N) Omit Steel
K Knob Adjust (717784-10) V Fluorocarbon / (SK08-2V) A Aluminum
S Screw Adjust
PV
T Tamper Resistant Cap (718083)
Proportional
Optional Pressure Setting Code Port Size Body Part No.
Pressure ÷ 10 Omit Cartridge Only
Valves
Code Pressure Range i.e. 235 = 2350 PSI 4P 1/4″ NPTF (B08-2-*4P)
(Omit if standard setting is used) 6P 3/8″ NPTF (B08-2-*6P)
15 6.9 - 103 Bar (100 - 1500 PSI) Setting Range:
Standard Setting: 4T SAE-4 (B08-2-*4T) CE
100 to 5000 PSI
Electronics
51.7 Bar (750 PSI) @ crack pressure All settings at crack pressure, 6T SAE-6 (B08-2-*6T)
approximately .95 LPM (.25 GPM)
Coils &
Standard Setting:
172.4 Bar (2500 PSI) @ crack pressure
approximately .95 LPM (.25 GPM)
TD
Technical
Data
9
PT Series
Applications
Together we can…
10
1
PT Series
Features
2
8 6
11
PT Series
Inside-Out Element
Flow Path
Contamination contained
within the element
12
PT Series
PT4-3 Element Performance
:[[^X^ZcXn Capacity
7ZiVGVi^c\ :[[^X^ZcXn PSID BAR
&%%%% 100
'F
6
*F
*F
80
2Q
&%%% ..#. 5Q 5
&%F 10Q
20Q
60 4
'%% ..#*
&%% ..#%
'%F 3
40
'% .*#% 2
20
1
' *%#%
0 0
% ) - &' &+ '% 0 20 40 60 80 100 120
B^XgdcH^oZX Capacity grams
15 1.0
10
PSID
BAR
0.5
0 0.0
0 10 20 30 40 50
GPM
Results typical from Multi-pass tests run per test standard ISO 16889 @ 45 gpm to 100 psid terminal - 10 mg/L BUGL.
Refer to Appendix on pages 264-265 for relationship to test standard ISO 4572.
17
PT Series
Specifications - PT4
PORT OPTIONS -
SEE TABLE
2.41
1.11
2.70
15/16 (24MM) HEX
TORQUE 200-240 IN-LBS 941664
Ø3.33
O-RING
THRU. HOLE
n.345 ON A
Ø5.50 B.C. 1/8-27 PTF
5 PLC'S 2 PLC'S
EQ. SPACED
Ø3.09
SECTION A-A
19
PT Series
PT4 Parts List
4
1.51
38.4
.36
9.1
5
3
1/8 NPT
THREAD
1.58
40.1
21
PT Series
How to Order
Select the desired symbol (in the correct position) to construct a model code.
Example:
Notes:
1. The filters include the element you
select already installed.
2. When “W” is selected in Box 8, the
PT2 port options are “N12” and
“S12”; the PT4 port options are
“N16” and “S16”.
22
HYDRAULIC
World Pressure Filters - 7000 psi
WPF Series
A New Standard in 7,000 psi Pressure Filters
Features:
High strength ductile iron filter head with integral indicator port
Proprietary element end cap assembly includes bypass and reverse flow valves
WPF Series
Specifications
Maximum Allowable Operating T-Port
Pressure (MAOP):
7000 psi (483 bar)
Operating Temperatures:-
15°F (-26°C) to 250°F (135°C)
Materials:
Head: SG Iron
Bowl: Steel
Indicator: Stainless Steel
with Plastic Connectors
Weights:
WPF1 9 lbs. (4.1 kg)
WPF2 13 lbs. (5.9 kg)
WPF3 21 lbs. (9.5 kg)
WPF4 45 lbs. (20.4 kg)
WPF5 67 lbs. (30 .4 kg)
Operating Temperatures:-
15°F (-26°C) to 250°F (135°C)
Materials:
Head: SG Iron
Bowl: Steel
Indicator: Stainless Steel
with Plastic Connectors
Weights:
WPF2 18 lbs. (8.2 kg)
WPF4 63 lbs. (28.6 kg)
WPF5 70 lbs. (31.7 kg)
WPF Series
Service & Maintenance Instructions
WPF Series
How to Order
Select the desired symbol (in the correct position) to construct a model code.
Example:
BOX 1 BOX 2 BOX 3 BOX 4 BOX 5 BOX 6 BOX 7 BOX 8
WPF 2 10QE V M2 K S12 1
Replacement Elements:
Media WPF1 WPF2 WPF3 WPF4 WPF5
Ecoglass III, 02QE 941029Q 941032Q 941035Q 941038Q 941041Q
Standard Collapse
Ecoglass III, 05QE 941030Q 941033Q 941036Q 941039Q 941042Q
300 psid/21 bar)
Ecoglass III, 10QE 941031Q 941034Q 941037Q 941040Q 941043Q
High Collapse Microglass III, 02QH 941044Q 941046Q 941048Q 941050Q 941052Q
(2000 psid/138 bar) Microglass III, 10QH 941045Q 941047Q 941049Q 941051Q 941053Q
Features:
- Die cast aluminum end covers.
- By-Pass valve available on most models(see tables).
- End caps are designed to provide a positive interlock with
epoxy bond to prevent leakage.
- Rated flow capacity at 5 ft/sec.
- Suitable with all petroleum base oils and fire retardant
hydraulic fluids, coolants and lubricants.
A B C D Rated Flow
Part Number
Outlet Port Wrench Flat Overall Length Outside Diameter @ 5 ft/sec
SS-003P006-1-01 3/8” NPT 1.20” 3.00” 2.75” 3 GPM
SS-005P008-1-X1
SS-008P012-1-X1
1/2” NPT
3/4” NPT
1.20”
1.50”
3.25”
3.25”
2.75”
2.75”
5 GPM
8 GPM
5
SS-010P100-1-X1 1” NPT 1.75” 5.50” 2.75” 10 GPM
SS-023P104-X-X 1 1/4” NPT 2.25” 6.60” 3.20” 23 GPM
SS-032P108-X-X 1 1/2” NPT 2.35” 8.60” 3.20” 32 GPM
SS-053P200-X-X 2” NPT 3.00” 7.20” 4.20” 53 GPM
SS-075P208-X-X 2 1/2” NPT 3.50” 9.30” 4.20” 75 GPM
SS-116P300-X-X 3” NPT 4.00” 12.50” 4.20” 116 GPM
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 155
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
8 7 6 5 4 3 2 1
7 8
E E
6 6
B 17 B
23.55 13
28.74 40.36
14
12
12 5
4 3
F D 2
6
31.00 44.00
UNLESS OTHERWISE SPECIFIED: NAME DATE
04
MATERIAL
ITEM 15 DETAIL CHANGE JP 8/09/13 DRAWING IS THE SOLE PROPERTY OF
AISI 304
SIZE DWG. NO. REV
B M104178
GLOBAL DRILLING SUPPORT INTL. ANY
12.00
16.00
3x, .75
TOP VIEW
12 3.00 6.00
30.36
C C
42.50
23.36 18
10.00
2x, .56 21.25
A
R.38 INSIDE
TYP
6.00 4.18
B 4.00 18 B
4x, 12.50 6x, .56
2x, 2.28
2.45 BOTTOM VIEW OF ASSEMBLY
1.22
40.00
7.00
.13
5.50
BOLT CIRCLE
B
5x, 90° 3.38 2.00
D D
THRU
1/8 x 45 CHAMFER 6X .31 THRU ALL
C 3/8-16 UNC - 2B THRU ALL
5X .31
45°
.75
DETAIL C 4.5
SCALE 1 : 2
2.50 1.00
54°
B 2.00 .18
90° 4.23
SECTION B-B
SCALE 1 : 4 ITEM 16 DETAIL
C C
ITEM 17 DETAIL
15.000
10.500
20x, .344
16.00
GDS International
TITLE:
A HPU TANK, A
5X .31 1.06
3/8-16 UNC - 2B .75
10 NOTE CLOCKING POSITION OF BOLT HOLES
BEVEL SIDE TO TANK.
D D
9.00 3/16
2X
8.12
11.00 2.88
2X
G
4.15
14.60 3.26
5.50 5.00
4.5 2.75 10 4.11
9 DETAIL G 16
C C
9 3X 3X SCALE 1 : 6
8.00 1.50
3/16
3/8-16 Tapped Hole 3X TYP
3/16
SECTION E-E
SCALE 1 : 12
1.06
14.91
INSIDE 7
9
2.00
1
8 3/16
6 TYP
.63 3/16
B B
8 7 18
2.45
3/16 FLUSH INSIDE
TYP 1.24
6 3/16
8 3/16 3/16
3/16 3/16 3
6
.98
SECTION F-F
4 SCALE 1 : 8 GDS International
1/8 1-4 TITLE:
A 5 HPU TANK, A
TYP
1/8" 1.00
12.00
D
16 D
5.63 INSIDE 7.62 H
12.00 9
.25 15
7
TYP 6"X6" J-BOX
16.56 1/8
MOUNT 17
PRESSURE FILTER
C
MOUNT
3.33 C
11
45°
6.00 6.00 5
5.00
4.75 1.25 .13 2x, .31
R.75 1.00 2
4x, .438 .25
6.00 1.00
.59
1.00
4.13
1.00
DETAIL ITEM 15
2x, 2.188 DESC: ANGLE, 1" X 1" X 1/8"
REQD: 2
REFERENCE HOLE
2x, 1.00 DIMENSIONS 15
B 2.05 B
DETAIL ITEM 11
2x, 1.23 DESC: ANGLE, 6" X 6" X 1/4"
REQD: 1
40.00 4x, .31
2x, 1.25
2x, 3.54 2x, R.25
15.00
.25 .63
1.71
45.00° 2x, 6.81
5.25 28.00
GDS International
DETAIL ITEM 1 TITLE:
A
DESC: PLATE 3/16"
REQD: 1 HPU TANK, A
B M104178
MATL: ASTM A 572
REQD: 1
2x, 4.00 DETAIL H 7
SCALE 1 : 6
SCALE: 1:16 WEIGHT: 394.72 SHEET 5 OF 7
8 7 6 5 4 3 2 1
3.00
2x .56 3.82
10.00 13
23.18 30.00
2x 2.28 40.00
1.78
ITEM 13 DETAIL
GDS International
TITLE:
A M104178 7
SCALE: 1:16 WEIGHT: 394.72 SHEET 6 OF 7
5 4 3 2 1
TAG X LOC Y LOC SIZE
B1 B3 C1
A1 5.00 9.82 3.00 THRU
B2 D1
B1 5.75 25.37 1.13 THRU
C2 B2 7.56 21.37 1.13 THRU
28.55 B3 9.38 25.37 1.13 THRU
A1
C1 13.63 25.37 1.41 THRU
X
6x .56
2x3.00
2x12.50
5.38
9.13 HPU TANK,
GDM, 120 GAL
5.82 1.45 SIZE DWG. NO. REV
31.00
A M104178 7
SCALE: 1:16 WEIGHT: 394.72 SHEET 7 OF 7
5 4 3 2 1
M
C McDANIEL
Liquid Filled, Stainless Steel Case
Utility Gauges
“For the price-conscious buyer . . .
McDaniel utility gauges are designed for the price-
conscious buyer and user who have an emphasis on
maintaining quality and accuracy in a general
purpose gauge.
SPECIFICATIONS
Accuracy: Temperature Utilization:
ASME B40.1 standard (Grade B) (3 – 2 – 3%) -4 + 176 degrees Farenheit.
-20 + 80 degrees Celsius.
Dial:
White enameled aluminum. Black figures. Pressure Utilization:
Static: 75% maximum scale.
Case: Dynamic: 66% maximum scale.
304 Stainless steel.
Stem and Socket:
Pointer: Brass. Restrictor screw standard.
Black enameled aluminum. J6 = 1/4” NPT (1/8” special order available)
T6 = 1/4” or 1/8” NPT available
Lens:
Polycarbonate. Dial Sizes / Ranges Available
2” - (T6) / Vac, Comp, Rec 3-15, up to 5,000 psi
Precision Movement 2 1/2”- (J6) / Vac, Comp, Rec 3-15, up to 15,000 psi
Brass.
Configurations Available:
Bourdon Tube: Bottom connected standard
(L) = Center-back connected
Copper alloy (C Form 600 PSI & below). (U) = U-Clamp mounted, Center-back connected
Phosphorous bronze (Spiral 800 PSI & above). (P) = Front flange, Center-back connected
I CAN EXPLODE!
... and can injure you
WARNING
and those around you.
•
~~~0~~8i7e·IL~~~!~~~~~A17~0~;
(504] 758-2782 • FAX (504) 758-1688
www.mcdanielcontrols.com
Model Gauge Selecta·on Guide
s * 1/4 11
STAINLESS
STEEL
Fillable
STAINLESS
STEEL
12)
1.5°/o
Grade A
Up to
10,000 psi
Lexan Lens
Compensating diaphragm
M_!IUNTING STYLES:
" Weather Tight Case
1/s" 304
T6 lf4"
STAINLESS
STEEL
Filled** en
,_ Utility Gauge
TB %"
ENAMELED
STEEL
Non·Fillable
Bottom, Center-back, U-Ciamp (except T71,
Panel mount
K 1(4"
STAINLESS
STEEL
Fillable
STAINLESS
STEEL
12)
Up to
20,000 psi
_,_ Repairable
-:- Weather Tight Case
Restrictor screw for pulsation dampening
_,_ Solid Front Blow out Back Case Available
* lfs" 304
Up to
J en
STAINLESS MOUNTING STYLES:
STEEL 1o/o 6,000 psi Bottom, Lower-back, U-Ciamp, Panel mount, Rear Flange,
%"
. en Grade 1A CElllter-Back available by spec1al order,
Fillable <(
* lfs" a: Laminated Safety Glass Lens " Repairable
u %"
CAST
BRASS
Fillable
m
131
Up to
10,000 psi
One-piece case and stem
MOUNTING STYLES:
Bottom, Center-back , U-Ciamp
_, Heavy-duty
2~" K9
STAINLESS
STEEL
STAINLESS
STEEL
2-1-2% Up to ,_ Rolled Threads " Welded Case and Stem
%" Grade A 10,000 psi MOUNTING STYLES:
Fillable 121 Bottom, Lower-back, U-Ciamp, Front Flange, Rear Flange
J6 1/4"
STAINLESS
STEEL
Filled** en
Up to
15,000 psi
Ut1l1ty Gauge
Polycarbonate Lens
JB 1/4 11
SPECIAL
ENAMELED
STEEL
Non-Fillable
FILLED ACCURACY
15,000 psi
RANGE
Bottom, Center-back, U-Clamp, Panel mount
(' 1 K =To avoid duplicate part numbers, use 1K when specifying 0-1000 range on models J6 and T6)
(' 4K = 4,000 psi range, non-stock, special order for: Models A, B, C, D, E, F, G, H, MPB, S, Y, z
To order mercury, FT of Sea water, or special ranges, describe the desired range, after the MODEL type.
Your new Orange Research Differential Pressure Instrument is a this instrument may need attention. Erratic pointer or switch
rugged instrument featuring simplicity of design to provide action may indicate that cleaning is required. For cleaning:
dependable and efficient service. Because it is an instrument it
should be handled with care. Read all instructions carefully
before attempting to install the instrument.
CAUTION: Do not exceed nameplate maximum operating
pressure. Use only fluids compatible with wetted parts.
HOW IT WORKS
The instrument operates on the difference between two pressures
(delta-P). The sensing element is a spring biased piston which
moves linearly in proportion to the difference between two basic
pressures. A magnet on the HI pressure side of the piston
assembly moves with the piston and rotates a follower magnet
located adjacent to the pressure cavity. The gauge pointer is
located at the end of the rotary magnet shaft and rotates with the 1. Remove the unit from service.
magnet to provide gauge readings proportional to differential 2. Remove both end caps with a 1” spanner wrench.
pressure variations. There are no mechanical seals between the 3. Remove the range spring and the piston/magnet assembly.
pressure side of the instrument and the gauge mechanism side. BE CAREFUL NOT TO LOSE STACKING SPACERS.
This is accomplished by coupling the forces between two adjacent 4. Clean parts in a solvent solution after removing O-Ring seals
magnets through a solid wall. from the end caps since some solvents will attack the seal
material.
SWITCH UNITS: On switch and indicating switch models, reed
5. It is good to practice to replace the O-Ring seals while the
switches are located adjacent to the pressure chamber and are
instrument is dismantled. DO NOT ATTEMPT TO MOVE
actuated when the piston magnet field interacts at a preset point
THE TEFLON PISTON SEAL FROM THE PISTON. If piston
with the reed switch armature. Reed switch set points are
seal is damaged order a new piston/magnet assembly.
adjustable.
To reassemble:
1. Lubricate the piston bore lightly with petroleum jelly, light oil
INSTALLATION or silicone grease.
Check instrument and identify the HI and LO markings. HI 2. Install the HI end cap first and tighten.
identifies the high pressure port; LO the low pressure port. If 3. Install the piston/magnet assembly (magnet facing HI
instrument is installed backwards, it will neither operate nor be pressure port).
damaged. Reverse connections if installed backwards. The 4. Insert stacking spacers in bottom of piston spring pocket and
instrument can be line mounted, bracket mounted or panel insert range spring.
mounted depending upon the model purchased. 5. Reassemble LO end cap making certain that spring is seated
Under normal conditions Series 1201 Instruments are designed in the end cap spring pocket.
for line pressure to 3000 psig and can sustain a continuous 3000 6. Tighten LO end cap and the instrument is now ready for
psig forward or reverse overpressure. service.
IMPORTANT: Magnet end of piston/magnet assembly
It is recommended that the instrument be located above the MUST be facing the HI pressure port of the instrument;
pressure source to allow drainage of the unit. otherwise, the instrument will not operate.
LENS REPLACEMENT: To replace a broken lens, check to see if
IMPORTANT: Because of the magnetic movement, this the lens is held on by a bezel or a snap-ring. To remove a bezel,
instrument should never be mounted in direct contact with a steel
twist off by hand (watch out for the broken glass).To remove a
surface; otherwise, a calibration shift will occur. Mount the snap-ring, pry out the ring with a small screwdriver. Remove all
instrument so that the pressure body is at least 1” away from glass chips, insert new lens and re-insert the bezel or snap. With
metal surfaces with non-magnetic spacers or an aluminum- snap-rings, locate the ring joint at the bottom of the gauge.
mounting bracket. Flush panel mounted instruments will not be
affected by contact with aluminum panels. However, 2” and 2½” POINTER REPLACEMENT: (Probably damaged when lens was
gauges flush mounted in a steel panel may require resetting of broken). Remove bezel or snap-ring as previously described and
the pointer at zero. This should be done at time of manufacture clean out glass chips. Remove old pointer with pointer puller or
but can be reset in the field with a small loss of accuracy. two small screwdrivers opposite each other under pointer hub. Pry
off evenly being careful not to bend the pointer shaft. Install new
pointer dead on zero. Re-install lens, as described under lens
replacement.
MAINTENANCE
Other than replacing broken lens there is only one area where
REPLACEMENT PARTS
GAUGE GLASS PLASTIC POINTER SST BEZEL
DIA. LENS LENS (press-fit)
2” GG1-1 GG2-1 AF15-1 M1-5
2 ½” GG1-2 GG2-2 AF15-2 M2-5
3 ½” GG1-3 GG2-3 AF15-3 M4-5
4 ½” GG1-4 GG2-4 AF15-4 M5-5
6” GG1-5 GG2-5 AF15-5 ---
PISTON/MAGNET ASSEMBLY
Aluminum SD12-1
316 SST SD12-3
PVC SD12-4
Naval Brass SD12-5
RECALIBRATION
Recalibration of this instrument is not required. However, if the range spring is damaged or a new dial is required, the instrument must
be returned to the factory for the parts and recalibration.
NOTE: When ordering replacement parts, identify instrument SO# or WO# from the nameplate. Identify parts required and quantity.
"B"-STYLE "E"
DIAL CASE "D" 1.00 DIAL CASE SIZES & DIMENSIONS
[25.4]
CL .50
GA. [12.7] 3.5" 4.5" 6.0"
"C" A 4.25[108.0] 5.25[133.4] 6.68[169.7]
B 3.94[100.1] 4.94[125.5] 6.44[163.6]
"B"
2.00 C .25[6.4] .62[15.7] 1.35[34.3]
"A" [50.8] D .13[3.3] .13[3.3] .13[3.3]
CL
E .72[18.3] .72[18.3] .75[19.1]
PORT
.75
[19.1]
"F"-STYLE "E"
DIAL CASE SIZES & DIMENSIONS
DIAL CASE "D" 1.00
[25.4]
3.5" 4.5" 6.0"
CL .50 5.00[127.0]
A 6.00[152.4] 7.62[193.5]
GA [12.7] 3.94[100.1]
B 4.94[125.5] 6.44[163.6]
C.25[6.4] .62[15.7] 1.35[34.3]
"C"
D.13[3.3] .13[3.3] .13[3.3]
"B"
2.00 E.72[18.3] .72[18.3] .75[19.1]
[50.8] PANEL CUTOUT: PANEL CUTOUT: PANEL CUTOUT:
"A" CL 4.00 5.00 6.50
PORT F 3 MTG. HOLES 3 MTG. HOLES 3 MTG. HOLES
.187 EQUALLY .218 EQUALLY .218 EQUALLY
SPACED ON A SPACED ON A
.75 4.56 B.C.
SPACED ON A
5.38 B.C. 7.00 B.C.
[19.1]
"F"
2.00 1.63
[50.8] [41.4]
STD. FINISHED
WIRE LENGTH STD. MTG. HOLES
1.00 1/4-20 UNC-2B x .375
IS 12 in. FULL THD. DEPTH
[25.4] 1.13 (2) PLCS.
1.43 [28.7]
[36.3]
2.25
1 SWITCH SHOWN [57.2]
1.00
[25.4]
.50
.50 3.00
[12.7]
[12.7] [76.2]
1.00
[25.4] 3.62
[91.9]
1.43
[36.3]
SHT. 2 of 2 REV. A
Product specifications for model 1201
Product Specifications, (gauge, switch)
Sensor type Piston
Functions Gauge, Gauge/Switch, Switch
Calibration medium Units with EPDM Seals: Water Brass or PVC: Water Alum or SS: Hydraulic Oil
Dial sizes PVC: 2.5”,3.5” style “M” only All Others: 2.5”,3.5”,4.5”,6” style “B” and “F”
Dial Starting Mark Approximately 10% of full scale
Lens PVC: Plastic All Others: Glass, Plastic
Range Min: 0-5 psid Max: PVC: 0-60 psid, All other 0-150 psid
Accuracy ±2% of full scale ascending after rap at room temperature
∗
Calibration accuracy is affected by temperature, liquid filling and follower-pointer applications.
Repeatability ±2% of full scale
Max. line\min. burst pressure PVC: 200\750 psig All Others: 3000\10500 psig
Direction of Pressure PVC: Left to Right All Others: Left to Right, Right to Left available (reverse porting)
Porting size & orientation PVC: 1/4 NPT Porting All Others: 1/8,1/2 NPT Porting and MS Ports
In-Line Only Gauge: In-Line, Back or Bottom
Gauge/Switch: In-Line, Back, or Bottom
Switch: In-Line Only
Standard max. temperature PVC: 120°F All Others: Gauge 200°F, 150°F plastic lens
Gauge/switch 176°F, 150°F plastic lens
Switch 176°F
High Temperature PVC: N/A All Others: 450°F (SST only, not available in aluminum or brass)
Minimum temperature PVC: 32°F All Others: Consult factory
Switch Type External hermetically sealed reed switch
Switch Adjustability Upper 80% of full scale ascending, 70% for B & C form switches in SS
Switch Dead Band 5-20% full scale
Switch Options PVC: N/A
All Others: -A SPST N/O (120VAC,0.7A,70VA;200VDC,1.0A,50W)
-B SPST N/C (120VAC,0.25A,5VA;175VDC,0.25A,5W)
-C SPDT (120VAC,0.25A,5VA;175VDC,0.25A,5W)
Switch Setting Top of range ascending or other set points within adjustability ascending or descending
Static & Piston Seals PVC: Viton All Others: Buna-N (Viton,Teflon,Neoprene,EPDM,Flourosilicone optional)
Primary Wetted Parts PVC: PVC All Others: aluminum, 316 SS, naval brass (in-line only)
Secondary Wetted Parts All: SS range spring, SS spacers, ceramic magnet, Teflon piston seal
Teflon coated spring, spacers & magnet available
Certification CSA (File 043810) ∗Consult factory for CE equivalent.
! WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED
HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide
product and/or system options for further investigation by users having expertise. It is important that you analyze all aspects
of your application, including consequences of any failure and review the information concerning the product or system in the
current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user,
through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring
that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are
subject to change by Parker Hannifin Corporation and its related companies at any time without notice.
Oil Coolers
Choosing the right cooler requires Cooling capacity
precise system sizing. The most
reliable way to size a cooler is
with the aid of our calculation
program. This program, together
with precise evaluations from our Lifetime
experienced, skilled engineers,
gives you the opportunity for more
cooling per $ invested. Overheating – an expensive recommended values. The correct
problem working temperature produces
An underestimated cooling a number of economic and
capacity produces a temperature environmental benefits:
that is too high. The consequences • The hydraulic system’s
are poor lubricating properties, useful life is extended.
higher internal leakage, a higher • The oil’s useful life is
risk of cavitation, damaged extended.
components, etc. Overheating • The hydraulic system’s
leads to a significant drop availability increases –
in efficiency which can be more operating time and
detrimental to our environment. fewer shutdowns.
• Service and repair costs
Temperature optimization – are reduced.
a basic prerequisite for • High efficiency level
cost-efficient operation maintained in continuous
Temperature balance in a hydraulic operation – the system’s
system occurs when the cooler can efficiency falls if the
cool down the energy input that temperature exceeds the
the system does not consume – ideal working temperature.
the system’s lost energy
(Ploss = Pcool = Pin – Pused).
4
ULAC with AC Motor
For industrial use – maximum cooling capacity 400 HP*
Optimized design with right choice of materials and components ensures reliable
and long lasting cooler with low service and maintenance costs.
Compact design resulting in lighter weight unit yet with higher cooling capacity
and lower pressure drop.
Easy to maintain and easy to retrofit into many applications.
Quiet fan design due to optimization of material and blade design.
AC motor – NEMA three phase motors are standard. Wide range of operating
voltages and frequencies available.
Cooler core with low pressure drop and high cooling capacity.
Optimized design and the right choice of materials and components produce a long
useful life, high availability and low service and maintenance costs.
Integrated circulation pump produces an even flow with low pressure pulsations.
Easy to maintain and easy to retrofit in many applications.
Compact design and low weight.
Quiet fan and pump.
Cooler core with low pressure drop and high cooling capacity.
Optimized design with right choice of materials and components ensures reliable
and long lasting cooler with low service and maintenance costs.
Compact design resulting in lighter weight unit yet with higher cooling capacity
and lower pressure drop.
Easy to maintain and easy to retrofit into many applications.
DC motor 12V/24V
Quiet fan and fan motor.
Optimized design and the right choice of materials and components produce a long
useful life, high availability and low service and maintenance costs.
Compact design resulting in lighter weight unit yet with higher cooling capacity
and lower pressure drop.
Easy to maintain and easy to retrofit into many applications.
Hydraulic motor with displacement from 8.4 cc/rev to 25.2 cc/rev.
Collar bearing for fan motor on larger models provides longer operating life.
Quiet fan design due to optimization of material and blade design.
Cooler core with low pressure drop and high cooling capacity.
5
Calculate the cooling capacity requirement
Cooling Flow? Measure in Contact
Installed
capacity Pressure? your existing Olaer USA
horse power
requirement? Pump efficiency? unit representative
Theoretical
horse power
losses
7
Catalog HY10-1700/Americas ULAC
The ULAC oil cooler with AC motor is optimized • Easy to maintain and easy to retrofit
for use in the industrial sector. Together with a wide into many applications.
range of accessories, the ULAC cooler is suitable for
installation in most applications and environments. • Quiet fan design due to optimization
of material and blade design.
• Optimized design with right choice
• AC motor – NEMA three phase motors
of materials and components ensures
are standard. Wide range of operating
a reliable and long lasting cooler with
voltages and frequencies available.
low service and maintenance costs.
• Cooler core with low pressure drop
• Compact design resulting in lighter
and high cooling capacity.
weight unit yet with higher cooling
capacity and lower pressure drop.
9
Catalog HY10-1700/Americas ULAC
12
Catalog HY10-1700/Americas ULAC
TYPE
A B C D E F G H I J K L M Nø
ULAC 007B 5.2 6.3 3.2 8.0 0.24 11.7 15.6 8.0 14.4 20.1 8.4 19.8 8.8 0.35
ULAC 011B 5.4 9.0 3.2 8.0 0.12 14.3 18.5 8.0 17.3 20.1 9.8 20.8 9.8 0.35
ULAC 016B 5.2 11.7 3.2 8.0 0.28 17.0 20.7 8.0 19.5 20.1 10.9 21.6 10.7 0.35
ULAC 023D 5.2 14.9 3.2 14.0 0.20 20.2 24.0 14.0 22.8 20.1 12.6 22.2 11.3 0.35
ULAC 033D 5.2 19.1 3.2 14.0 NA 24.5 28.4 14.0 27.2 20.1 14.8 23.1 12.5 0.35
ULAC 033F 5.2 19.1 3.2 14.0 NA 24.5 28.4 14.0 27.2 24.0 14.8 25.6 12.5 0.55
ULAC 044D 4.6 26.1 3.2 14.0 NA 31.5 34.1 14.0 27.2 20.1 17.6 24.1 13.3 0.35
ULAC 044F 4.6 26.1 3.2 14.0 NA 31.5 34.1 14.0 27.2 24.0 18.3 26.6 13.5 0.55
ULAC 058G 5.2 26.1 3.2 20.0 NA 31.5 35.4 20.0 34.2 24.0 18.3 29.9 15.2 0.55
ULAC 078G 5.2 32.3 3.9 26.8 NA 38.9 41.4 20.4 40.2 35.4 21.1 30.9 16.2 0.55
ULAC 112H 5.1 38.8 3.9 31.1 0.14 45.4 47.8 23.6 46.7 35.4 24.4 31.9 17.2 0.55
ULAC 200K 7.2 50.9 5.0 49.6 1.2 61.0 64.2 55.9 59.4 35.4 32.7 41.5 18.7 0.71
All dimensions listed above are in inches.
13
Catalog HY10-1700/Americas ULAC
MATERIAL
1. OIL COOLER SERIES WITH AC MOTOR; ULAC
Cooler core Aluminum
Fan blades/hub Glass fiber reinforced polypropylene/
2. COOLER SIZE/MODEL
Aluminum
007B, 011B, 016B, 023D, 033F, 033D, 044F, 044D,
Fan housing Steel
058G, 078G, 112H and 200K.
Fan guard Steel
Other parts Steel
3. MOTOR TYPE
Surface treatment Electrostatically powder-coated
No motor =W
Three-phase 190/380V 50 Hz, 208-230/460V 60 Hz = M*
COOLER CORE
Three-phase 208-230/460V 60 Hz =N
Maximum static working pressure 300 psi
Three-phase 230/460V 60 Hz =P
Dynamic working pressure 200 psi*
Three-phase 575V 60 Hz =Q
Heat transfer tolerance ±6%
Single-phase 115/230V 60 Hz =R
Maximum oil inlet temperature 250 °F
Single-phase 230 V 60 Hz =S
* Tested in accordance with ISO/DIS 10771-1
Explosion proof, Division 1, Class 1 Group D,
Class II Group F & G, T3C =X
COOLING CAPACITY CURvES
Not listed, consult Olaer USA =Z
Cooling capacity curves are based on testing in accordance with
* The M-motor is our standard motor sizes 1 hP and lower. The performance at
50 hZ will be reduced by approximately 10%
EN1048 with ISO VG 46.
5. CORE BYPASS*
No Bypass = SW
20 psi External Hose Bypass (standard option) = SA
65 psi External Hose Bypass (standard option) = SB
30 psi External Tube Bypass = SG
75 psi External Tube Bypass = SH
120 psi External Tube Bypass = SJ
120 °F External Thermo-Bypass = SM
140 °F External Thermo-Bypass = SN
160 °F External Thermo-Bypass = SP
195 °F External Thermo-Bypass = SQ
Full Flow External Bypass = SF
* The standard cores are single pass. Two pass cores and other options
available upon request, please consult Accumulator and Cooler Division.
14
Magnaloy Flexible Drive Couplings
SECTION 1
1
NOTE: Due to Magnaloy’s policy of continuous improvement, specificaitons are subject to change without notice.
Check with the factory or our Web Site at www.magnaloy.com for the latest information.
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 1
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Magnaloy Coupling Design Features
Load-Lock Design... is simple and effective. The drive lug
configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-lock
design protects bearings and equipment by eliminating end
thrust in both directions.... and it requires only one set-screw in
each hub.
1
1 Radial Lug Design... is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking and the
associated heat generation. Magnaloy Coupling’s drive lugs are in a true
radial orientation. Applied forces are evenly distributed in the compressive
direction only, eliminating the heat generating radial component. True
compressive loading reduces internal heat generation and improves elastomer
life.
Magnaloy Coupling Design...
Under loaded conditions, the resultant forces applied on the element
segments are evenly distributed in the compressive direction only. This
results in no radial forces to multiply the internal heat generation.
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 3
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Dimensional Specifications
Magnaloy Coupling Dimensional Specifications
Model 500
500
A 4.67
B 4.800 X*: Maximum Space between
shaft ends to allow full
C 4.00
shaft engagement in
D 1.04 Hub Bore.
E 1.23
F .064 W*: Minimum Space between
shaft ends.
G .070
W 1/16 * Given for reference only.
X 1.41
T 3/8-16 TOLERANCES: 2 Place Decimals ± .01
3 Place Decimals ± .001
4 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Bore & Keyway Combinations
Standard Bore and Keyway Combinations
Magnaloy “Standard” Bore Key Combinations Magnaloy “Standard” Bore Key Combinations
Model Bore/Key Model Model Bore/Key Model
Code Code Bore Key Code Code Bore Key
100
200
300
400
500
600
700
800
900
100
200
300
400
500
600
700
800
900
M _ _ _ 01203 3/8 x 3/32 * * M _ _ _ 12414 1 3/4 x 7/16 * * * * *
M _ _ _ 01403 7/16 x 3/32 * * M _ _ _ 12816 1 7/8 x 1/2 * * * * * *
M _ _ _ 01404 7/16 x 1/8 * * M _ _ _ 13016 15/16 x 1/2 * *
M _ _ _ 01604 1/2 x 1/8 * * * M _ _ _ 20016 2 x 1/2 * * * * *
M _ _ _ 01804 9/16 x 1/8 * * * M _ _ _ 20416 2 1/8 x 1/2 * * * * *
M _ _ _ 02005
M _ _ _ 02006
5/8 x
5/8 x
5/32
3/16
*
*
*
*
*
* *
M _ _ _ 20816
M _ _ _ 21220
2 1/4 x 1/2
2 3/8 x 5/8
* *
* *
*
*
*
*
*
*
1
M _ _ _ 02206 11/16 x 3/16 * * * * M _ _ _ 21620 2 1/2 x 5/8 * * * *
M _ _ _ 02404 3/4 x 1/8 * * * M _ _ _ 22020 2 5/8 x 5/8 * * * *
M _ _ _ 02406 3/4 x 3/16 * * * * * * M _ _ _ 22420 2 3/4 x 5/8 * * *
M _ _ _ 02806 7/8 x 3/16 * * * * * * M _ _ _ 22824 2 7/8 x 3/4 * * *
M _ _ _ 02808 7/8 x 1/4 * * * * * * M _ _ _ 30024 3 x 3/4 * *
M _ _ _ 03008 15/16 x 1/4 * * * M _ _ _ 30824 3 1/4 x 3/4 * *
M _ _ _ 10006 1 x 3/16 * * * * * * M _ _ _ 31228 3 3/8 x 7/8 * *
M _ _ _ 10008 1 x 1/4 * * * * * * M _ _ _ 31628 3 1/2 x 7/8 * *
M _ _ _ 10408 1 1/8 x 1/4 * * * * * * M _ _ _ 32028 3 5/8 x 7/8 * *
M _ _ _ 10608 1 3/16 x 1/4 * * M _ _ _ 32428 3 3/4 x 7/8 * *
M _ _ _ 10808 1 1/4 x 1/4 * * * * * M _ _ _ 32832 3 7/8 x 1 * *
M _ _ _ 10810 1 1/4 x 5/16 * * * * * * * M _ _ _ 40032 4 x 1 *
M _ _ _ 11210 1 3/8 x 5/16 * * * * * * * M _ _ _ 40432 4 1/8 x 1 *
M _ _ _ 11212 1 3/8 x 3/8 * M _ _ _ 40832 4 1/4 x 1 *
M _ _ _ 11412 1 7/16 x 3/8 * * * M _ _ _ 41232 4 3/8 x 1 *
M _ _ _ 11610 1 1/2 x 5/16 * * * M _ _ _ 41632 4 1/2 x 1 *
M _ _ _ 11612 1 1/2 x 3/8 * * * * * * M _ _ _ 41640 4 1/2 x 1 1/4 *
M _ _ _ 12012 1 5/8 x 3/8 * * * * * * M _ _ _ 42040 4 5/8 x 1 1/4 *
M _ _ _ 12412 1 3/4 x 3/8 * * * * * M _ _ _ 42440 4 3/4 x 1 1/4 *
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 5
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Insert Selection Guide
Magnaloy Coupling’s full range of flexible inserts permit
custom design performance for a wide range of applications.
All insert materials offer complete electrical insulation, as
Magnaloy’s design eliminates all metal-to-metal contact.
1
1
Neoprene (Code N) - Black material - Standard
material with Magnaloy Coupling. Good general
purpose material offering good resiliency and
load capabilities. Temp range -300F to +2500F
(-340C to -1210C). Optional 80A durometer
(painted Gold) and 90A durometer (painted
Silver) are available for slight increased load
capability and less resiliency.
Nitrile (Buna N)(Code B) - Painted Blue. Excellent
material with petroleum products. Excellent
compression set and abrasion resistance
characteristics. Temp range -600F to +2500F
(-510C to +1210C).
Urethane (Code U) - Yellow material. Excellent
mechanical and physical properties. Offers good
medium duty durability and resiliency. Urethane
tends to soften at higher temperatures and humid
conditions. Temp range -300F to +1500F (-340C
Part Number Usage: Magnaloy Coupling Insert part
to +660C).
numbers may be specified using the following format:
Viton (Fluorocarbon)(Code V) - Red material.
Start with the letter “M” for Magnaloy, followed by the 3
Excellent fluid compatibility and high temperature
digit Basic Insert Number Code (170, 270, etc.), then the
characteristics. Good compression set and
specific single letter Insert Material Code. If an optional
resiliency. Temp range -200F to +3500F (-290C to
durometer is being specified, after the Material Code
+1770C).
supply the durometer number divided by 10.
Hytrel (Code H) - Blue material. Superior physical
and mechanical properties and excellent fluid
Examples: Urethane insert for Model 300: M370U. 80
compatibility and high temperature characteristics.
Durometer Neoprene for Model 200: M270N8.
Hardness (50D) approaches that of plastic and
offers little resiliency. Excellent performance
under heavy duty conditions. Temp range -650F to
+3000F (-540C to +1490C).
Other materials are available for special applications.
Consult factory for recommendations and availability.
78 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Coupling Selection Guide
Service Factors - Load Characteristics
Type of Prime Mover
Load Standard Motor High Torque I.C. Engine I.C. Engine
Classification or Turbine Motor 6 or more cyl. less than 6 cyl.
Uniform (U) 1.0 1.5 1.5 2.0*
Moderate (M) 1.5 2.0 2.0 2.5*
Heavy (H) 2.0* 2.5* 2.5* 3.0*
Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts, infrequent reversals,
1
peak torque may exceed average rating of prime mover by up to 125%.
Heavy Load: Uneven loading with heavy shock, frequent reversals, peak torque may exceed
average rating of prime mover by up to 150%.
* Recommend use of Hytrel Insert.
Drive Unit Load Sym.
Agitators U Selection Method
Blowers U
Compressors - Centrifugal U 1. Several specifics must be considered to make the best
- Rotary M choice of couplings:
- Reciprocating H* A. Type of prime mover and load characteristics (see table
Conveyors - U
- Reciprocating M above)
- Screw M B. Shaft diameter and key size or spline configuration (No. of
- Shaker H teeth, pitch ratio, pressure angle)
Cranes & Hoists M C. Horsepower rating of loads to be transmitted.
Crushers H*
D. Maximum operating speed (rpm)
Elevators M
- Freight & Pass. H* E. Maximum operating misalignment
Fans - Centrifugal U F. Clearance limitations
- Propeller M 2. Calculate effective hp/100 rpm by use of table above and
- Cooling Tower H select the minimum size coupling recommended
Generators U
- Welding H
3. VERIFY YOUR SELECTION:
Mills H* A. Check for maximum bore size
Machine Tools M B. Check dimensions for adequate clearance
Mixers M C. Indicate any special insert specification and/or coupling
Paper Mill Machinery M coating for environmental protection, if required
Pumps - Centrifugal
U Equation: Effective HP per 100 RPM = rated HP x Service
- Rotary
- Reciprocating
M Factor x 100 / RPM
H* Example: 150 HP, 4 cyl. Diesel Engine Driving a Reciprocating
- On Injection
H*
Molding Equip. Irrigation Pump operating at 3250 RPM
Screens - Air & Water U Service Factor - 3.0 (Hytrel Insert Recommended)
Washing
Eff. HP per 100 RPM = 150 HP x 3.0 x 100 /
- Freight & Pass. H
Stokers U 3250 RPM = 13.85 HP/100 RPM. Model 600
Textile Machinery M rating with Hytrel Insert is 23.7 HP/100 RPM.
Woodworking Machinery M
Winches H*
Note: Above service factors are intended for use as a general guide only.
*Recommend use of Steel Bushing and Clamp with Splined Bores.
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 98
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Installation Instructions
Shaft spacing should be within range given by
dimensions ‘W’ and ‘X’ as shown in charts on page 4.
Position each hub on proper size shaft - Magnaloy
couplings are bored to standard “push fit” tolerances,
if a tight fit exists, check shaft for burrs.
Maximum benefits are obtained with hubs positioned
to allow complete shaft engagement within bore.
However, some equipment designs do not permit this
1
1 condition - maximum shaft engagement should be
utilized in any case.
190 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Mis-Alignment Capabilities
Magnaloy Couplings offer four-way flexibility (parallel, angular, axial and
torsional) and require no lubrication. They are easily installed and
properly aligned without use of special tools or equipment - a straight
edge and hex wrench ar the only tools required. Magnaloy’s insert
reduces noise and vibration and permits needed flexibility for proper
operation within alignment capabilities.
Recommended Torques
for Fasteners 1
Model Set Screw Clamp Screw
100 60 - 70 in lbs 130 - 140 in lbs
200 75 - 85 in lbs 130 - 140 in lbs
300 75 - 85 in lbs 210 - 220 in lbs
400 190 - 200 in lbs 210 - 220 in lbs
500 190 - 200 in lbs 300 - 310 in lbs
600 190 - 200 in lbs 35 - 36 ft lbs
700 300 - 310 in lbs 35 - 36 ft lbs
800 300 - 310 in lbs 49 - 50 ft lbs
900 100 - 110 ft lbs 100 - 110 ft lbs
Intended as a general guide for fastener torques with
Magnaloy Couplings.
Perfect alignment of equipment shafts, in most cases, is impractical to obtain or maintain, and misaligned
equipment produces, excess stress on bearings and the coupling. Magnaloy’s insert design will accept
misalignment strain and, when excessive, will cause insert wear as a visual and audible indication of
misalignment problems. However, Magnaloy’s inserts are inexpensive and easily replaces; under normal
conditions the insert seldom requires replacement.
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 1110
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Technical Bulletin & Notes
Keystock Interference with Drive Lug
Since the Magnaloy Coupling keyway, in a bored and keyed hub, is broached between the drive lugs, there is a
potential for interference with the keystock of the drive hub and the drive lugs of the opposing hub. This
interference will result when ALL the following conditions exist:
A) The shaft diameter is Greater than listed below
B) This shaft extends into the hub insert core area
C) The keystock on this shaft extends with the shaft into the insert core area
1
1 The interference condition can be corrected by shortening the keystock so it does not extend into the insert core
area. The insert length should be limited to the length of the coupling hub bore.
Notes
1112 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Magnaloy Pump/Motor Mounts
SECTION 2 2
NOTE: Due to Magnaloy’s policy of continuous improvement, specificaitons are subject to change without notice.
Check with the factory or our Web Site at www.magnaloy.com for the latest information.
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 17
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Pump/Motor Mounts - General Information
Magnaloy Pump/Motor Mounts
Power Unit design is greatly simplified by use of the Magnaloy Pump/Motor Mount. Direct mounting of flange
mount pumps to NEMA C’Face motors or Pilot mount engines via a Magnaloy Mount assures accurate shaft
alignment and eliminates the need for a coupling guard, foot brackets, shims, risers and mounting plate. The
result is the easiest to install, most accurate and cost effective method available to mount a pump to a drive unit.
For over 30 years Magnaloy has produced the highest quality flexible drive couplings in the industry.
Magnaloy’s long tradition of high quality and immediate delivery has become an industry goal for other
manufacturers to attain. Every mount Magnaloy manufactures is guaranteed to be within .003 inch concentric
from the motor pilot to the pump pilot. Further, the mounting faces are parallel to each other and perpendicular
to the pilot centerline within .002 inch. These exacting tolerances mean accurate shaft alignment which helps
prolong bearing, seal and coupling life in addition to reducing noise and vibration. Other mount manufacturers
talk about quality, but Magnaloy puts it in writing with measurable standards (see Illustration A).
2
Magnaloy is the most complete, single source for
Horizontal, Vertical and Engine requirements. A large
selection of SAE and Metric pump mounting flanges to
NEMA motors and I.C. Engines in a variety of lengths are
available from stock for immediated shipment. OR
special requirements can be met from our complete
offering of Welded Steel Mounts. Whatever your
mounting needs, you need look no further than Magnaloy.
Consult your Magnaloy Distributor for Magnaloy’s Product
CD ROM which includes the Magnaloy Pump/Motor Mount
Selection Program. Illustration A
Using Magnaloy’s Pump/Motor Mounts ensure a lightweight, high strength, precision mount for efficient assembly,
quiet operation, accurate shaft alignment and complete coupling concealment.
A MOUNT KIT is included which contains all the bolts and washers required to attach the pump and motor to the
mount.
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 19
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Horizontal Pump/Motor Mounts - NEMA Frame Motors
1
25
00
XAK XAJ2 XBF2 XAJ4 XBF4 MOUNT NO. CL M MOUNT NO. CL M MOUNT NO. CL M
/3
50
7.
9.
17
8.
USA4F17 4 Bolt 1.782 2.84 5/16-18 M182474F 4.00 4.75 M182504F 4.31 5.00 M182524F 4.31 5.25
SAE AA 2 Bolt 2.001 3.25 3/8-16 M182472AA 4.00 4.75 M182502AA 4.31 5.00 M182522AA 4.31 5.25
SAE A 2(4) Bolt 3.251 4.19 3/8-16 4.12 3/8-16 M182472A 4.00 4.75 M182502A 4.31 5.00 M182522A 4.31 5.25
63 2A/B4 2(4) Bolt 63.01mm 100mm 5/16-18 85mm 5/16-18 M1824763M 4.00 4.75 M1825063M 4.31 5.00 M1825263M 4.31 5.25
63 S4 4 Bolt 63.01mm 80mm 11/32 M1824763MS 4.00 4.75 M1825063MS 4.31 5.00 M1825263MS 4.31 5.25
80 2A/B4 2(4) Bolt 80.01mm 109mm 3/8-16 103mm 5/16-18 M1824780M 4.00 4.75 M1825080M 4.31 5.00 M1825280M 4.31 5.25
80 S4 4 Bolt 80.01mm 100mm 5/16-18 M1824780MS 4.00 4.75 M1825080MS 4.31 5.00 M1825280MS 4.31 5.25
PUMP FLANGE PUMP END DATA 4.75 LENGTH 5.0 LENGTH 5.25 LENGTH
MOTOR END DATA
RADIAL CLEARANCE “Z” = 5.00
AJ BF BD AK
2
1
25
00
50
7.
9.
17
8.
USA4F17 4 Bolt 1.782 2.84 5/16-18 M182584F 5.06 5.81 M182684F 6.06 6.81
SAE AA 2 Bolt 2.001 3.25 3/8-16 M182582AA 5.06 5.81 M182682AA 6.06 6.81
SAE A 2(4) Bolt 3.251 4.19 3/8-16 4.12 3/8-16 M182582A 5.06 5.81 M182682A 6.06 6.81
63 2A/B4 2(4) Bolt 63.01mm 100mm 5/16-16 85mm 5/16-18 M1825863M 5.06 5.81 M1826863M 6.06 6.81
63 S4 4 Bolt 63.01mm 80mm 11/32 M1825863MS 5.06 5.81 M1826863MS 6.06 6.81
80 2A/B4 2(4) Bolt 80.01mm 109mm 3/8-16 103mm 5/16-18 M1825880M 5.06 5.81 M1826880M 6.06 6.81
80 S4 4 Bolt 80.01mm 100mm 5/16-18 M1825880MS 5.06 5.81 M1826880MS 6.06 6.81
PUMP FLANGE PUMP END DATA 5.81 LENGTH 6.81 LENGTH
1
25
00
XAK XAJ2 XBF2 XAJ4 XBF4 MOUNT NO. CL M MOUNT NO. CL M MOUNT NO. CL M
/3
50
7.
9.
17
8.
SAE B 2(4) Bolt 4.001 5.75 1/2-13 5.00 1/2-13 M182522B 4.50 5.25 M182582B 5.06 5.81 M182602B 5.25 6.00
SAE C 2(4) Bolt 5.001 7.12 5/8-11 6.38 1/2-13 M182522C 4.50 5.25 M182582C 5.06 5.81 M182602C 5.25 6.00
100 A2/B4 2(4) Bolt 100.01mm 140mm 1/2-13 125mm 3/8-16 M18252100M 4.50 5.25 M18258100M 5.06 5.81 M18260100M 5.25 6.00
125 A2/B4 2(4) Bolt 125.01mm 180mm 5/8-11 160mm 1/2-13 M18252125M 4.50 5.25 M18258125M 5.06 5.81 M18260125M 5.25 6.00
PUMP FLANGE PUMP END DATA 5.25 LENGTH 5.81 LENGTH 6.00 LENGTH
magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 21
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Bulletin E-73
Rugged and reliable the Flotect® L4 Level switch operates automatically SPECIFICATIONS
to indicate tank level. Perfect for starting or stopping pumps, opening or Service: Liquids compatible with wetted materials.
closing valves, or actuate level alarm signals. A unique magnetically Wetted Materials:
actuated switching design gives superior performance. There are no Float and Rod: 316 SS;
bellows, springs, or seals to fail. Instead, the free-swinging float attracts Body: Brass or 316 SS standard;
a magnet within the solid metal switch body, actuating a snap switch by Magnet Keeper: 430 SS standard, 316 SS or nickel optional.
means of a simple lever arm. Float arm hinge design limits the arm angle Temperature Limits: 4 to 275°F (-20 to 135°C) standard, MT high
to prevent vertical hangup. temperature option 400°F (205°C) [MT option not UL, CSA, ATEX or
IECEx]. ATEX, IECEx options: Ambient temperature -4 to 163°F (-20 to
73°C); Process temperature -4 to 163°F (-20 to 73°C).
FEATURES Pressure Limit: Brass body 1000 psig (69 bar), 316 SS body 2000 psig
• Leak proof body machined from bar stock (138 bar). Standard float rated 100 psig (6.9 bar). For other floats see
• Choice of floats dependent on maximum pressure and specific gravity model chart on next page.
• Weatherproof, designed to meet NEMA 4 Enclosure Rating: Weatherproof and Explosion-proof. Listed with UL
• Explosion-proof (listings included in specifications) and CSA for Class I, Groups C and D; Class II, Groups E, F, and G.
• Installs directly and easily into tank with a thredolet or flange ATEX 0518 II 2 G Ex d IIB T6 Gb -20°C≤Tamb≤73°C.
(see application drawings on page 4) -20°C≤Process Temp≤73°C.
• Electrical assembly can be easily replaced without removing the unit EC-Type Certificate No.: KEMA 03 ATEX 2383.
from the installation so that the process does not have to be shut down ATEX Standards: EN60079-0: 2009; EN60079-1: 2007.
• Horizontal installation or optional top mount vertical installation IECEx Certified: For Ex d IIB T6 Gb -20°C≤Tamb≤73°C. -20°C≤Process
Temp≤73°C.
APPLICATIONS IECEx Certificate of Conformity: IECEx DEK 11.0071.
• Direct pump control for maintaining level IECEx Standards: IEC 60079-0: 2007; IEC 60079-1: 2007.
• Automatic tank dump operations Switch Type: SPDT snap switch standard, DPDT snap switch optional.
• Control levels or provide alarms in sumps, scrubber systems, hydro- Electrical Rating: UL, FM, ATEX or IECEx models: 10A @ 125/250 VAC
pneumatic tanks, low pressure boilers, and various waste (V~). CSA models: 5A @ 125/250 VAC (V~); 5A res., 3A ind. @ 30 VDC
water/sewage treatment processes (V ). MV option: 1A @ 125 VAC (V~); 1A res., .5A ind. @ 30 VDC (V ).
MT option: 5A @ 125/250 VAC (V~). [MT and MV option not UL, CSA, FM,
ATEX or IECE].
Electrical Connections: UL and CSA models: 16 AWG, 6˝ (152 mm)
long. ATEX or IECEx unit: terminal block.
Process Connection: 1-1/2˝ male NPT standard, 2-1/2˝ male NPT
standard optional floats.
Mounting Orientation: Horizontal installation standard, optional vertical
top mount.
Weight: 4 lb 9 oz (2.07 kg).
Dead Band: 3/4˝ (19 mm) for standard float.
Specific Gravity: 0.7 minimum with standard float. For other floats see
model chart.
Ø1-5/8
Ø2-1/2 PARTS LIST
[63.50] 3-11/32
[41.28] [84.93]
MAGNET 1. Cover lock. (ATEX/IECEx unit only).
5 6 3
[127.00] [152.40] KEEPER [76.20]
430 STNLS. 5 3/4 FEMALE NPT 2. External ground. (ATEX/IECEx unit only).
STL. [127.00] CONDUIT
8-7/32
[208.76]
CONNECTION 3. Enclosure housing and cover.
19-7/32
[488.16] 4. Terminal block. (ATEX/IECEx unit only,
UL/CSA unit has 6˝ leads).
UL/CSA unit
5. Internal ground.
6 5 3 2 1
1-1/2 NPT *6. Magnet arm and switch assembly.
7. Switch body.
2-1/2
1-5/8 [63.50] 3-11/32
[41.28] [84.93] *8. Float, arm and block assembly.
5 6 *Approved replacement parts
[127.00] [152.40] 3
[76.20] 3/4 NPT
5
8-7/32 [127.00]
[208.76]
19-7/32
[488.16]
ATEX/IECEx unit
Bulletin E-73
INSTALLATION NOTE: ATEX and IECEx units only: The temperature class is
determined by the maximum ambient and/or process temperature. Units
NOTES: are intended to be used in ambient of -20°C ≤Tamb≤73°C. Units may be
• Check all ratings given in the instructions and on the product to make used in process temperatures up to 133°C providing the enclosure and
sure that the product is suitable for your application. Do not exceed switch body temperature do not exceed 73°C. The standard
electrical ratings, pressure ratings, or temperature ratings of the product. Temperature Class is T6 Process Temp ≤73°C.
• Disconnect power supply before beginning installation to prevent 5. For units supplied with both internal ground and external bonding
possible equipment damage or electrical shock. terminals, the ground screw inside the housing must be used to ground
the control. The external bonding screw is for supplementary bonding
1. Remove packing material from switch body-cap and remove tape from when allowed or required by local code. When external bonding
magnet keeper. Install standard switch in thredolet previously welded to conductor is required, conductor must be wrapped a minimum of 180°
tank. Install optional switch mountings per application drawings. Make about the external bonding screw. See below.
sure locknuts on float are tight.
2. When mounting switch in the side of a tank, the arrow on the side of
LOCKWASHER CONDUCTOR
the switch must point up.
SCREW
3. Wiring: UL and CSA units only: Thread connecting wires through
conduit and connect. Wire in accordance with local electrical codes.
Black - Common
Blue - N.O.
Red - N.C.
NOTE: Double pole, double throw switches have dual black, blue and
red leads. These are connected in the same manner as single pole,
double throw switches, as described above. CLAMP
ATEX and IECEx Installation Instructions: FRONT VIEW DETAIL SIDE VIEW DETAIL
Cable Connection
The cable entry device shall be certified in type of explosion
protection flameproof enclosure “d”, suitable for conditions of use
and correctly installed. Cable entry may exceed 70°C. Conductors
and cable gland rated ≥90°C shall be used.
Conduit Connection
An Ex d certified sealing device such as a conduit seal with setting
compound shall be provided immediately to the entrance of the
valve housing. Cable entry may exceed 70°C. Conductors and cable
gland rated ≥90°C shall be used. SPDT DPDT
TERMINAL CONNECTIONS
NOTE: The switch is deactivated and contacts are in normal condition
when the liquid is below the float.
Limited Warranty: The Seller warrants all Dwyer instruments and equipment to be free from defects in workmanship or material under normal use and service for a period
of one year from date of shipment. Liability under this warranty is limited to repair or replacement F.O.B. factory of any parts which prove to be defective within that time or
repayment of the purchase price at the Seller’s option provided the instruments have been returned, transportation prepaid, within one year from the date of purchase. All
technical advice, recommendations and services are based on technical data and information which the Seller believes to be reliable and are intended for use by persons
having skill and knowledge of the business, at their own discretion. In no case is Seller liable beyond replacement of equipment F.O.B. factory or the full purchase price. This
warranty does not apply if the maximum ratings label is removed or if the instrument or equipment is abused, altered, used at ratings above the maximum specified, or otherwise
misused in any way.
THIS EXPRESS LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTATIONS MADE BY ADVERTISEMENTS OR BY AGENTS AND ALL
OTHER WARRANTIES, BOTH EXPRESS AND IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE FOR GOODS COVERED HEREUNDER.
Buyers Remedies: THE BUYER’S EXCLUSIVE AND SOLE REMEDY ON ACCOUNT OF OR IN RESPECT TO THE FURNISHING OF NON-CONFORMING OR DEFECTIVE
MATERIAL SHALL BE TO SECURE REPLACEMENT THEREOF AS AFORESAID. THE SELLER SHALL NOT IN ANY EVENT BE LIABLE FOR THE COST OF ANY LABOR
EXPENDED ON ANY SUCH MATERIAL OR FORM ANY SPECIAL, DIRECT, INDIRECT OR CONSEQUENTIAL DAMAGES TO ANYONE BY REASON OF THE FACT THAT
IT SHALL HAVE BEEN NON-CONFORMING OR DEFECTIVE.
APPLICATION DRAWINGS FOR FLOTECT®
AUTOMATIC FLOAT SWITCHES
1-1/2 THREDOLET
CUT HOLE 1-15/16 [49] DIA.
STANDARD INSTALLATION
ANSI RF
3/4 NPT
THREADED
REDUCING
ANSI RF THREADED
FLANGE
REDUCING FLANGE
11-3/4
3/4 NPT
[298.5]
*FLANGE FACE TO CENTERLINE OF FLOAT
SPECIFIED BY CUSTOMER NORMALLY HORIZONTAL, FLANGE INSTALLATION
SHOULD NOT EXCEED 20' [508 MM].
VERTICAL, FLANGE INSTALLATION
2-1/2 X 1-1/2
FACE BUSHING
© Copyright 2014 Dwyer Instruments, Inc. Printed in U.S.A. 9/14 FR# 82-440631-00 Rev. 5
YOUR LOGO
80 180
70 160
60 140
50 120
L2
L3
L1
40 100
30
80
20
60
10
40
0
-10 20
C F
20
40 60
80
S N X S-T
0 100
Dial Thermometer with
Probe T1/T2 (optional)
Clearance Hole:
E F Ø13 (Ø.51) for M12 / Ø10,5 (Ø.41) for M10 /
Ø13,5 (Ø.53) for UNC, UNF and UNEF
Characteristics Dimensions Maximum admissible tolerance for the bolt center spacing (dimension L2) according to DIN ISO 2768-f: ±0,20 mm / .008 in for all nominal sizes.
Visual fluid level indication in hydraulic reservoirs with Nominal Size Dimensions (mm/in)
maximum tank pressures not exceeding 2 bar / 29 PSI A B C (Max.) D E F (with T1) F (with T2) L1 L2 L3
45 34,5 8 27 43,5 165,5 265,5 108 76 31
SNA 076
1.77 1.36 .32 1.06 1.71 6.52 10.45 4.25 2.99 1.22
Nominal Sizes and Designs 45 34,5 8 27 43,5 165,5 265,5 159 127 76
6 nominal sizes from 76 mm / 2.99 in to 305 mm / 12.00 in SNA 127
1.77 1.36 .32 1.06 1.71 6.52 10.45 6.26 5.00 2.99
Display either undivided (SNA 076 ... 176) or subdivided 45 34,5 8 27 43,5 165,5 265,5 182 150 99
SNA 150
by strut(s) into 2 (SNA 254) or 3 sections (SNA 305) 1.77 1.36 .32 1.06 1.71 6.52 10.45 7.17 5.91 3.90
45 34,5 8 27 43,5 165,5 265,5 208 176 124
SNA 176
1.77 1.36 .32 1.06 1.71 6.52 10.45 8.19 6.93 4.88
Please see page E5 for alternative nominal sizes and designs. 45 34,5 8 27 43,5 165,5 265,5 285 254 192
SNA 254
1.77 1.36 .32 1.06 1.71 6.52 10.45 11.22 10.00 7.56
Media Compatibility 45 34,5 8 27 43,5 165,5 265,5 336 305 244
SNA 305
Suitable for use with Mineral and Petroleum based 1.77 1.36 .32 1.06 1.71 6.52 10.45 13.23 12.00 9.61
hydraulic fluids (HL and HLP)
Order Codes
Materials
Housing made of Steel St 12, black epoxy-coated
Sight tube and plugs made of Polyamide (PA) SNA 127 B - S - O - 12 - O - 60
Sealings made of NBR (Buna-N®)
Scale plate made of PVC
Inquiry Checklist
In case that you require a special property or custom-designed level gauge, please use this checklist to provide us
with details. If necessary, please also include further details, like the type of fluid in use, its temperature and viscosity.
Housing Design Regular housing design with positioning of strut(s) based on engineering considerations
Accessories
Hydraulic
Banjo Bolt Size M12 M10 1/2–13 UNC
E
Banjo Bolt Material Steel Stainless Steel
Level Indication Scale plate (only for nominal sizes smaller than 670 mm / 26.4 in)
Floating element (recommended option for nominal sizes larger than 670 mm / 26.4 in)
www.stauff.com E5
Standard
Hydraulic
Power Units
Maintenance Manual
Standard Hydraulic Power Units
Introduction .... 1
Description .. . ... 1
Preparation for Use . . . . . . . . . . . . . . . . ...... 2
Unpacking and Checking
Storage
Removing from Shipping Skids
Installation . . . . . . . ..... 2
Locating Power Unit
Service Connections
Supply and Return Connections
Reservoir Inspection
Reservoir Filling
Coupling Alignment
Start Up Procedure ........ . . ... 5
Special Tools .. . ... 6
General Maintenance ........ . . ..... 6
Recommended Spare Parts ..... . . ... 6
Reference Data ... 6
Introduction
This manual provides descriptive information, operation and maintenance instruc-
tions for standard Hydraulic Power Units manufactured by the Power Unit Division
of Parker Hannifin Corporation, Orrville, Ohio 44667. Any additional information
may be obtained from the Power Unit Division by referencing to the Unit's Model
Number and Serial Number stamped on the Reservoir Nameplate, or by
contacting your authorized Parker Distributor.
Some of the information in this manual may not apply to your power unit, and
information on more custom units may require obtaining service and application
information from other sources.
Warning
It is imperative that personnel involved in the installation, service, and operation of
the power unit be familiar with how the equipment is to be used, the limitations of
the system and it's component parts, and have knowledge of good hydraulic
practices in terms of safety, installation, and maintenance.
Description
The standard Hydraulic Power Unit usually consists of a JIC reservoir (see
figure 1), or "L" shaped reservoir (see figure 2) both of which incorporate a baffle,
clean-out access, 314 NPT sump drain, oil level gage, filter/breather assembly and
spare return connections.
The pump will be coupled to the motor using a flexible shaft coupling and will be
mounted using a bell housing (requires NEMA "C" Motor) or will be foot mounted
requiring a pump foot bracket, coupling guard, and pump/motor mounting plate.
Also included on most standard units is a Pump Suction Filter (or Suction Strainer),
Relief Valve, and a Pressure Gauge with Shut-Off Valve.
More custom type power units may have heat exchangers for oil cooling; pressure
or return filters, oil immersion heaters, directional valves, and other pressure and
flow control valves, or monitoring instrumentation.
-1-
Maintenance Manual
Standard Hydraulic Power Units
to the vendor. All open ports on the Power Unit were plugged at the factory to pre-
vent the entry of contamination. These plugs must not be removed until just before
piping connections are made to the unit.
Storage
If the Power Unit is not going to be installed immediately, it should be stored in-
doors, covered with plastic sheet, and all open ports plugged. If long term storage
is expected (6 months or more) we recommend filling the reservoir completely with
clean hydraulic fluid to prevent the entry of moisture.
Installation
Locating Power Unit
The unit should be installed indoors, and preferably in a clean dry environment
with an ambient temperature of 60 to 100°F. The unit can be installed outdoors if
the reservoir was provided with optional weatherproof construction, and provisions
were made for extreme temperature conditions. The reservoir can be secured to
the floor or base using the four mounting holes located on the reservoir legs.
Service Connections
Water (If water cooled heat exchanger has been provided) Connect the water sup-
ply to the inlet of the heat exchanger, with a shut-off valve and strainer (if not sup :
plied by Parker). If a Temperature Control Valve (Model WTC-* *)has been provid-
ed, it also should be installed on the inlet side. The outlet of the hear exchanger
should be connected directly to the facility drain system. On single pass heat ex-
changers the water connections should be installed as shown below. On multi-pass
heat exchanger the water flow direction is not important.
Oil In 011 Out Temperature
Control Shut-off
Water Valve Water
Strainer Inlet
Outlet .---a------.....L.....,
Heat Exchanger
-2-
Maintenance Manual
Standard Hydraulic Power Units
Electrical Connect the pump motor to the facility power source following good
practices as outlined in the National Electric Code and any local codes which may
apply. Verify that the available voltage is the same as the voltage identified on the
motor nameplate. Most motors have dual voltage ratings, so verify that the leads
in the conduit box have been connected together as defined on the motor
nameplate to match the facility power source available.
Warning
Check to insure that the proper rated hose or pipe is used on pressure lines.
One of the key ingredients for good service and long life from a hydraulic system
is cleanliness, and since it has been our experience that most dirt infiltrates
a hydraulic system during installation, we recommend the following rules be
adhered to:
a) All open ports on the power unit, cylinders, etc. must remain plugged
with tape or plastic plugs until just before the hydraulic connections are
made.
b) All interconnecting tubing, pipe, or hose should be clean, and free of rust,
scale and dirt. The ends of all connectors should be plugged until just
before they are to be installed in the system.
c) All openings in the reservoir such as the filler breather or access end
covers holes must remain closed during installation.
d) If Teflon tape, or pipe dope is used, be sure it doesn't extend beyond the
first thread of the pipe fitting.
-3-
Maintenance Manual
Standard Hydraulic Power Units
Reservoir Inspection
The reservoir has been thoroughly cleaned and sprayed with rust inhibitor at
Parker prior to shipping. It is suggested, however, to remove the reservoir access
covers and re-inspect the tank for cleanliness. JIC reservoirs are provided with a
removable baffle for greater access for cleaning.
Note
On JIC reservoirs it is important for the baffle to be centered in the tank, and for
the sealing gaskets to take a good set if the end covers are to seal properly.
Reinstall end covers as follows:
a) Locate the baffle in the center of the tank.
b) Install end covers hand tight, being careful not to move the baffle.
c) Torque one cover a small amount, and then torque the opposite end
cover a small amount more. Continue going back and forth between the
covers until both are torqued equally. (See figure 1 for proper torque
value.)
Reservoir Filling
The reservoir must be filled with clean fluid thru the filler cap on the reservoir.
The type of fluid must be compatible with the seals used on the power unit, and
must comply with the recommendations of the manufacturers of the component
parts.
Coupling Alignment
It is possible for pump/motor shaft alignment to be incorrect because of shock in-
curred during shipping. The alignment should be re-checked before start-up.
If the pump/motor assembly has been foot mounted, the coupling alignment should
be checked using the coupling installation instructions provided in the appendices
of this manual. If re-aligning is required, the motor mounting bolts should be
loosened, and shims inserted. Note, see figure 3 for Lovejoy or Magnaloy couplings.
If the pump/motor assembly has been mounted with a bell-housing, the only
check required is to verify that the coupling halves have adequate clearance, and
that the coupling set-screws are tight. A slot is provided in the bell housing for this
purpose.
-4-
Maintenance Manual
Standard Hydraulic Power Units
Start-Up Procedure
1) Open any ball or gate valve (if applicable) located in the pump suction
line.
2) Back the system relief valve and/or pump pressure compensator adjust-
ment knob out, so that the pressure will be near zero during the initial
start.
Note
If the power unit has been provided with a variable displacement pump or
any piston pump, the pump case should be filled with clean oil prior to
priming. In most cases this can be accomplished by disconnecting the
pump case drain line and pouring the oil into the pump case drain port.
3) If the system has been provided with an open center directional valve,
the oil during start-up will flow directly back to tank. If the system has a
closed centered valve, it may be necessary to loosen a fitting momen-
tarily at the pump discharge, to bleed any air in the pump during the
priming operation.
4) Jog the pump motor once, and verify that the pump is rotating in the
same direction as the arrow tag on the pump case. If the direction is in-
correct, reverse two (2) of the three (3) motor leads, and recheck the
rotation.
5)Jog the pump motor (3) to (6) times to prime the pump and allow the
pump to run for several minutes at zero pressure. Check the piping for
any leaks and correct immediately. (Leaks in fittings and tubing can be
the result of vibration during shipping.)
6) Begin adjusting the relief valve and/or pump compensator to increase the
pressure gradually. Note; on systems with open center directional valves,
it will be necessary to actuate the valve to build pressure.
?)Continue increasing pressure until normal operating pressure is obtained,
and recheck system for leaks. Lock adjustment screws in place.
Note
If the system has been provided with a pressure compensated pump and
a relief valve, adjust the relief valve approximately 10% higher than the
compensator so that excessive heat is not generated by the relief valve.
8) During the start-up sequence, all filters should be monitored closely.
Replace any filters element immediately, as soon as they begin to go into
by-pass as indicated on the visual indicator.
9)After the entire system has been wetted with fluid, refill the reservoir to
the normal operating level.
10) Verify that the cooling water to the hear exchanger (if applicable) is flow-
ing. If the power unit has been provided with a water control valve (Model
WTC-* *), and the oil temperature is exceeding 135°F, adjust the valve to
increase the water flow.
-5-
Maintenance Manual
Standard Hydraulic Power Units
Special Tools
All normal service and maintenance on standard power units can be accomplished
with standard handtools. No special tools are required.
General Maintenance
Electric Motors · Lubricate as recommended by the motor manufacturer.
Filters · Change or clean as required or as indicated on filters supplied with visual
indicators.
Suction Strainers · Should be cleaned after 10 hours operation and 100 hours
thereafter. See appendicies for cleaning instructions.
Reservoirs· Maintain oil level at all times. The oil should be checked after the first
100 hours and verify that the class of oil meet the requirements of the pump being
used. Change the oil every 1000 to 2000 hours depending on the application and
operation environment.
Components · See component literature in appedicies.
Preventive Maintenance
Filter Service
Filters must be maintained. The key to good filtration is filter maintenance.
A machine may be equipped with the best fUters available and they may be posi-
tioned in the system where they do the most good; but, if the filters are not taken ·
care of and cleaned when dirty, the money spent fot the filters and their installa-
tion has been wasted. A filter which gets dirty after one day of service and is
cleaned 29 days later gives 29 days of non-filtered fluid. A filter can be no better
than the maintenance afforded it.
NEEDS CLEANING
BY-PASSING
-6-
Maintenance Manual
Standard Hydraulic Power Units
Maintenance Suggestions
1) Set up a filter maintenance schedule and follow it dilligently.
2) Inspect filter elements that have been removed from the system for signs
of failure which may indicate that the service interval should be
shortenend and of impending system problems.
3) Do not return to the system any fluid which has leaked out.
4) Always keep the supply of fresh fluid covered tightly.
5) Use clean containers hoses, and funnels when filling the reservoir. Use
of a filter cart when adding oil is highly recommended.
6) Use common sense precautions to prevent entry of dirt into components
that have been temporarily removed from the circuit.
7) Make sure that all clean-out holes, filler caps, and breather cap filters on
the reservoir are properly fastened.
8) Do not run the system unless all normally provided filtration devices are
in place.
9) Make certain that the fluid used in the system is of a type recommended
by the manufacturers of the system or components.
10) Before changing from one type of fluid to another (e.g., from petroleum
base oil to a fire resistant fluid), consult component and filter manufac-
turers in selection of the fluid and the filters that should be used. Also
consult the publication "Recommended Practice for the use of Fire
Resistant Fluids for Fluid Power Systems" published by the National
Fluid Power Association.
11) Parker offers an oil sampling kit which can be used to ascertain the
condition of the system fluid.
The oil in your hydraulic system was designed for operation within a specified
temperature range. You may be able to run it at hotter temperatures for short
periods of time, intermittently, without bad effects. If you run continuously with oil
that's too hot, however, your equipment will operate poorly, and eventually key
components will fail and halt your machine.
-7-
Maintenance Manual
Standard Hydraulic Power Units
Some hydraulic systems are designed to operate at 130°F. or higher. If you don't
know the maximum operating temperature for your equipment, check your component
manual for temperature and viscosity limitations.
If your machine doesn't have a reservoir thermometer, use the "palm test." First
check the tank with your fingertip; if it's not too hot to touch, place your palm on
the tank. You'll be able to hold it there without discomfort if the oil temperature is
about 130°F. or below.
Isolating Trouble-Spots
To determine which components are "running hot" and overheating the oil,
feel the outlet fittings and lines at the valves, pumps and motors. If the oil is
normal going into a component but hot coming out-that could be one of the
trouble-makers.
A sticking valve can cause excessive heat. If a spool does not return promptly to
the neutral position, the pump flow will be dumped continuously. This builds up
heat rapidly.
If a relief valve is set too low, part of the oil will be dumped across the valve with
every cycle. This too, generates excessive heat. Even when all valves are set
properly, they may not be operating well because of worn orifices or seals.
Always remove and check the hot components first, before the others.
Oil that has been running too hot will look darker and feel thinner than new oil. It
will also smell burned. Chances are, it will contain more contaminants, because
hot oil leads to accelerated wear of component parts.
-8-
Maintenance Manual
Standard Hydraulic Power Units
Preventive Measures
How can you keep your equipment's hydraulic system from running too hot?
1) Set up a regular schedule for checking the oil temperature,
appearance, smell and feel. Change oil as recommended by the
equipment manufacturer.
2) Be prompt about removing, checking and repairing or replacing valves,
pumps or other components that are running hot.
3) If relief or flow-control valves are running hot, check and adjust their
settings. Follow your equipment owner's manual.
4) Break in new components gradually. New, close-fittings parts expand at
different rates, and are especially prone to seize when they get too hot.
5) Start a cold pump or motor on hot oil by jogging just enough to draw the
hot oil into the component. Then wait a few minutes to allow
the temperature to equalize in all the pump's parts. Repeat until
the temperature on the outside of the pump is the same as that on
the piping.
6) Keep your equipment clean. A thick layer of dirt acts as insulation. It
will prevent the hydraulic system from getting rid of heat.
7) On hot days, and in hot climates, check and change the oil more
frequently. Be sure to use an oil recommended for hot-weather operation
by the equipment manufacturer or oil supplier.
Troubleshooting
Troubleshooting Areas
Dirty oil
1) Components not properly cleaned after servicing.
2) Inadequate screening in fill pipe.
3) Air breather left off. (No air breather provided ... inadequate unit
provided ... insufficient protection of air breather.)
4) Tank not properly gasketed.
5) Pipe lines not properly covered while servicing machine.
6) Improper tank baffles not providing settling basin for heavy materials.
7) Filter dirty or ruptured.
-9-
Maintenance Manual
Standard Hydraulic Power Units
Foaming oil
1) Return of tank line not below fluid level. Broken pipe, line left out between
a bulkhead coupling and the bottom of the tank after cleaning tank.
2) Inadequate baffles in reservoir.
3) Fluid contaminated with imcompatible foreign matter.
4) Suction leak to pump aerating oil.
5) Lack of anti-foaming additives.
Moisture in oils
1) Cooling coils not below fluid level.
2) Cold water lines fastened directly against hot tank causing condensation
within tank.
3) Soluble oil solution splashing into poorly gasketed tanks or fill pipes left
open.
4) Moisture in cans used to replace fluid in tanks.
5) Extreme temperature differential in certain geographical locations.
6) Drain not provided at lowest point in tank to remove water collected over
possibly long operating periods.
Overheating of system
1) Water shut off or heat exchanger clogged.
2) Continuous operation at relief setting.
a. Stalling under load, etc.
b. Fluid viscosity too high or too low.
3) Excessive slippage or internal leakage.
a. Check stall leakage past pump, motors and cylinders
b. Fluid viscosity too low.
4) Reservoir sized too small.
-10-
Maintenance Manual
Standard Hyd rau Iic Power Units
Troubleshooting Pumps
Pump makes excessive noise
1) Check for vacuum leaks in the suction line. (Such as leak in fitting or
damaged suction line.
2) Check for vacuum leaks in the pump shaft seal if the pump is internally
drained. Flooding connections with the fluid being pumped may
cause the noise to stop or abate momentarily. This will locate the point of
air entry.
3) Check alignment with drive mechanism. Misalignment will cause wear
and subsequent high noise level in operation.
4) Check manufacturers specifications relative to wear possibilities and
identification of indications of wear as high operating noise level, etc.
-11-
Maintenance Manual
Standard Hydraulic Power Units
-12-
Maintenance Manual
Standard Hydraulic Power Units
-13-
Maintenance Manual
Standard Hydraulic Power Units
4) Tight spool or other mechanical parts of the valve being actuated can
prevent the solenoid from completing its stroke and subsequently burning
out.
5) Replacement springs too heavy in valve. Overloads solenoid and shortens
life.
6) Wrong voltage or frequency will either prevent operation because of in-
adequate capacity to handle the load with the lower voltage or burn out
the coil because of improper winding and excessive voltage.
7) Dirty contacts may not supply sufficient current to solenoid to satisfy
inrush demands.
8) Low voltage direct current solenoids may be affected by low battery
capacity on cold mornings directly after starting cold engine.
9) Long feed lines to low voltage solenoids may cause sufficient voltage
drop to cause erratic operation.
-14-
Maintenance Manual
Standard Hydraulic Power Units
8) Has mounting pad been warped from external heating? (Loosen mounting
bolts slightly and see if valve functions. End caps can also be removed
and check for tight spool.)
9) Is fluid media excessively hot? (Check for localized heating which may
indicate an internal leak ... check reservoir temperature and see if it is
within machine specifications.)
10) Is there foreign matter in the fluid media causing gummy deposits?
(Check for contamination ... make certain seals and plumbing are compati-
ble with the type of fluid being used.)
11) Is an adequate supply of fluid being delivered to actuate the load? (Many
times there is sufficient pressure to shift the valve but not enough to
actuate the work load. Check pump supply pressure and volume if
necessary ... physical measurement of flow through relief valve with units
blocked may be necessary.)
12) Check circuit for possible interlocks on pressure sources to valve or
to pilot.
-15-
Three-Phase General Purpose Motors
Three Phase General Purpose Motors W22
W22 - Cast Iron TEFC - Cast Iron
General Purpose
General Purpose
Three-Phase
Three-Phase
Motors
Motors
Standard Features:
• 50/60 Hz rated (380V on
nameplate - 400/415 available) New Cooling System
Terminal Box
• Rated 50HZ at same horsepower Fan Cover
g Aerodynamic design
Fan
g Reinforced fan hub structure
g Better connection quality
up to 250HP 1.0 Service Factor g Noise level reduction g Noise level reduction
g Easier cable handling
Features that make a difference: g Better air flow distribution over frame g Increased air flow
during installation
for 2,4 & 6 pole motors g Increased mechanical strength g Fan with higher stiffness
g More space available for
accessory installation
• Rated 50Hz at same horsepower • All NEMA Premium ratings have a 1.25 service factor (up g Easier Maintenance
to 100 HP) resulting in cooler operation and extended life g Mounting F1/F2/F3
8 pole motors
• All Cast Iron Construction, including Terminal Box and
• Class F insulation (impregnation Fan Cover (*)
resin and magnet wire are class • Solid feet for reduced vibration levels and impact Bearing Caps
H) absorption External
g Finned surface for
• F1 mounted (cast iron frames are • Optimized ventilation system for cooler operation and improved bearing
heat dissipation
F2 convertible). Frames 447T and extended life Internal
up can easily be F2 converted by • High Grade FC200 cast iron provides superior mechanical
g Change of grease
path for positive
simply rotating the terminal box strength and heat dissipation lubrication
g Bearing lubrication
adapter • All WEG W22 motors are Totally Enclosed Fan Cooled quality improvement
g Reduced bearing
Inverter Rated • Balanced to 0.08 inches per second vibration limits to high-pressure
Frame cleaning
1000:1 for Variable Torque (Meets IEEE841 standard) g Reduced temperature on windings Enhanced Lifting Provisions
NEMA Premium • Four Bolt Conduit Cover with glued Neoprene Gasket
and bearings
Noise level reduction
g Easier handling - horizontal & vertical
g Higher mechanical strength and
g
Endshields Subsystem
20:1 Constant Torque up to 250HP g Terminal box position outlet on top handling safety
• Impregnation Resin and magnet wire are insulation class H DE (Drive Endshield)
6:1 Constant Torque 300HP and up Pad for vibration sensor Solid feet
g
g New fin design
g Displaced 90 0 from each other More impact resistance
High Efficiency (EPAct) • Stainless Steel Nameplate - Laser etched with high g
Ideal for high vibration level
g Bearing moved outwards for better load support
Improved bearing heat dissipation for reduced bearing
contrast background
g
applications
12:1 Constant Torque up to 250HP g
temperature
Reinforced endshield structure
4:1 Constant Torque 300HP and up • Corrosion Proof Drains
NDE (Non-Drive Endshield)
• Inverter Duty per NEMA MG1, Part 31 g New design with smooth exterior surface
g Improved air flow
ADDITIONAL TECHNICAL DATA • Certified Class I Div 2, Groups A, B, C & D; Class II, Div 2, g Noise level reduction
g Improved structural rigidity for low vibration
Groups F & G
ELECTRICAL DATA: p. B-6
• Suitable for IEEE45 and USCG 259 – Marine Duty
MECHANICAL DATA: p. C-2
*Cast iron fan cover available as an option on 143-215T frames
A-18 www.weg.net/us Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934) A-19
Three-Phase General Purpose Motors Three-Phase General Purpose Motors
General Purpose
General Purpose
Three-Phase
Three-Phase
Motors
Motors
Approx. Approx. FL
FL "C" "C"
NEMA List Mult. Shipping Service FL. Eff NEMA List Mult. Shipping Service Amps FL. Eff
HP kW RPM Catalog Number Amps Dimension Voltage (V) Notes HP kW RPM Catalog Number Dimension Voltage (V) Notes
Frame Price Symbol Weight Factor (%) Frame Price Symbol Weight Factor @ (%)
@ High (in) (in)
(lbs) (lbs) High
3600 L447/9TS 45036ET3G449TS-W22 49,610 N1 3492 1.00 475 95.8 53.431 460 1 3600 143/5TC 00136ET3E143TC-W22 566 N1 43 1.25 1.43 78.5 13.346 208-230/460
1800 586/7 45018EP3G586/7-W22 46,053 W1 5204 1.15 503 95.8 61.902 460 30 1800 143/5TC 00118ET3E143TC-S 484 RSP 43 1.15 1.47 85.5 13.583 208-230/460 9
1800 L447/9T 45018ET3G449T-W22 48,010 N1 3524 1.15 501 96.2 57.181 460 1800 143/5TC 00118ET3E143TC-W22 555 N1 49 1.25 1.41 85.5 13.346 208-230/460
1800 L447/9T 45018ET3GRB449T-W22 48,010 N1 3542 1.15 501 96.2 57.181 460 14 1800 143/5TC 00118ET3ERS143TC 484 RSP 41 1.15 1.55 85.5 14.095 208-230/460 9
1 0.75
1200 586/7 45012EP3G586/7-W22 56,592 W1 4933 1.00 536 95.4 61.902 460 1;30 1800 143/5TC 00118ET3H143TC-W22 555 N1 49 1.25 1.13 85.5 13.346 575
450 330
1200 586/7 45012EP3GRB586/7-W22 56,592 W1 5248 1.00 536 95.4 61.902 460 1;14;30 1200 143/5TC 00112ET3E145TC-S 554 RSP 43 1.15 1.58 82.5 13.583 208-230/460 9
1200 586/7 45012EP3H586/7-W22 56,592 W1 5248 1.00 429 95.4 61.902 575 1;30 1200 143/5TC 00112ET3E145TC-W22 636 N1 56 1.25 1.73 82.5 13.346 208-230/460
1200 586/7 45012ET3G586/7-W22 62,251 N1 4877 1.00 532 96.2 61.902 460 1 1200 143/5TC 00112ET3ERS145TC 554 RSP 47 1.15 1.75 82.5 14.095 208-230/460 9
1200 586/7 45012ET3GRB586/7-W22 62,251 N1 5248 1.00 532 96.2 61.902 460 1;14 3600 143/5TC 00156ET3E143TC-S 497 RSP 39 1.15 1.87 84 13.583 208-230/460 9
900 588/9 45009ET3G588/9-W22 68,715 N1 5189 1.00 554 95.8 69.381 460 1 3600 143/5TC 00156ET3E143TC-W22 571 N1 48 1.25 1.91 84.0 13.346 208-230/460
3600 586/7S 50036ET3G586/7S-W22 56,305 N1 4571 1.15 530 96.2 55.027 460 3600 143/5TC 00156ET3ERS143TC 497 RSP 40 1.15 1.95 84.0 14.095 208-230/460 9
1800 L447/9T 50018ET3G449T-W22 50,594 N1 3652 1.00 561 96.2 57.181 460 1;19 3600 143/5TC 00156ET3H143TC-W22 571 N1 45 1.25 1.53 84.0 13.346 575
500 370
1800 L447/9T 50018ET3GRB449T-W22 50,594 N1 5424 1.00 561 96.2 57.181 460 1;14 1800 143/5TC 00158ET3E145TC-S 504 RSP 43 1.15 2.02 86.5 13.583 208-230/460 9
1200 586/7 50012ET3G586/7-W22 62,962 N1 4896 1.00 603 96.2 61.902 460 1 1.5 1.1 1800 143/5TC 00158ET3E145TC-W22 579 N1 55 1.25 2.02 86.5 13.346 208-230/460
3600 588/9S 60036ET3G588/9S-W22 64,635 N1 5261 1.00 650 96.5 62.506 460 1 1800 143/5TC 00158ET3ERS145TC 504 RSP 49 1.15 2.25 86.5 14.095 208-230/460 9
600 450 1800 586/7 60018ET3G586/7-W22 60,316 N1 4900 1.00 665 96.5 61.902 460 1 1800 143/5TC 00158ET3H145TC-W22 579 N1 57 1.25 1.62 86.5 13.346 575
1200 588/9 60012ET3G588/9-W22 71,374 N1 6000 1.00 743 96.2 69.381 460 1 1200 182/4TC 00152ET3E182TC-S 690 RSP 73 1.15 2.22 87.5 16.339 208-230/460 9
3600 588/9S 65036ET3G588/9S-W22 66,835 N1 4805 1.00 685 96.6 62.506 460 1 1200 182/4TC 00152ET3E182TC-W22 792 N1 100 1.25 2.39 87.5 15.860 208-230/460
650 480
1800 588/9 65018ET3G588/9-W22 66,701 N1 3308 1.00 734 96.6 69.381 460 1 1200 182/4TC 00152ET3ERS182TC 690 RSP 90 1.15 2.39 87.5 16.404 208-230/460 9
3600 588/9S 70036ET3G588/9S-W22 71,254 N1 5754 1.00 736 96.6 62.506 460 1 3600 143/5TC 00236ET3E145TC-S 539 RSP 45 1.15 2.47 85.5 13.976 208-230/460 9
700 515
1800 588/9 70018ET3G588/9-W22 71,185 N1 5893 1.00 788 96.6 69.381 460 1 3600 143/5TC 00236ET3E145TC-W22 619 N1 58 1.25 2.53 85.5 13.346 208-230/460
750 550 1800 588/9 75018ET3G588/9-W22 74,025 N1 3308 1.00 840 96.7 69.381 460 1 3600 143/5TC 00236ET3ERS145TC 539 RSP 48 1.15 2.50 85.5 14.095 208-230/460 9
3600 143/5TC 00236ET3H145TC-W22 619 N1 56 1.25 2.02 85.5 13.346 575
1800 143/5TC 00218ET3E145TC-S 558 RSP 47 1.15 2.72 86.5 13.976 208-230/460 9
2 1.5 1800 143/5TC 00218ET3E145TC-W22 640 N1 59 1.25 2.61 86.5 13.346 208-230/460
1800 143/5TC 00218ET3ERS145TC 558 RSP 55 1.15 2.85 86.5 14.095 208-230/460 9
1800 143/5TC 00218ET3H145TC-W22 640 N1 57 1.25 2.09 86.5 13.346 575
1200 182/4TC 00212ET3E184TC-S 747 RSP 83 1.15 3.00 88.5 17.126 208-230/460 9
1200 182/4TC 00212ET3E184TC-W22 857 N1 112 1.25 3.23 88.5 15.860 208-230/460
1200 182/4TC 00212ET3ERS184TC 747 RSP 101 1.15 3.22 88.5 16.404 208-230/460 9
Continued on next page
Note: Flanged motors on Cast Iron frame sizes 143/5 to 254/6 have non-NEMA BA dimension. Refer to mechanical section of this catalog for details.
Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES” Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES”
For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com
A-32 www.weg.net/us Data subject to change without notice. Data subject to change without notice. Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934) A-33
Three-Phase General Purpose Motors Three-Phase General Purpose Motors
TEFC – C-Flange – Foot Mount continued TEFC – C-Flange – Foot Mount continued
General Purpose
General Purpose
Three-Phase
Three-Phase
Motors
Motors
Approx. FL Approx. FL
"C" "C"
NEMA List Mult. Shipping Service Amps FL. Eff NEMA List Mult. Shipping Service Amps FL. Eff
HP kW RPM Catalog Number Dimension Voltage (V) Notes HP kW RPM Catalog Number Dimension Voltage (V) Notes
Frame Price Symbol Weight Factor @ (%) Frame Price Symbol Weight Factor @ (%)
(in) (in)
(lbs) High (lbs) High
3600 182/4TC 00336ET3E182TC-S 698 RSP 71 1.15 3.67 86.5 16.339 208-230/460 9 3600 213/5TC 01036ET3E215TC-S 1,205 RSP 173 1.15 11.5 90.2 21.654 208-230/460 9
3600 182/4TC 00336ET3E182TC-W22 802 N1 103 1.25 3.63 86.5 15.860 208-230/460 3600 213/5TC 01036ET3E215TC-W22 1,383 N1 187 1.25 11.6 90.2 19.517 208-230/460
3600 182/4TC 00336ET3ERS182TC 698 RSP 91 1.15 3.68 87.5 16.404 208-230/460 9 3600 213/5TC 01036ET3ERS215TC 1,205 RSP 170 1.15 11.5 91.7 20.257 208-230/460 9
3600 182/4TC 00336ET3H182TC-W22 802 N1 103 1.25 2.90 86.5 15.860 575 3600 213/5TC 01036ET3H215TC-W22 1,383 N1 185 1.25 9.28 90.2 19.517 575
1800 182/4TC 00318ET3E182TC-S 610 RSP 87 1.15 3.81 89.5 17.894 208-230/460 9 1800 213/5TC 01018ET3E215TC-S 1,154 RSP 142 1.15 12.2 91.7 19.291 208-230/460 9
1800 182/4TC 00318ET3E182TC-W22 700 N1 100 1.25 3.88 89.5 15.860 208-230/460 10 7.5 1800 213/5TC 01018ET3E215TC-W22 1,325 N1 196 1.25 12.4 91.7 19.517 208-230/460
3 2.2
1800 182/4TC 00318ET3ERS182TC 610 RSP 72 1.15 3.91 89.5 16.404 208-230/460 9 1800 213/5TC 01018ET3ERS215TC 1,154 RSP 166 1.15 12.7 91.7 20.257 208-230/460 9
1800 182/4TC 00318ET3H182TC-W22 700 N1 100 1.25 3.10 89.5 15.860 575 1800 213/5TC 01018ET3H215TC-W22 1,325 N1 197 1.25 9.92 91.7 19.517 575
1200 213/5TC 00312ET3E213TC-S 1,028 RSP 142 1.15 4.17 89.5 19.291 208-230/460 9 1200 254/6TC 01012ET3E256TC-S 2,148 RSP 277 1.15 13.8 91 23.346 208-230/460 9
1200 213/5TC 00312ET3E213TC-W22 1,180 N1 154 1.25 4.41 89.5 19.517 208-230/460 1200 254/6TC 01012ET3E256TC-W22 2,465 N1 324 1.25 12.9 91.0 24.945 208-230/460
1200 213/5TC 00312ET3ERS213TC 1,028 RSP 142 1.15 4.41 89.5 20.257 208-230/460 9 1200 254/6TC 01012ET3ERS256TC 2,148 RSP 282 1.15 13.3 91.0 24.925 208-230/460 9
900 213/5TC 00309ET3E215TC-W22 2,166 N1 192 1.25 4.56 85.5 19.517 208-230/460 3600 213/5TC 01536ET3E215TC-W22 1,748 N1 199 1.25 17.0 91.0 19.517 208-230/460
3600 182/4TC 00536ET3E184TC-S 793 RSP 86 1.15 5.90 88.5 17.894 208-230/460 9 3600 254/6TC 01536ET3E254TC-S 1,649 RSP 220 1.15 17.4 91 22.559 208-230/460 9
3600 182/4TC 00536ET3E184TC-W22 911 N1 110 1.25 5.90 88.5 15.860 208-230/460 3600 254/6TC 01536ET3E254TC-W22 1,893 N1 283 1.25 17.2 91.0 24.945 208-230/460
3600 182/4TC 00536ET3ERS184TC 793 RSP 101 1.15 5.96 89.5 16.404 208-230/460 9 3600 254/6TC 01536ET3ERS254TC 1,649 RSP 235 1.15 16.9 91.7 24.925 208-230/460 9
3600 182/4TC 00536ET3H184TC-W22 911 N1 112 1.25 4.72 88.5 15.860 575 3600 254/6TC 01536ET3H254TC-W22 1,893 N1 282 1.25 13.8 91.0 24.945 575
1800 182/4TC 00518ET3E184TC-S 706 RSP 79 1.15 6.49 89.5 17.894 208-230/460 9 15 11 1800 254/6TC 01518ET3E254TC-S 1,670 RSP 242 1.15 18.2 92.4 22.559 208-230/460 9
5 3.7 1800 182/4TC 00518ET3E184TC-W22 810 N1 109 1.25 6.45 89.5 15.860 208-230/460 1800 254/6TC 01518ET3E254TC-W22 1,917 N1 336 1.25 18.0 92.4 24.945 208-230/460
1800 182/4TC 00518ET3ERS184TC 706 RSP 97 1.15 6.40 89.5 16.404 208-230/460 9 1800 254/6TC 01518ET3ERS254TC 1,670 RSP 259 1.15 18.0 92.4 24.925 208-230/460 9
1800 182/4TC 00518ET3H184TC-W22 810 N1 108 1.25 5.16 89.5 15.860 575 1800 254/6TC 01518ET3H254TC-W22 1,917 N1 330 1.25 14.4 92.4 24.945 575
1200 213/5TC 00512ET3E215TC-S 1,206 RSP 156 1.15 6.74 89.5 20.079 208-230/460 9 1200 284/6TC 01512ET3E284TC-W22 3,388 N1 409 1.25 17.9 91.7 27.929 208-230/460
1200 213/5TC 00512ET3E215TC-W22 1,384 N1 177 1.25 6.83 89.5 19.517 208-230/460 1200 284/6TC 01512ET3H284TC-W22 3,388 N1 408 1.25 14.3 91.7 27.929 575
1200 213/5TC 00512ET3ERS215TC 1,206 RSP 158 1.15 6.83 89.5 20.257 208-230/460 9 3600 254/6TC 02036ET3E256TC-S 2,136 RSP 256 1.15 22.7 91 22.559 208-230/460 9
3600 213/5TC 00736ET3E213TC-S 1,025 RSP 144 1.15 8.67 89.5 19.291 208-230/460 9 3600 254/6TC 02036ET3E256TC-W22 2,451 N1 318 1.25 23.2 91.0 24.945 208-230/460
3600 213/5TC 00736ET3E213TC-W22 1,177 N1 160 1.25 8.76 89.5 19.517 208-230/460 3600 254/6TC 02036ET3ERS256TC 2,136 RSP 266 1.15 22.9 92.4 24.925 208-230/460 9
3600 213/5TC 00736ET3ERS213TC 1,025 RSP 147 1.15 8.63 91.0 20.257 208-230/460 9 3600 254/6TC 02036ET3H256TC-W22 2,451 N1 319 1.25 18.6 91.0 24.945 575
3600 182/4TC 00736ET3H184TC-W22 1,112 N1 93 1.25 7.01 89.5 15.860 575 20 15 1800 254/6TC 02018ET3E256TC-S 1,978 RSP 271 1.15 24.5 92.4 23.346 208-230/460 9
3600 213/5TC 00736ET3H213TC-W22 1,177 N1 158 1.25 7.01 89.5 19.517 575 1800 254/6TC 02018ET3E256TC-W22 2,270 N1 367 1.25 24.1 93.0 24.945 208-230/460
1800 213/5TC 00718ET3E213TC-S 994 RSP 131 1.15 9.07 91.7 18.898 208-230/460 9 1800 254/6TC 02018ET3ERS256TC 1,978 RSP 286 1.15 24.4 93.0 24.925 208-230/460 9
7.5 5.5 1800 213/5TC 00718ET3E213TC-W22 1,141 N1 174 1.25 9.00 91.7 19.517 208-230/460 1800 254/6TC 02018ET3H256TC-W22 2,270 N1 366 1.25 19.3 93.0 24.945 575
1800 213/5TC 00718ET3ERS213TC 994 RSP 154 1.15 9.29 91.7 20.257 208-230/460 9 1200 284/6TC 02012ET3E286TC-W22 4,060 N1 456 1.25 24.2 91.7 27.929 208-230/460
1800 213/5TC 00718ET3H213TC-W22 1,141 N1 167 1.25 7.20 91.7 19.517 575 3600 284/6TSC 02536ET3E284TSC-W22 3,096 N1 407 1.25 28.5 91.7 26.557 208-230/460
1200 254/6TC 00712ET3E254TC-S 1,859 RSP 248 1.15 9.98 91 22.559 208-230/460 9 3600 284/6TSC 02536ET3H284TSC-W22 3,096 N1 406 1.25 22.8 91.7 26.557 575
25 18.5
1200 254/6TC 00712ET3E254TC-W22 2,134 N1 295 1.25 9.48 91.0 24.945 208-230/460 1800 284/6TC 02518ET3E284TC-W22 2,840 N1 439 1.25 29.5 93.6 27.929 208-230/460
1200 254/6TC 00712ET3ERS254TC 1,859 RSP 262 1.15 9.73 91.0 24.925 208-230/460 9 1800 284/6TC 02518ET3H284TC-W22 2,840 N1 432 1.25 23.6 93.6 27.929 575
900 254/6TC 00709ET3E256TC-W22 3,726 N1 324 1.25 11.1 87.5 24.945 208-230/460 Continued on next page
Note: Flanged motors on Cast Iron frame sizes 143/5 to 254/6 have non-NEMA BA dimension. Refer to mechanical section of this catalog for details. Note: Flanged motors on Cast Iron frame sizes 143/5 to 254/6 have non-NEMA BA dimension. Refer to mechanical section of this catalog for details.
Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES” Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES”
For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com
A-34 www.weg.net/us Data subject to change without notice. Data subject to change without notice. Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934) A-35
Part Number Configuration
Ordering
WEG model numbers contains up to 20 characters, distributed as follows:
X X X
ENCLOSURE EFFICIENCY PHASE
E - Totally Enclosed S - Standard Efficiency 1 - 1 Phase
S - Severe Duty IEEE 841 P - High Efficiency 3 - 3 Phase
O - Open drip proof T - NEMA Premium
X - eXplosion proof G - Super Premium
A - Totally Enclosed Air Over
N - Totall Enclosed Non Ventilated
Application + Frame -
Volts -
For
A - 115V L - 415V Definite Purpose lines, two pre-selected
letters
B - 115 / 208 - 230V M - 220 / 380 - 415V must be used after voltage code:
C - 208 - 230V N - 220 / 380V AD - Auger Drive
D - 230V O - 380 - 415V AL - ALuminum Frame
E - 208 - 230 / 460V* P - 200V AX - ATEX Motor
F - 230 / 460V Q - 460V
BM - Brake Motor
G - 460V PWS R - 115 / 230V
CD - Compressor Duty
H - 575V V - 200 / 400V
CT - Cooling Tower
I - 220V W - 460/220-240/380-415V
J - 380V X - Other Voltage
DP - Double Pole (2 Speed)
EC - Evaporative Cooler
K - 190 / 380V Y - 460/380-415/660-690V
FD - Farm Duty
FP - Fire Pump
HP - Hydraulic Pump
HS - Hollow Shaft
IB - Inverter Duty (TEBC)
* Suitable for PWS on 254T and larger on low voltage connection.
IE - IEEE 841 (Severe Duty IEEE 841)
IP - Irrigation Pumping
1)
• For IEC Metric motors, the output will be given in kW: JP - Jet Pump
.12 - .18 - .25 - .37 - .55 - .75 - 001 - 0015 - 002 - 003 - 004 - 0045 - 005 - KD - Crusher-Duty
007 - 009 - 011 - 015 - 018 - 022 - 030 - 037 - 045 - 055 - 075 - 090 - 110 - OL - Manual OverLoad Protection
130 - 150 - 185 - 200 - 220 - 250 - 300 - 315 ... OT - Oil Well Pumping - Triple Rated
• 0015 (1.5HP) is the rating that will have four digits for output OW - Oil Well Pumping
Identification and only one for RPM. PF - Poultry Fan
• 0045 (4.5kW) is the rating that will have four digits for output PM - Pad Mount
identification and only one for RPM. R - (Before the frame size): Round Body
RB - Roller Bearings (Integrals)2
RB - Resilient Base (Fractionals)
Frame RS - Rolled Steel Frame
The frame number must be included as long as the
SA - Saw Arbor
number of remaining characters allow.
SP - Split Phase
Example: 143T, 143TC, 405T, 405TS, 184JP.
SS - Stainless Steel
-W22 Suffix VD - Vector Duty (TEBC or TENV)
-W22 Suffix will be added to the catalog number of totally
enclosed motors with the new W22 WEG design. Depending on the
number of remaining characters this suffix might appear as -W or -W2.
WAGO
381
System 750
Overview
Topics of Discussion
Specialty
Managed &
Modules
Unmanaged
Switches
Wireless IP67 PFCs
16+ Networks Bluetooth
Interface
Boards
PFC200
IP67 HMI/PLC
382
WAGO-I/O-SYSTEM 750 Components
1) Coupler/Controller
2) I/O Modules
3) End Module
Fieldbus Independent
• DeviceNet • ModbusTCP
• PROFIBUS • EtherNet/IP
• INTERBUS • Firewire
• MODBUS • CANopen
• LonWorks • And More…
383
Programmable Fieldbus Controllers Fieldbus Couplers
CONTROLLERS (IEC61131-3 Programmable)
750-804 INTERBUS FIELDBUS COUPLERS
384
750-881 Ethernet Controller
385
WAGO ECO ETHERNET Controller 750-852
• Features
• Member of the ETHERNET 2.0 controller family
• Programmable with CoDeSys
• 2 Ethernet interfaces + integrated switch
• Maintenance free
• Advantages
• Performs like a 750-88X
• Considerations
• No Web server
• No real time Clock
• Lower memory
• Benefits
• Cost savings
Introducing PFC200
Introduction of
4 different types of Controllers with
different interfaces
758-8xx IPC’s
Starting List $2,100
386
The Controller PFC200
• Features
• Standard System 750 I/O
• Programmable in IEC and C/C++
• CoDeSys Version 2
• Maintenance-free (no battery)
• Advantages
• Small package with high performance
• Web Based Managment
• Web Server
• Benefits
• Compact Size
• Muliple Fieldbus interfaces
• Use as a Gateway
• Powerful programming software
• Easy to engineer
• Powerful controller
Controller PFC200
• Interfaces
• Ethernet (switch)
• RS232/485 (D-SUB 9 female)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
RESET)
• LED (System, Fieldbus, USER)
Part Number: 750-8202
© WAGO Corporation, Germantown WI 17
Controller PFC200
• Interfaces
• Ethernet (switch)
• CAN; CANopen (D-SUB 9 male)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
RESET)
Part Number: 750-8203 • LED (System, Fieldbus, USER)
387
Controller PFC200
• Interfaces
• Ethernet (switch)
• RS232/485 (D-SUB 9 female)
• CAN; CANopen (D-SUB 9 male)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
RESET)
Part Number: 750-8204 • LED (System, Fieldbus, USER)
Controller PFC200
• PFC200 Controller
Eth&Serial&CAN&PROFIB
• Cortex A8, 600 MHz
• Interfaces
• Ethernet (switch)
• RS232/485 (D-SUB 9 female)
• CAN; CANopen (D-SUB 9 male)
• PROFIBUS Slave (D-SUB 9 female)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
Part Number: 750-8206 RESET)
• LED (System, Fieldbus, USER)
© WAGO Corporation, Germantown WI 20
Stability
• Hot-Plug USB Sticks
– Automatic mounting and dismounting
• Application: Data logging on USB stick
388
Next Generation CoDeSys IPCs
Example Architectures
Industrial PC
IP67 Programmable
Programmable Fieldbus Controllers
3rd Party Controllers & Couplers
Fieldbus Controllers
Fieldbus Couplers
Fieldbus Couplers
Modular
* System can support up to 250 I/O modules with Bus Extension modules.
389
Digital Input Modules
DI 5/12 VDC 750-1421 4 Channel DC 24V 0.2 ms, 3 conductor connection
750-434 8 Channel, DC 5/12 V, 0.2 ms , high-side switching 750-1422 4 Channel DC 24V 3.0 ms, 3 conductor connection, LSS
750-414 4 Channel, DC 5 V, 0.2 ms, high-side switching 750-436 8 Channel, DC 24 V, 3.0 ms, low-side switching
750-1425 8 Channel PTC Thermistors 750-437 8 Channel, DC 24 V, 0.2 ms, low-side switching
750-1400 16 Channel DC 24V 3.0 ms, ribbon cable 750-428 Channel, AC/DC 42 V, 2-conductor connection
750-1405 16 Channel DC 24V 0.2 ms, CAGE CLAMP® S 750-412 2 Channel, DC 48 V, 3.0ms, high-side switching
750-1407 16 Channel DC 24V 0.2 ms, CAGE CLAMP® S,LSS 750-427 2 Channel, DC 110 V, Configurable high or low-side
750-1416 8 Channel DC 24V 0.2 ms, 2 conductor connection 750-406 2 Channel, AC 120 V, high-side switching
750-1417 8 Channel DC 24V 3.0 ms, 2 conductor connection, LSS 750-405 2 Channel, AC 230 V, high-side switching
750-1420 4 Channel DC 24V 3.0 ms, 3 conductor connection 753-440 4 Channel, AC 120/230
750-1506 8DI 8DO 24V DC 0.5 A, CAGE CLAMP® S 750-513 2 Channel, AC 230 V, DC 30 V, AC/DC 2 A, isolated
outputs, 2 make contacts
750-1515 8 Channel DC 24V 0.5 A, 2 conductor connection
750-523 1 Channel, AC 230 V, AC 16 A, isolated output, 1 make
750-1516 8 Channel DC 24V 0.5 A, 2 conductor connection, LSS contact, bistable, manual operation
390
Analog Output Modules
AO 0 - 20 mA
750-552 2 Channel, 0 - 20 mA
750-553 4 Channel, 0 - 20 mA
750-585 2 Channel, 0 - 20 mA, EEx i
AO 4 - 20 mA
750-555 4-channel, 4 - 20 mA
750-554 2-channel, 4 - 20 mA
750-563 2-channel, 4 - 20 mA or 0 - 20 mA, 16 bit
AO DC 0 - 10 V
750-550 2 Channel, DC 0 - 10 V
750-559 4 Channel, DC 0 - 10 V
750-560 2 Channel, DC 0 - 10 V,10 bit
750-562 2 Channel, DC 0 - 10 V or ± 10 V , 16 bit
AO DC ± 10 V
750-556 2 Channel, DC ± 10 V
750-557 4 Channel, DC ± 10 V
Specialty Modules
Serial Interfaces
750-650 Serial Interface RS 232 C
Counter Modules
750-653 Serial Interface RS 485
750-404 Up / Down Counter, DC 24 V, 100 kHz
750-652 Serial Interface RS 232/RS 485 Configurable
750-638 2 Channel, Up / Down Counter, DC 24 V/ 16Bit / 500 Hz
750-651 TTY-Serial Interface, 20 mA Current Loop
Frequency Measuring
750-654 Data Exchange Module
750-404/ Frequency Measuring 0.1Hz – 100kHz
000-003 Networking
Supply Modules
391
I/O Modules: Color Code and Markers
Status LED
(module specific) Internal Bus Contacts
(KBUS)
WSB Markers
CAGE CLAMP
Connections
WAGO-I/O-SYSTEM 750 Ex i
392
Series 750 For Harsh Temperature Environments
Tool-less assembly of
connector and module
Coding feature
For added safety
Built-in eyelet
for wire-tie
strain relief
393
Assembly Features
Controller
Locking Disc Secure
Tongue and
Groove
Connections
Cage Clamp
FIELDBUS
POWER
FIELD WIRING POWER
394
Internal System Supply
750-881 Total Current for I/O Modules is 1700 mA (Catalog W5V3 pg 40)
750-512 Current Consumption 100mA/module (Catalog W5V3 pg 135)
750-405 Current Consumption 2mA/module (Catalog W5V3 pg 119 )
395
Internal System Supply Module
Internal
System
Supply
Module
(750-613)
Field Supply
+24 VDC
POWER
0 VDC JUMPER
CONTACTS
GROUND
= Spring Contact
= Blade Contact
396
Power Jumper Contacts
PROBLEM
These two modules cannot be adjacent to
each other as shown. The left module does
not have a lower spring contact for the right
module’s lower blade.
SOLUTION
Rearrange the node to remove this
incompatibility (swap modules), or insert a
supply module between them. A supply
module has 0 blade contacts and 3 spring
contacts
Supply Modules
Supply Modules provide field side power through the power jumper contacts.
They are use to introduce a new field potential or boost the current capacity of
the existing potential (available in 24VDC, 0-230VAC/VDC, 120VAC,
230VAC, fused, and diagnosis).
Fused Supply Modules provide quick and easy access to fuses for
replacement. Additionally, a blown fuse indicator LED is
provided.
Fuse
Blown Replacement
Fuse LED
Fuse
Holder
397
Field Supply Example
PFC Supply
Field Modules
Supply
398
Input Process Image Example
1 AI MODULE 1, WORD 2
2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...
1 AI MODULE 1, WORD 2
2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...
1 AI MODULE 1, WORD 2
2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...
399
Input Process Image Example
1 AI MODULE 1, WORD 2
2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...
1 AI MODULE 1, WORD 2
2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...
1 AI MODULE 1, WORD 2
2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...
400
Output Process Image Example
1 AO MODULE 1, WORD 2
2 AO MODULE 2, WORD 1
3 AO MODULE 2, WORD 2
4 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
5
...
1 AO MODULE 1, WORD 2
2 AO MODULE 2, WORD 1
3 AO MODULE 2, WORD 2
4 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
5
...
1 AO MODULE 1, WORD 2
2 AO MODULE 2, WORD 1
3 AO MODULE 2, WORD 2
4 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
5
...
401
Digital Input/Output Offset
2 2
M M
64
1
1
1
0 9 8 7 6 5 4 3 2 1 0 64 1 0
402
Internal Bus Cycle Example
The Internal Bus can exchange one word of data per module per bus cycle.
Therefore, when multi-word modules are used, the controller requires multiple bus
cycles to exchange all module data.
EXAMPLE NODE DATA EXCHANGE PER BUS CYCLE
4 4 2 4
CYCLE 1 DIGITAL DATA 2CHAN WORD1 4CHAN WORD1
P C
H
C
H
C
H
C
H
nN
The 4-Channel Analog module used in this node, forces the controller to perform
four bus cycles to exchange all module data.
This comparison illustrates that using two 2 -Channel Analog module, instead of
one 4-Channel Analog module, improves the bus cycle.
PERSPECTO® CP TV
Integrated HMI and PLC
Features
• PLC-HMI runtime
• Logic Programming: CoDeSys V2.3
• Graphic Development: CoDeSys
V2.3
Advantages
• Reduce engineering development
time
• Advanced logic editor
• Easy connection to WAGO I/O
403
PERSPECTO® CP TV
15.0”
762-3150/000-001w/o CANopen
762-3150/000-001 w/ CANopen
Intel Atom 1.6GHz
RAM:256M
Flash: 128M
PERSPECTO® CP TV
10.4”, 12.1”, 15” Memory
Expansion
5.7” •Data Logging
3.5” •Trend data
•Event Data
758-879/000-000 1 GB
Industrial CF Memory Card
758-879/000-001 1 GB
Industrial SD Memory Card
758-879/000-002 1 GB
CF Card SD Card microSD Industrial microSD Memory Card
PERSPECTO® CP TV
12.1”& 10.4” 5.7”
Multiple
Communication
Ports
Serial &
CAN bus
Ethernet USB
Port Port
Battery USB 24V Power
Serial
Ports Ports 1,2
24V Power Ethernet
Battery USB Port
Ports Serial Ports CAN bus
Ethernet 1,2 & 3
Port 3.5
CAN bus ”
Ports 1 & 2
24V Power Battery
404
PERSPECTO® CP TV
RAS Server
SCADA
System
Supervisory Database
System Server
767 SPEEDWAY
Distributed I/O ETHERNET 2.0
PLCs
CF, SD,
AC Drives
MicroSD for
Serial memory
Expansion
CANopen
J1939
SPEEDWAY
750/ 753 Device
Distributed
Series I/O
CANopen
Distributed
I/O
© WAGO Corporation, Germantown WI 70
WAGO-I/O-SYSTEM
750 XTR
PERSPECTO
Industrial PC
PFC200
Automation Platforms
750 Series Standard
for your specific
SPEEDWAY – IP67
applications
405
eXTReme I/O for extreme applications
TAKING IT TO THE EXTREME -
750XTR
Benefits:
• Use in mobile applications
• Install on high vibration tools
• Use in high voltage applications
406
eXTReme altitudes
Benefits:
• Use in high altitude applications
407
WAGO 750 Series I/O module comparison
<60 V: 0,5 kV AC /
60 V: 0,5 kV AC / 0,5 60 V: 0,5 kV AC / 0,5 kV
1,0 kVimpulse
kV impulse voltage impulse voltage
voltage (VW1)
Electric insulation (EN
60870-2-1)
≥ 60 V: 2,5 kV AC /
≥ 60 V: 1,5 kV AC / 2,5 ≥ 60 V: 1,5 kV AC / 2,5
5,0 kVimpulse
kV impulse voltage kV impulse voltage
voltage (VW3)
WAGO-I/O-SYSTEM
750 XTR
408
Bluetooth® Ethernet Bridge (758-915)
Applications
Ethernet Ethernet
Ethernet Ethernet
409
ECO 852-1111 Gigabit Switch
WAGO-I/O CHECK 3
WAGO 750-923
USB cable
410
WAGO-I/O CHECK 3
WAGO-I/O CHECK 3
WAGO-I/O-CHECK 3
411
Applications
Gas Measurement equipment
WAGO Products:
750 I/O system
Applications
Application:
Modernize Prison Controls
WAGO Products:
Series 750 PFC & I/O
Series 758 IPC
Series 787 P.S.
Solution:
Compact Hardware
Flexible Software
Support
750-880
- Door releases, Door position,
Water, Lighting, Telephone
Intercom button, Smoke
detection
IPC’s
Applications
Industry: Advanced ROV
Exploration & Ocean Research
WAGO Products:
• 750-316 MODBUS Coupler
• 788 series relays
Problem Solved:
Reduce overall weight of ROV while
increasing on-board functions for
chemical dispensing and sample
collections.
412
Applications
Industry:
Transportation
WAGO
Products:ProfiBus
PFC Relays,
Distribution blks,
Fuse blks, Double
Deck
Problem Solved:
Reduced parts
and added
reliability.
Applications
Industry:
Fuel Cells as
Alternative
Energy
Problem Solved:
WAGO Products: 870, Quick start up, end of loose terminations and now
280, 859, & 750-841 additional modularity with 750 series I/O
© WAGO Corporation, Germantown WI 95
Applications
413
Applications
Offshore Safety on drilling
and production platforms.
WAGO Products:
750-841, 750-87, I/S,
280 Series
Applications
Industry: Pharmaceutical
WAGO Products:
WAGO 750-841 Controller along with
750 series I/O
Problem Solved:
The WAGO 750-841 provided a fast &
reliable solution to control 48x
Temperature PID zones
Drives controlled by WAGO Serial
interface/Modbus
© WAGO Corporation, Germantown WI 98
Applications
Drying Systems(Printing)
• Small and Wide Web systems
• Easily customized to customer
requirements
• Modular systems
750-881
Programmability– PID loop, RTD
module and discrete I/O.
IEC61131-3 programming tool for
selling to Europe
Ethernet IP or Modbus TCP
Built in switch
414
Applications
Applications
Industry:
Semiconductor
Application Description:
Metallization- Sputter Problem Solved: The WAGO 750 Series I/O spec’d. as the
Deposition Systems for new preferred System Control Platform. The utilization of
WAGO products significantly reduced costly wiring and
processing wafers.
offered a much more flexible off-the-shelf I/O solution.
Applications
Flight Simulators
• Wago 750-880 Ethernet
• Wago TJS Terminal Blocks
• Wago 788 Relays
415
Applications
• Industry: Chemicals
• Wago Products used:
750 Series I/0
• Problem Solved:
– Replaced expensive, obsolete
Yokogowa DCS I/O
Manufacture chemicals
used in Paper/Pulp,
Leather production,
Water Treatment, and
Performance chemicals
© WAGO Corporation, Germantown WI 103
Applications
Seam Welding Machines
• 750-881
• Thermocouple
• Encoders
• Various Other Analog & Discrete
Awnings
Inflatable life rafts
Inflatable furniture
Whitewater rafts
Applications
Tug boat transfer Barges
APPLICATION:
Engine Monitoring:
Engine Data used to find the
right mix of Biofuel/Diesel
Monitoring Engines
4-20 mA: Oil Pressure, Fuel Pressure
Thermocouple & RTD: Water, Oil, Exhaust,
Intake Air, Fuel
DI & DO: Fuel Tank/Water Level & Alarm
Current and Voltage Measurement: Ship Bus &
Steering Motor
Frequency Measurement: Engine Speed
© WAGO Corporation, Germantown WI 105
416
Applications
Thank You
WAGO Corporation
P.O. Box 1015
Germantown, WI 53022
E-Mail: [email protected]
Internet: www.wago.com
417