65 0 T O N T O P D R I V E
650/850 TON TOP DRIVE
Training Manual
GDS International 9841 Windmill Park Lane Houston, Texas 77064
www.globaldrillingsupport.com
1
GDM 650 Ton TOP DRIVE
OPERATIONS AND MAINTENANCE
MANUAL
2
G D M 5 0 0 / 6 5 0
T O P
D R I V E
Table of Contents
Section 1 – General ....................................................................................................4
Using this Manual
Top Drive Specifications
Torque Data
Section 2 – Operations ...............................................................................................9
Top Drive Console
HMI Touch Screens
Section 3 – Maintenance and Inspection..................................................................33
Top Drive Maintenance Diagram
Maintenance
Inspection
Maintenance Checklist
Load Path Inspection Drawings
Section 4– Rig Up Procedure .............................................................................................. 63
Section 5 – Drawings and Parts.................................................................................74
5A - Assembly Drawings
5B – Electrical Schematics
Section 6 – OMRON ......................................................................................................... 166
Section 7 – HPU -WILSON .............................................................................................. 254
Section 8 – WAGO............................................................................................................. 381
3
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
4
G D M 5 6 5 0
T O P
D R I V E
Using this Manual
This manual is organized as follows:
Section
Description
1 – General
Contains an outline of this manual and defines precautionary terms; also describes
Top Drive specifications, and how to find information.
2 – Operations
Instructions for operating the Top Drive Console and HMI Touch Screens.
3 – Maintenance and
Inspection
Describes maintenance and inspection requirements and routines.
4 – Drawings and
Parts
Contains assembly drawings and electrical, gear lube, and hydraulic schematics.
Parts shown in drawings are outlined in their respectively allocated Bills of
Material.
5 – Certifications
Certificate of Conformance and GDS’s API License and Certifications.
Important Safety Information
Throughout this manual, the following precautionary terms are used. It is imperative that their meanings
are fully understood before proceeding:
WARNING – This term immediately precedes or follows any procedural instruction or
information which, if not properly adhered to, poses the potential to cause personnel injury or
death.
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.
NOTE – This term is used liberally to emphasize important information.
5
G D M 6 5 0
T O P
D R I V E
Top Drive Specifications
GDM 500/650 AC
Static Hoist Rating
Drilling Electric Motor
Maximum Continuous Current
Maximum Intermittent Current
Maximum Voltage
Frequency Range
Cooling System
Continuous HP Rating
Gear Ratio
Continuous Torque Rating
Maximum Torque Rating
Brake Capacity
Maximum Connection Break Out Torque
Pipe Clamp Capacity
Pipe Handler Orientation
Quill Connection
Mud Passage Diameter
Mud Passage Maximum Circulating PSI
Remote Actuated IBOP
Manual Actuated IBOP
Counterbalance Travel
Hook Weight
Lubrication System
6
500 Short Tons
650 Short Tons
GEB20
1185 Amps
1470 Amps (15 Seconds)
575 Volts
0 to 117 Hz
15 HP Local Blower 3900 CFM
800 HP
1150 HP
8.7059 : 1
45,000 Ft-Lbs.
55,000 Ft-Lbs.
75,000 Ft-Lbs.
65,000 Ft-Lbs.
50,000 Ft-Lbs.
80,000 Ft-Lbs.
75,000 Ft-Lbs.
110,000 Ft-Lbs.
360˚/Unlimited – Comes with Lock
6-5/8” Reg.
7-5/8” Reg.
3”
5,000 PSI (7,500 PSI Opt.)
10,000 PSI
10,000 PSI
7.25”
34,000 Lbs.
2HP 5GPM Flow
G D M 6 5 0
T O P
D R I V E
Top Drive Specifications
GDM 500/650 DC
Static Hoist Rating
Drilling Electric Motor
Maximum Continuous Current
Maximum Intermittent Current
Maximum Voltage
Frequency Range
Cooling System
Continuous HP Rating
Gear Ratio
Continuous Torque Rating
Maximum Torque Rating
Brake Capacity
Maximum Connection Break Out Torque
Pipe Clamp Capacity
Pipe Handler Orientation
Quill Connection
Mud Passage Diameter
Mud Passage Maximum Circulating PSI
Remote Actuated IBOP
Manual Actuated IBOP
Counterbalance Travel
Hook Weight
Lubrication System
7
500 Short Tons
650 Short Tons
GE 752
1185 Amps
1435 Amps (15 Seconds)
750 Volts DC
0 to 117 Hz
15 HP Local Blower 3900 CFM
800 HP
1150 HP
8.7059 : 1
45,000 Ft-Lbs.
55,000 Ft-Lbs.
75,000 Ft-Lbs.
65,000 Ft-Lbs.
50,000 Ft-Lbs.
80,000 Ft-Lbs.
75,000 Ft-Lbs.
110,000 Ft-Lbs.
360˚/Unlimited – Comes with Lock
6-5/8” Reg.
7-5/8” Reg.
3”
5,000 PSI (7,500 PSI Opt.)
10,000 PSI
10,000 PSI
7.25”
34,000 Lbs.
2HP 5GPM Flow
G D M 6 5 0
T O P
D R I V E
Torque Data
8
G D M 650 / T O P
D R I V E
Section
2
Operations
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
9
G D M 650 / T O P
D R I V E
HMI Touch Screens..........................................................23
HMI Main Screen
Figure 5 – Main Screen
HPU Pump Selection........................................................24
Top Drive HPU E-Stop
Additional Features...........................................................25
Bypass Pipe Handler Lock
Torque and Speed Settings and Limits............................26
Automatic Pipe Handler...................................................27
Top Drive Remote Motor Control via HMI.....................28
Drill Mode
Torque Mode
Top Drive Remote Pipe Handler via HMI......................31
Testing & Configuration Screen .....................................32
Switches
Push Buttons
10
G D M 650 / T O P
D R I V E
Top Drive Console
Figure 1 – Top Drive Console
Following is a description of the Top Drive Console and its functional controls:
LED Indicator Lights (L1 – L4)
Drill Enabled (L1)
Green lamp illuminates when TD Enable switch is placed from OFF to the
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.
Motor Temp (L4)
Amber lamp illuminates when main drilling motor temperature exceeds
acceptable limit.
11
G D M 650 / T O P
D R I V E
Alarm Reset (PB1)
Illuminated
Indicates that an alarm exists. PB1 is a spring-return, red translucent push button
over an indicator lamp. Depressing the button will reset Top Drive alarms to
determine whether any faults still exist.
Extinguished
Indicates that there are no current Top Drive alarms. This can also be verified in
the Active Status Summary block at the top right-hand corner of any HMI screen.
CAUTION
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
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.
Top Drive Lockout (PB2)
Depressed
Shuts off all electrical power to the Top Drive and disables all Top Drive
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.
Released
Enables the VFD to allow ownership of the Top Drive.
12
G D M 650 / T O P
D R I V E
Handler Bypass (PB3)
Illuminated
PB3 is a spring-return translucent red push button used for timed-override of
Handler Lock Proximity Sensor feedback control. This function is designed for
use in the event of a sensor or circuit malfunction. The button illuminates when
depressed and held for 3 seconds, and will remain illuminated during the 30second window that the override is permitted. MAKE UP and BREAK OUT
functions are activated during this time, however this places responsibility in the
hands of the operator to ensure that the Handler is physically locked before
making or breaking connections. Use of the bypass is logged in case of incident.
Extinguished
Indicates normal operation.
WARNING
USE EXTREME CAUTION WHEN USING THIS FEATURE.
IT IS IMPERATIVE THAT THE OPERATOR ENSURES THROUGH
VERIFICATION THAT THE HANDLER IS PHYSICALLY LOCKED
BEFORE ATTEMPTING TO MANIPULATE ANY CONTROLS.
FAILURE TO DO SO MAY RESULT IN CATASTROPHIC
EQUIPMENT FAILURE, SEVERE INJURY, OR DEATH.
E-Stop (PB4)
Depressed
Pulled Out
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:
► Tripping the VFD breaker on GDS supplied VFD units
► Tripping the feeder breaker at the GDP panel
Normal Top Drive operation.
13
G D M 650 / T O P
D R I V E
Backup Wrench / BUW (PB5)
Depressed
PB5 is a black spring-return push button, activated when the Mode Select switch
on the Top Drive console is in the TORQUE position. Push and hold PB5 to
engage the BUW clamp.
Released
Retracts the BUW clamp piston.
Note
The BUW function is NOT interlocked with the Drawworks.
CAUTION
DO NOT OPERATE DRAWWORKS WITH BUW CLOSED.
Hydraulic Power Unit Selection Switch (SW1)
HPU 1
SW1 is a translucent green 3-position maintained switch (HPU1 / OFF / HPU2).
Selecting HPU 1 energizes the motor starter for HPU # 1, charging the main hydraulic
manifold on the Top Drive to allow hydraulic functions when enabled. Drill and Trip
screens on the HMI will indicate that HPU 1 is running.
Off
De-energizes HPU 1 and 2 motor starters, removing available hydraulic power.
HPU 2
Energizes the motor starter for HPU # 2.
Note
Only one HPU motor will run at a time. If HPU 2 is selected while HPU 1 is
running, HPU 1 will first shutdown before HPU 2 starts. Either HPU may run
continuously.
14
G D M 650 / T O P
D R I V E
Brake Switch (SW2)
Off
SW1 is a translucent red 2-position maintained switch (OFF / ON). In the
OFF position, it allows the Top Drive to rotate freely. Brakes are
hydraulically applied, spring released. The HPU must be on in order for
the brake to release when turned from ON to OFF.
On
Brakes will engage.
Note
Brakes will remain released during Torque and Spin operations; Brake
position is indicated on the HMI as ON or OFF in the Drill, Trip, and
Remote Operation screens.
Top Drive Enable Selection Switch (SW3)
Trip
The HMI’s Drill, Trip, and Remote Operation screens will indicate that
Top Drive tripping is enabled; allows the operator to actuate all
hydraulic functions. Enables tripping and hydraulic functions.
Drill
The HMI’s Drill, Trip, and Remote Operation screens will indicate that
Top Drive drilling is enabled; allows the operator to utilize Drilling and
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.
Note
The drill motor blower is automatically activated when motor reaches
150˚F.
Lube Pump operates continuously while in Drill Mode.
15
G D M 650 / T O P
D R I V E
Stand Jump Switch (SW4)
Off
SW4 is a black 2-position maintained switch (OFF / ON) with a white positionindicating stripe across the knob. In the OFF position, the Stand Jump function is
disabled.
On
Enables the Stand Jump function only in Torque Mode.
IBOP Switch (SW5)
Open
SW5 is a translucent amber 2-position maintained switch (OPEN / CLOSE).
Selecting OPEN will open the remote-actuated IBOP.
Close
Closes the remote-actuated IBOP.
Note
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
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.
16
G D M 650 / T O P
D R I V E
Top Drive Mode Selection Switch (SW6)
Reverse
SW6 is a black 3-position maintained switch (REV / DRILL / TORQUE) with a
white position-indicating stripe across the knob. The REV position allows the
Top Drive to run in reverse (counterclockwise) to a maximum of 100 RPM, as
commanded through the operator’s TD Motor Control Joystick.
Drill
Enables normal Drill operations (clockwise).
Torque
Allows for BUW / Make & Break operations.
Limit Selection Switch (SW7)
RPM
SW7 is a black 3-position spring-loaded return-to-center switch (RPM / neutral or
centered / TORQUE) with a white position-indicating stripe across the knob.
Holding the switch in RPM mode allows the operator to simultaneously
manipulate the Limit Adjustment Switch knob to set desired tool speed.
Torque
Holding the switch in TORQUE mode allows the operator to simultaneously
manipulate the Limit Adjustment Switch knob to set desired torque.
Note
Used in conjunction with Limit Adjustment Switch (SW8).
Switch Position Function
SW6-Drill, SW7 RPM = Drill Preset RPM
SW6-Drill, SW7 Torque = Drilling Max Torque
SW6-Torque, SW7 RPM = Spin in/Out RPM
SW6-Torque, SW7 Torque = Make-Up Torque
SW6-Rev, SW7 RPM = N/A
SW6-Rev, SW7 RPM = Reverse Torque
17
G D M 650 / T O P
D R I V E
Limit Adjustment Switch (SW8)
Decrease
SW8 is a black 3-position spring-loaded return-to-center switch (DEC / neutral or
centered / INC) with a white position-indicating stripe across the knob. While
holding the Limit Selection switch (SW7) in either RPM or TORQUE mode, the
operator can toggle or ‘bump’ SW8 between neutral center and the DEC position
repeatedly to decrease any previously set speed or torque limit by increments of
10. Holding SW8 in the DEC position while SW7 is enabled will quickly decrease
the desired set limit to zero.
Increase
While holding the Limit Selection switch (SW7) in either RPM or TORQUE
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.
Note
Used in conjunction with Limit Selection switch (SW7).
18
G D M 650 / T O P
D R I V E
Top Drive Handler Joystick (JS1)
Figure 2 – Top Drive Handler Joystick (JS1) function diagram
Link Tilt Joystick (JS2)
Figure 3 – Link Tilt Joystick (JS2) function diagram
19
G D M 650 / T O P
D R I V E
Top Drive Motor Control Joystick (JS3)
Figure 4 – Top Drive Motor Control Joystick (JS3) function diagram
Top Drive Console Analog Gauges
The Top Drive Console RPM gauge may be one of two types:
Tachometer
► Traditional analog gauge, RPM from 0 – 250 in two-revolution increments,
with large tic marks in 10 RPM intervals and numerical values printed in
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:
Torque Meter
► Traditional analog gauge, torque range from 0 – 100,000 Ft. Lbs. in 1,000#
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.
20
GDM 650 TON TOP DRIVE
Directional Controls
Drill Mode
Up
(Increase
Speed)
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.
Releasing the joystick will not decrease speed. If the joystick is released, the 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.
Down
(Decrease
Speed)
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.
If the joystick is released, the 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 (counterclockwise) direction.
Right
(Preset
Speed)
Left
(Zero
Speed)
Moving the joystick RIGHT will enter the preset speed value (preset value is
displayed and modified on HMI) into the speed reference. The Top Drive speed
will ramp up or down, as applicable, until its preset value is achieved.
When the joystick is released, speed will be maintained at its preset value.
Toggling the joystick LEFT will ramp the Top Drive speed down to Zero speed.
Operation is the same in both forward and reverse.
21
GDM6 50 TON TOP DRIVE
Torque Mode
Make up should only be used once the joint is shouldered up with Spin In first.
Up
(Make Up)
Holding the Top Drive Motor Control Joystick UP (Make Up) with DRILL
enabled (SW3) and TORQUE mode selected (SW6) will rotate the Top Drive
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.
Down
(Break Out)
Holding the Top Drive Motor Control Joystick DOWN (Breakout) with DRILL
enabled (SW3) and TORQUE mode selected (SW6) will rotate the Top Drive
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
(Spin Out)
When the joystick is released, the Top Drive will stop rotating.
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.
22
GDM6 50 TON TOP DRIVE
HMI Touch Screens
Main Screen
Figure 5 –Main Screen
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.
23
GDM6 50 TON TOP DRIVE
HPU Pump Selection
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 start when the button is toggled.
HPU 1 ON
The HMI will indicate if HPU 1 is running properly. If there is a problem
with HPU 1, a fault will be displayed on the HMI, such as:
HPU 1 not running (tripped).
Low hydraulic oil level.
High hydraulic oil temperature.
HPU 1 OFF
HPU 1 will stop when the button is toggled. If HPU 1 is running and HPU
2 is started, HPU 1 will shut off first.
HPU 2
Operation is the same as HPU 1.
Top Drive HPU E-Stop
When the HPU E-stop is pressed, this will prevent either HPU pump from operating under any conditions
and the HMI will indicate that the HPU E-Stop has been pressed.
24
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.
Bypass Pipe
Handler Lock
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
seconds. Normal Handler Lock operation will resume after 30 seconds. Use
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.
25
GDM6 50 TON TOP DRIVE
Torque and Speed Settings and Limits
This feature is normally used when the Top Drive is stalled. Press the
Torque Ramp Down push button to unwind the torque.
Torque Ramp
Down
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
remains pushed.
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.
This feature is normally used when the Top Drive is stalled.
Torque Restore
After you use the Torque Ramp Down push button (to unwind torque), you
can press the Torque Restore button to restore the Torque Limit to the Drill
Limit Set Point. The speed reference will remain at 15 RPM until you
increase or use the preset with the joystick.
Speed Preset
Drill Speed Preset adjustable from 0 to 200 RPM.
Can be adjusted on either the Drilling screen or the Remote Operation
screen.
Spin Speed
Spin Speed adjustable from 5 to 40 RPM.
Can be adjusted on either the Drilling screen or the Remote Operation
screen.
Make Up
Make up Torque Limit adjustable from 0 to 65,000 ft/lbs.
Can be adjusted on either the Drilling screen or the Remote Operation
screen.
Drill Limit
Drill Torque Limit adjustable from 0 to 55,000 ft/lbs.
Can be adjusted on either the Drilling screen or the Remote Operation
screen.
Spin Limit
Spin Torque Limit adjustable from 2,000 to 6,000 ft/lbs.
Can be adjusted on either the Drilling screen or the Remote Operation
screen.
26
GDM6 50 TON TOP DRIVE
Automatic Pipe Handler
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.
Auto Mode
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.
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.
Joystick Operation
When the Automatic Pipe Handler is in Automatic mode, the Joystick Pipe
Handler Unlock push button and LEFT and Right joystick movements
work the same as the HMI LEFT and RIGHT push buttons.
Remote Operation
When the Automatic Pipe Handler is in Automatic mode, the Remote Pipe
Handler Unlock push button and LEFT and RIGHT Joystick push buttons
work the same as the HMI LEFT and RIGHT push buttons.
27
GDM6 50 TON TOP DRIVE
Top Drive Remote Motor Control via HMI
Activate
Remote Motor
Joystick
PB1
(Black -Drill
Reverse)
PB2
(Red -BUW
Close)
PB3
(Yellow -Spin
Maintain)
PB4
(Green Torque/Drill)
Activating Remote Motor Control will enable the HMI Remote Operation and
disable the joystick from functioning.
Toggling the Top Drive Motor Control Joystick Drill Reverse push button will
toggle the Top Drive Motor direction between Forward and Reverse; this button
is active only if the Top Drive Mode is selected to DRILL mode.
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.
Once the BUW is Closed, perform Torque function. When torque ft-lbs reaches
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
window to toggle the joystick left or right (Spin In or Spin Out).
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
modes.
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.
28
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
(Increase
Speed)
If the Joystick UP push button is released at any time, the speed will be maintained at
the value it was at prior to release.
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
(Decrease
Speed)
If the joystick is released at any time, the speed will be maintained at the value it was at
prior to release.
With the Top Drive Mode in DRILL REVERSE, the operation will be the same but
rotation will be in the Reverse direction.
Right
(Preset Speed)
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.
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
(Zero Speed)
Toggling the Joystick LEFT push button will ramp the Top Drive speed down to Zero
speed.
29
GDM6 50 TON TOP DRIVE
Torque Mode
Make Up should only be used once the joint is shouldered up with Spin in first.
Up
(Make Up)
Holding the Top Drive Motor Control Joystick UP PB (Make Up) with DRILL
enabled and selected to TORQUE mode will rotate the Top Drive forward at a
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
(Breakout)
Holding the Top Drive Motor Control Joystick DOWN PB (Breakout) with
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.
Left
(Spin In)
Right
(Spin Out)
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
modified on HMI).
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
HMI).
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.
30
GDM6 50 TON TOP DRIVE
Top Drive Remote Pipe Handler via HMI
Activate
Remote Pipe
Handler
PB3
(Yellow Pipe Handler
Unlock)
PB4
(Green - Link
Tilt Float)
Activating Remote Pipe Handler will enable the HMI Remote Operation and
disable the joystick from functioning.
Toggling the Top Drive Remote Pipe Handler Pipe Handler Unlock push button will
activate the Pipe Handler Lock to UNLOCK.
The Pipe Handler will stay unlocked for 3 seconds, unless the Pipe Handler is
rotated, in which case the Pipe Handler will remain unlocked as long as the
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
activate the Link Tilt Cylinders to FLOAT if in Maintain, and MAINTAIN if in
Float.
Activating either EXTEND or RETRACT will unlatch Float.
UP
(Link Tilt
Extend)
Pressing the Top Drive Remote Pipe Handler in the UP direction will activate the
Link Tilt Cylinders to EXTEND.
Down
(Link Tilt
Retract
Pressing the Top Drive Remote Pipe Handler in the DOWN direction will activate
the Link Tilt Cylinders to RETRACT.
Left
(Pipe
Handler
Rotate
Forward)
Toggle the Pipe Handler Unlock (PB3) first. Pressing the Top Drive Remote Pipe
Handler in the LEFT direction will move the Pipe Handler in the Forward
(clockwise) direction.
Right
(Pipe
Handler
Rotate
Reverse)
Toggle the Pipe Handler Unlock (PB3) first. Pressing the Top Drive Remote Pipe
Handler in the RIGHT direction will move the Pipe Handler in the Reverse
(counter clockwise) direction.
31
GDM650 TON TOP DRIVE
Testing & Configuration Screen
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.
Encoder Bypass
At power up, the Bypass is deactivated. The Top Drive must be in OFF
position in order to switch between the two modes.
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.
Meter Test Mode
In order to utilize this mode, the Top Drive must be in the OFF position.
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
Lube Pump
Restart
If the Blower Motor trips while in in Auto mode, it can be restarted by this
push button, provided the OL has reset.
If the Lube Pump Motor trips while in Auto mode, it can be restarted by this
push button, provided the OL has reset.
32
G D M 650 / T O P
3
Section
D R I V E
Maintenance and Inspection
Contents
Top Drive Maintenance Diagram .................................34
Figure 6 – Maintenance Points 1
Figure 7 – Maintenance Points 2
Figure 8 – Maintenance Points 3
Maintenance ..................................................................37
Lubrication
Hydraulic Oil
Filtration
Grease
Top Drive Gearbox
Top Drive Gearbox Oil Capacity
Figure 9 – Y Strainer
Figure 10 – Breather
Inspection ......................................................................42
Recommended Inspection Program
Quarterly or Upon Rig Move
Five Year Inspection
Inspection Following Periods of Severe Drilling
Conditions
Wear Limits
Main Bearing Pre-Load Inspection
Pinion Bearing Pre-Load Inspection
Washpipe Inspection Instructions
Top Drive Disc Brake Inspection
Manual Brake Bleeding
Maintenance Checklist...................................................49
Load Path Inspection Drawings ...................................50
33
G D M 650 / T O P
D R I V E
Top Drive Maintenance Diagram
Figure 6 – Maintenance Points 1
NOTE:
See Maintenance
Checklist on Page
3-17
GDM500650 Rev. 2
34
G D M 650 / T O P
D R I V E
Figure 7 – Maintenance Points 2
GDM500650 Rev. 2
35
G D M 650 / T O P
D R I V E
Figure 8 – Maintenance Points 3
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.
The temperature of the oil at any point in the system
must not exceed 180°F (during continuous operations).
Hydraulic Oil General Recommendations
GDM500650 Rev. 2
Ambient Temperature
(°C)
ISO Grade of Oil
-45° to -15°
-20° to 15°
10° to 35°
20° to 45°
25° to 55°
15
22
32
46
68
37
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
Fittings
Application
Frequency
Washpipe
1
To excess
Every 12 hours
Elevator Tilt Plate
Pins
8
To excess
Daily
Load Collar
1
10 pumps per fitting
Weekly
Back-up Wrench
Grabber Cylinder
2
10 pumps per fitting
Weekly
Slewing Gear
2
10 pumps per fitting
Daily
Actuator
4
3 to 4 pumps per
fitting
Every 12 hours
Back Up Wrench
Pin
1
To excess
Weekly
Location
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
Top Drive Gearbox
GDM Top Drives are designed to be used with ISO Industrial EP (Extreme Pressure) Gear Oils.
EP oils are high quality, extreme pressure compounded type oils for use in all types of industrial gear
sets, except those with built-in variable speed type friction drive mechanisms.
The use of EP ensures increased life of your GDM Top Drive, especially during periods of heavy
jarring. The EP oils give superior corrosion protection to ferrous metal surfaces and are noncorrosive to steel, copper, brass, bronze and other common bearing materials.
1
Ambient
Temperature
(°C)
A.G.M.A
Number
GDS Top Drive Gear Oil
25°C & Up1
EP 9005-E02
Chevron ISO Meropa 220
Contact OEM for recommendations for other ambient temperature ranges.
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
Top Drive Gearbox Oil Capacity
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
41
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.
42
G D M 650 / T O P
DRIVE
Quarterly or Upon Rig Move (whichever is first)
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.
5.
Visually check the blower and welds on the blower frame.
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.
Five Year Inspection
The following major inspection is recommended every five years, as a minimum, or at alternate
intervals as specified by regulatory authorities, operator or contractor policies or following severe
drilling conditions:
1.
Disassemble the Top Drive unit.
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:
Block Interface Bail
Block Interface Beam
Block Interface Pins (2)
Side Load Plates (2)
Load Pins (4)
Gearbox
Gearbox Lid
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.
Inspection Following Periods of Severe Drilling Conditions
After periods of rough drilling, especially on surface hole, various Top Drive components may
became damaged or loose from vibration and jarring.
The following inspection procedure is recommended after periods of severe drilling conditions:
Visually examine the Top Drive for any signs of damage.
Visually inspect the mud inlet piping.
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.
Check all guards, vents, and covers 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.
Visually examine inside electrical junction boxes for loose components.
Inspect the motor armature to ensure it has not dropped:
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
Main Bearing Pre-Load Inspection
Main bearings are preloaded from the manufacturer. To see if shimming is required, follow
instructions below:
1.
Install dial indicator to read movement on quill.
2.
Apply upward force to quill.
3.
Read measurement on dial indicator. If no movement is recorded, shimming is not
necessary. If end play is present, use formula below to determine how much shim to remove.
End play + 0.010 inches = Shim to be added. *Note* preload not to exceed 0.005 inches
Pinion Bearing Pre-Load Inspection
Pinion bearings are preloaded from the manufacturer. To see if shimming is required, follow
instructions below:
1.
Install dial indicator to read movement on pinion shaft.
2.
Apply upward force to pinion shaft.
3.
Read measurement on dial indicator. If no movement is recorded, shimming is not
necessary. If end play is present, use formula below to determine how much shim to remove.
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
Washpipe Inspection Instructions
Packing Assembly
Instructions
1.
Set magnetic base of dial indicator to quill or packing box.
2.
Rotate sleeve 360° and record total indicator reading (TIR) at indicator positions A, B, C.
Recommended Tolerances
Maximum allowable misalignment at gooseneck support bore = 0.008 inches TIR B.
Maximum allowable misalignment at gooseneck pilot = 0.010 inches TIR
Maximum allowable washpipe misalignment after complete assembly = 0.010 inches TIR
Inspection may indicate misalignment exceeding recommended limits.
Washpipe packing assemblies are designed to accommodate misalignments of quill to gooseneck and
will operate with some excessive misalignment.
However, to achieve maximum packing life, the alignment at the washpipe should be maintained
within recommended limits.
47
G D M 650 / T O P
DRIVE
Top Drive Disc Brake Inspection
Check Brake Calipers
Brake calipers should be checked weekly.
A function test should be done at this time.
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.
Manual Brake Bleeding
1. Activate brakes.
2. Place clear hose over into bucket bleeder.
3. Slightly loosen bleeder to remove air.
4. Re-tighten bleeder.
5. Repeat until air is no longer present.
48
G D M 650 / T O P
DRIVE
Maintenance Checklist
GDM 500/650 Maintenance Checklist
For Week Ending: ________________
EVERY 12 HOURS
Grease Washpipe Packing
Grease Remote Actuator
Check Oil Level in Top Drive Gearbox
Mon
Tues
Wed
Thurs
Fri
Sat
Sun
Mon
Tues
Wed
Thurs
Fri
Sat
Sun
Mon
Tues
Wed
Thurs
Fri
Sat
Sun
Mon
Tues
Wed
Thurs
Fri
Sat
Sun
Mon
Tues
Wed
Thurs
Fri
Sat
Sun
By:
DAILY
Grease Slewing Gear
Check Cooler Fins for Debris
Grease Link Tilt Elevator Plate Pins
Check Indicator on Hydraulic Filter
Check Indicator on Lube Oil Filter
Check Gearbox Breather
Check Top Drive for Loose or Leaking
Hydraulic Fittings or Components
Examine Top Drive for Loose Bolts, Etc.
Check Oil Level in HPU Reservoir
Check Indicator on HPU Pressure Filter
Check Indicator on HPU Return Filter
By:
WEEKLY
Grease Load Collar
Grease BUW Pin
Grease Stand Jump Pins
Check & Clean Lube Suction Y-Strainer
Examine Brake Pads & Calipers for Wear
By:
MONTHLY
Grease Motor per Manufacturer
Documentation
Remove & Check Lube Nozzles for Debris
@ Oil Change
By:
EVERY 3 MONTHS
Change Oil in Top Drive Gearbox
Date Due:
Form 257 Rev 0
Feb 2014
49
G D M 650 / T O P
DRIVE
Load Path Inspection Drawings
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
Prior To Top Drive Installation Install All Rig Specific Equipment
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
1.
2.
SHACKLES
ATTACH LIFTING EQUIPMENT TO PADEYES ON
TRAVEL STAND.
ATTACH SLINGS TO BACK UP LINE TO THE
BOTTOM OF THE TRAVEL STAND.
BACKUP LINE
1.
2.
3.
FOLD UP RACKING BOARD FINGERS (IF POSSIBLE)
BEFORE RAISING THE HORIZONTAL TOP DRIVE AND
TRAVEL STAND INSTALLATION.
ATTACH SLINGS TO SHACKLES AT THE TOP OF THE
TRAVEL STAND.
ATTACH DUAL SLING BACK UP LINE TO THE BOTTOM
OF THE TRAVEL STAND.
NOTE: 50,000 LB ( 22,700 KG) WORKING LOAD WITH SUITIBLE
EQUIPMENT FOR ALL LIFTING.
BACKUP LINE
SHACKLES
1.
2.
WHILE RAISING TOP DRIVE TO FLOOR, USE
BACKUP LINE TO ASSIST IN CONTROLLING TOP
DRIVE FROM HORIZONTAL TO VERTICAL
POSITION.
PULL TOP DRIVE PACKAGE INTO POSITION
AND PREPARE TO REMOVE TOP DRIVE FROM
STAND.
1.
2.
WITH THE TOP DRIVE PACKAGE UPRIGHT ON
FLOOR, BRING TRAVELING BLOCK TO FLOOR
REMOVE SLINGS.
CONNECT TRAVELING BLOCK TO BAIL.
1.
2.
3.
PUT A LITTLE TENSION ON TRAVELING
ASSEMBLY AND REMOVE LOWER TOP
DRIVE SHIPPING PINS FROM
TRACK/RUNNER AREA.
REMOVE BOLTS FROM SKID TO TRACK
THEN UNBOLT THE TRAVEL STAND GUIDES.
WITH UPPER TOP DRIVE SHIPPING PINS
REMAINING, LIFT TOP DRIVE AND TOP
PIECE OF TRACK OUT OF THE TRAVEL/RIG
UP STAND.
1.
2.
LIFT TOP DRIVE CLEAR OF THE TRAVEL STAND.
REMOVE TRAVEL STAND FROM THE DRILL FLOOR.
NOTE: TRAVEL STAND WEIGHS 8,600 LBS (3,900 KG)
1.
USING WINCH, LIFT THE TRACK TO THE
DRILL FLOOR. 1 SECTION AT A TIME. TAG LINES
SUGGESTED TO PERVENT TOP DRIVE PACKAGE
FROM TWISTING.
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
1.
2.
INTRODUCE THE TRACK HOOK TO THE PIVOT PIN.
ENGAGE THE HOOK AND PIVOT PIN.
LIFT
LOCKING PIN
LOCKING PIN
1.
2.
LIFT THE TOP DRIVE AND TRACK SECTION.
WITH LOCKING PINS HOLES ALIGNED, INSTALL
LOCKING PINS AND SAFETY BOLTS/NUTS.
1.
2.
3.
4.
5.
REPEAT PREVIOUS STEPS UNITL ALL TRACK
SECTIONS ARE INSTALLED.
ATTACH TOP TRACK TO CROWN PER RIG
SPECIFIC INSTRUCTIONS.
INSTALL TORQUE REACTION ASSEMBLY
PER RIG SPECIFIC INSTRUCTIONS.
INSTALL MID MAST KITS PER RIG SPECIFIC
INSTRUCTIONS.
REMOVE UPPER SHIPPING PINS FROM
THE TOP OF THE TRACK AFTER CROWN
ASSEMBLY IS CONNECTED.
5
Section
650/850 T O N T O P D R I V E MANUAL REV 0
Drawings and Parts
Contents
5A Assembly Drawings ...................................................................75
Assembly Drawings Index...............................................................76
5B Schematics...................................................................................134
Electrical Schematics Index............................................................135
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
Drawing No.
Revision
Description
A500268
01
TOP DRIVE CORE, TOP DRIVE ASSY
A500373
01
GEARBOX ASSY, GDM500, 6/8 SINGLE
A500239
01
ASSY, IDLER GEARS, GEARBOX
A500226
01
IDLER GEARS ASSY
A500010
02
QUILL ASSY
A600003
01
QUILL ASSY, 650T, 7 5/8
A500279
01
ASSY, MOTOR, GDM 500
A500231
01
ASSY, MOTOR, DISC BRAKE
A500252
01
ASSY, BLOWER, 15HP, 575V, 3600
P500001
03
BLOWER ELIMINATOR 15 HP, 3600 RPM, 575V
STAINLESS STEEL
A500277
02
GUARD ASSY GDM 500
A500149
01
SERVICE PLATE ASSY, TOP DRIVE ASSY
A500110
01
PINION ASSY, SERVICE PLATE ASSY
A500101
02
PROXIMITY SENSOR MOUNT ASSY
M500105
01
IDLER GEAR ASSY, SERVICE PLATE ASSY
M500107
01
ENCODER ASSY, PINION ASSY
A500355
01
ASSY, LINK, TOP DRIVE, GDM 500
A500015
01
LINK COLLAR ASSY GDM 650/500
A500160
01
ROTATING PLATE ASSY, LINK ASSY
A500348
01
LOAD COLLAR, REAR ASSY, LINK ASSY
GDM500650 Rev. 8
76
G D M 5 0 0 / 6 5 0
T O P
D R I V E
Drawing No.
Revision
Description
A500347
01
EVE. TILT PLATE CYL. ASSY
A500349
01
ELEVATOR TILT PLATE ASSY, LINK ASSY
A500162
01
LOAD COLLAR FRONT BRACKET ASSY
A500411
01
ELEVATOR LINK ASSY GDM
A500271
01
BUW ASSY, TOP DRIVE CORE
A500345
01
GRABBER ASSY, 500T
A500102
01
GDM 650/500 TON, GATE SIDE DIE BLOCK ASSY
A500103
01
GDM 650/500 TON, ROD SIDE 3 ½” DIE BLOCK
ASSY
A500105
01
GDM 650/500 TON ROD SIDE 5 1/2” DIE BLOCK
ASSY
A500353
01
GDM 650/500 TON GATE SIDE 6.625 -8.50 DIE
BLOCK ASSY
A500254
01
GRIPPER SPRING STABILIZER, GRABBER ASSY
A500175
01
GRABBER BOX ASSY, GDM
A500370
01
BONNET ASSY, GDM
A500230
01
ASSY, HYDRAULIC GDM 500
A500329
02
BLOCK INTERFACE ASSY, WITH SIDE PLATES
A500240
01
BLOCK INTERFACE ASSY
A500024
01
STAND JUMP ASSY
GDM500650 Rev. 8
77
'
'
&
&
%
%
81/(6627+(5:,6(63(&,),('
$
35235,(7$5<$1'&21),'(17,$/
5(9'(6&!
5(9
'(6&5,37,21
'*: ;;;;;;
,1,7,$/
'$7(
7+(,1)250$7,21&217$,1(',17+,6
'5$:,1*,67+(62/(3523(57<2)
*/2%$/'5,//,1*6833257,17/$1<
5(352'8&7,21,13$5725$6$:+2/(
:,7+2877+(:5,77(13(50,66,212)
*/2%$/'5,//,1*6833257,17/,6
352+,%,7('
1$0(
',0(16,216$5(,1,1&+(6
72/(5$1&(6
)5$&7,21$/ $1*8/$50$&+ %(1' 21(3/$&('(&,0$/ 7:23/$&('(&,0$/ 7+5((3/$&('(&,0$/ '5$:1
,17(535(7*(20(75,&
72/(5$1&,1*3(5$60(<0
;;;
;;;;;;
(1*$335
;;;
;;;;;;
0)*$335
;;;
;;;;;;
4$
;;;
;;;;;;
&+(&.('
0$7(5,$/
*'63$571R5HYLVLRQ
$
*'6,QWHUQDWLRQDO
'$7(
'*:
7,7/(
723'5,9(&25(
723'5,9($66<
6,=( ':*12
%
),1,6+
5(9
6&$/( :(,*+76+((72)
'21276&$/('5$:,1*
$
$
,7(012
'
3$57180%(5
'(6&5,37,21
47<
$
*($5%2; *($56*($5%2;$66<
$
(/(&75,&027256833257$66<
$
$66<02725*'0
$
*8$5'$66(0%/<*'0
$
6(59,&(3/$7($66<
$
723'5,9(/,1.$66<*'0
$
%8:$66<723'5,9(&25(
$
%211(7$66<
$
$
$66<+<'5$8/,&*'0
%/2&.,17(5)$&($66(0%/<:,7+6,'(
3/$7(6*'0
1
$500024
'
2
STAND JUMP ASSEMBLY
&
&
%
%
*'6,QWHUQDWLRQDO
7,7/(
$
723'5,9(&25(
723'5,9($66<
6,=( ':*12
%
$
6&$/(
5(9
6+((72)
:(,*+7
$
8
5
6
7
4
2
3
1
26
11 62
D
D
63.25
C
29 28
C
54
71
20
56
28 29
64
C
C
11 62
51.00
A
8
11 62
F
B
E
E
G
G
B
101.69
F
D
D
NAME
DATE
DGW
3/25/14
CHECKED
DF
1/20/15
APPR.
DF
1/20/15
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
3/25/14
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GEARBOX ASSY,
GDM500, 6-5/8 SINGLE
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 6
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500373
A
1
8
24
D
5
6
7
55
4
18
24
8
30
18
51
2
3
52
56
57
64
12
31 27
73
9
1
72
15
58
D
26
68
41
67
70
16
35
14
22
C
C
23
75
37
2
10
B
B
61
8
28 29
13
21
GDS International
TITLE:
GEARBOX ASSY,
GDM500, 6 5/8 SINGLE
A
44 42
53
17
25
25
44 42
33
47
40 34
69
34
46
1
SIZE DWG. NO.
B
SECTION A-A
SCALE 1 : 7
8
7
6
5
A500373
SCALE: 1:8
4
3
2
REV
01
SHEET 2 OF 6
WEIGHT:
1
A
8
6
7
5
4
2
3
1
D
D
7
3
48
C
C
50
50
6
74
B
B
4
43 32
5
49
GDS International
TITLE:
GEARBOX ASSY,
GDM500, 6 5/8 SINGLE
A
SECTION C-C
SCALE 1 : 8
SIZE DWG. NO.
B
A500373
7
6
5
4
3
2
01
SHEET 3 OF 6
SCALE: 1:18 WEIGHT:
8
REV
1
A
8
5
6
7
4
3
2
1
D
D
69
34 40
56
33 43
60
21
59
28 29
59
29 28
65 66
36
C
C
5
38 39
63
43 32
B
B
42 44
SECTION E-E
SECTION D-D
GDS International
TITLE:
GEARBOX ASSY,
GDM500, 6 5/8 SINGLE
A
SIZE DWG. NO.
B
A500373
7
6
5
4
3
2
01
SHEET 4 OF 6
SCALE: 1:12 WEIGHT:
8
REV
1
A
8
45
29 28
5
6
7
4
54
20
28 29
2
3
1
45
76
D
75
D
60
60
C
C
B
B
59
28 29
28 29
19
19
SECTION G-G
SCALE 1 : 12
59
GDS International
SECTION F-F
A
TITLE:
GEARBOX ASSY,
GDM500, 6 5/8 SINGLE
SIZE DWG. NO.
B
A500373
SCALE: 1:6
8
7
6
5
4
3
2
REV
01
SHEET 5 OF 6
WEIGHT:
1
A
8
D
C
B
A
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
7
PART NUMBER
M100967
M500024
M500243
M500240
M500245
M500242
A500239
A500010
M500305
M500239
230101.1000
M500246
M500247
M500248
M500249
M500254
M500255
M500256
S500014
M500259
M500260
M500262
M102888
S101566
S101567
026211.1656DH2
208201.1200
026211.0824DH2
230101.0800
026211.0716DH2
008122.1228DH2
008121.1236DH2
008121.1232DH2
008121.0616DH2
026211.1232DH2
H102597
M500253
220102.0800
008121.0822DH2
220102.0600
M500059
008121.1440DH2
220102.1200
220102.1400
S100419
8
6
5
DESCRIPTION
DOWEL PIN, 1/2'' x 2'' LONG
PINION
FLANGE, IDLER GEARS, TOP
FLANGE, IDLER GEARS, BOTTOM
COVER, IDLER GEARS, BOTTOM
RETAINER, FLANGE, BOTTOM
IDLER GEARS ASSY
QUILL ASSY
13" DIA ROUND BAR
FLINGER, LOWER BEARING, GEARBOX
WASHER,LOCK,HI COLLAR 5/8
FLANGE, SEAL, PINION, TOP
FLANGE, PINION, BOTTOM
FLANGE, PINION, TOP
COUPLING, RETAINER
SPACER, SHAFT, PINION
FLANGE, QUILL, BOTTOM
SEAL, CAGE, TOP
O-RING, 2.406 ID x .139
FLANGE, FILLER CAP
COVER, FLANGE, PINION, BOTTOM
SHIMS, SET, PINION
BEARING, TAPERED ROLLER 130X230X67.75MM
SEAL, OIL SEAL 8.5 X 10 X .625
SEAL, OIL SEAL 10.5 X 12.5 X .625
CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2
WASHER,FLAT,Gr8, 3/4
CAPSCREW,SOCKET HEAD, 1/2-13UNC X 1.50, DH2
WASHER,LOCK,HI COLLAR 1/2''
CAPSCREW, SOCKETHEAD, 7/16-14UNC X 1
CAPSCREW, HEXHEAD, 3/4-16UNF X 1-3/4
CAPSCREW,HEX HEAD, 3/4-10UNC X 2.25,DH2
CAPSCREW,HEX HEAD, 3/4-10UNC X 2.00,DH2
HEX HEAD, 3/8-16 UNC x 1 IN, GR 8 WIRED
CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.00, DH2
CLAMP, SADDLE, LUBE PIPE
FLINGER, BEARING, TOP, GEARBOX
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
SCREW, HEX HEAD, 1/2-13 X 1-3/8, GR8
WASHER,LOCK,NORDLOCK,1 PAIR 3/8
FLANGE TOP QUILL, LOAD COLLAR ASSY
CAPSCREW,HEX HEAD, 7/8-9UNC X 2.50,DH2
WASHER,LOCK,NORDLOCK,1 PAIR 3/4
WASHER,LOCK,NORDLOCK,1 PAIR 7/8
O-RING,2-224,NITRILE, N70, 1.75 X 2.00 X 1/8
7
6
4
QTY.
4
1
2
2
2
1
1
1
1
1
36
1
1
1
1
1
1
1
4
1
1
1
2
2
2
15
1
26
26
8
1
20
10
8
10
6
1
10
10
8
1
12
30
12
2
5
ITEM NO.
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
3
PART NUMBER
S101530
S100079
S100081
S500003
S101439
S100123
S500004
S100129
M500295
M500297
A500011
S500005
M500290
M500498
A500095
M500257
026211.1028DH2
M500294
026211.1032DH2
220102.0400
026211.0412DH
A500272
S101448
M500611
M500261
H100728
S100124
S500008
M500264-250
M500703
026211.0828DH2
2
1
DESCRIPTION
O RING, 6 1/4 X 6 1/2 X 1/8, 2- 259, 70 DUROMETER
O-RING, 8 3/4 x 9 x 1/8, NITRILE
O-RING, 9 x 9 1/4 x 1/8,2-270 70 DUR
O-RING, 9.50 X 9.75 X .125, N-70
O-RING,NITRILE,2-278
O-RING, 10 1/2 x 11 x 1/4
O-RING, 13.5 X 14.0 X .250, N-70
O-RING, 15 x 15 1/2 x 1/4
FLANGE, LUBE PIPE, GDM 500
SPACER CAGE SEAL, GEARBOX
GEARBOX ASSEMBLY MACHINING FINIAL
ORING, 70 NITRILE, 2-276
RE-WORK RENOLDS COUPLING, HUB COUPLING ASSY.
FLANGE, SUCTION DRAIN, GDM 500
KIT, GEARBOX VIEWPORTS, GDM 500
SLEEVE, TAPER
CAPSCREW,SOCKET HEAD, 5/8-11UNC X 1.75, DH2
LUBE PIPE GEAR BOX
CAPSCREW,SOCKET HEAD, 5/8-11UNC X 2.00, DH2
WASHER,LOCK,NORDLOCK,1 PAIR 1/4
CAPSCREW,SOCKET HEAD, 1/4-20UNC X 0.75, DH
RETAINER, MOTOR COUPLING ASSEMBLY
SEAL,ROUND EXTRUDED SILICONE CLOSED CELL FOAM
BRACKET - LINK TILT CYLINDER HOSE
SHIMS, KIT, QUILL
PLUG, HOLLOW HEX, 3/4'' NPT
O-RING, 11 1/2 X 12 X 1/4
O-RING, 11.375 X .250, N-70
SHIM, IDLER, 0.250
OIL RING, GDM 650, NEW
CAPSCREW,SOCKET HEAD, 1/2-13UNC X 1.75, DH2
QTY.
1
1
2
2
4
1
1
1
1
1
1
1
1
2
1
1
28
1
8
12
12
1
1
1
1
1
1
1
1
1
8
D
C
B
GDS International
TITLE:
GEARBOX ASSY,
GDM500, 6 5/8 SINGLE
SIZE DWG. NO.
B
A500373
3
2
01
SHEET 6 OF 6
SCALE: 1:24 WEIGHT:
4
REV
1
A
8
5
6
7
4
ITEM NO.
D
C
2
3
PART NUMBER
1
DESCRIPTION
QTY.
1
A500226
IDLER GEARS ASSEMBLY
1
2
M500241
PL. 1" OR BAR ROUND 5"
2
3
M500234
BEARING, ROLLER
2
4
M500315
SLEEVE, WITHDRAWAL
2
5
026221.0824DH2 CAPSCREW,SOCKET HEAD, 1/2-20-UNF X 1.50, DH2
4
12
D
4
C
C
C
SECTION C-C
5
2
3
1
3
2
5
B
B
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
11/3/2014
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
11/3/14
DGW
11/3/14
DF
11/3/14
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ASSY, IDLER GEARS,
GEARBOX
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500239
A
1
8
5
6
7
4
ITEM NO.
1
2
3
4
5
D
1
2
3
PART NUMBER
M500025
M500026
M500320
M100967
026221.1440DH2
1
DESCRIPTION
IDLER PINION, M12-19-HA8-X1=0.20-LH
IDLER GEAR, M10-38T-HA 15-X2=0.00
COVER, DOWEL PIN, IDLER GEAR
DOWEL PIN, 1/2" X 2" LONG
CAPSCREW,SOCKET HEAD, 7/8-14-UNF X 2.50 DH2
E
2
QTY.
1
1
2
2
18
D
3
5
A
C
C
1
16 4 "
3
3
26 16 "
B
E
B
4
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
ENSURE HOLE
ALIGNMENT
A
DETAIL A
SCALE 1 : 2
1
REV.
4
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
PROPRIETARY AND CONFIDENTIAL
SECTION E-E
10/31/2014
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
10/31/14
DGW
10/31/14
DF
10/31/14
GDS International
TITLE:
IDLER GEARS ASSEMBLY
THIRD ANGLE
PROJECTION
MATERIAL
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
A500226
2
REV
01
SHEET 1 OF 1
WEIGHT: 517.53 LBS
DO NOT SCALE DRAWING
3
A
1
8
13
5
6
7
14
18
6
7
4
2
3
1
10
9
1
1
D
D
DETAIL C
SCALE 1 : 4
A
DETAIL B
SCALE 1 : 4
3
13
C
4
12
C
C
B
15
A
2
1
1
B
17
ITEM 15
APPLY WHITE ASSEMBLY GREASE (LUBRIPLATE)
TORQUE TO 1750 FT/LBS
B
ITEM 16 APPLY BLUE LOCTITE
6
11
5
15
2
8
10
16
9
1
SECTION A-A
NAME
DATE
DGW
11/4/13
CHECKED
DF
1/7/15
APPR.
DF
1/7/15
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
02
UPDATED DRAWING TO REFLECT E2
1/7/15
DF
01
RELEASE FOR MANUFACTURE
11/4/13
DGW
DATE
APPROVED
REV.
DESCRIPTION
8
7
6
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
QUILL ASSY
A
THIRD ANGLE
PROJECTION
MATERIAL
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
02
SHEET 1 OF 2
WEIGHT: 1482.34 LBS
DO NOT SCALE DRAWING
3
A500010
REV
1
8
D
C
ITEM NO.
1
2
3
4
5
6
7
PART NUMBER
M500017
M500027
M500019
M500020
M500060
M500263
7
8
9
10
11
12
13
14
15
16
17
18
6
5
DESCRIPTION
M500284
M100044
M500281
M102890
M102887
M102079
R100364
S100413
026211.2072DH2
312221.0610
312221.0816
S101517
4
GEAR
LANDING COLLAR, 500T
14.5" DIAMETER BAR
3/16" PLATE
<Description>
QTY.
1
1
1
1
1
1
9-1/4" OD X 1.0" W.T. PIPE
BRG, TPRD ROL, THRUST
SLEEVE SEAL, QUILL, LOWER
BEARING, CYLINDRICAL ROLLER
BEARING, TAPERED ROLLER
RING, RETAINING
LINER, UPPER STEM
SEAL
CAPSCREW,SOCKET HEAD, 1-1/4-7UNC X 4.50, DH2
SETSCREW, 3/8-24 UNF X 0.63 CUP POINT
SETSCREW, 1/2-20UNF X 1IN, CUP POINT
O-RING, 3 7/8 INCH ID
2
1
1
1
1
1
1
1
20
6
3
1
3
2
1
D
C
B
B
GDS International
TITLE:
A
QUILL ASSY
A
SIZE PART/DWG NO.
B
A500010
WEIGHT: LBS
8
7
6
5
4
3
2
REV
02
SHEET 2 OF 2
1
8
13
14
5
6
7
1
18
4
18
6
2
3
10
9
1
1
D
D
DETAIL C
SCALE 1 : 4
A
DETAIL B
SCALE 1 : 4
13
C
3
12
4
C
C
B
A
2
1
1
15
B
B
ITEM 16 APPLY BLUE LOCTITE
17
ITEM 15
APPLY WHITE ASSEMBLY GREASE (LUBRIPLATE)
TORQUE TO 1325 FT/LBS
6
7
5
11
15
2
8
10
16
1
SECTION A-A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/21/2015
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
5/14/14
DF
1/21/15
DGW
1/21/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
QUILL ASSY,
650T, 7 5/8
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 2
WEIGHT: 1476.31 LBS
DO NOT SCALE DRAWING
3
A600003
REV
1
8
D
C
ITEM NO.
1
2
3
4
5
6
7
PART NUMBER
M500570
M500027
M500019
M500020
M500060
M500263
7
8
9
10
11
12
13
14
15
16
17
18
19
20
M500284
M100044
M500281
M102890
M102887
M102079
R100364
S100413
026211.2072DH2
312221.0610
312221.0816
S101517
M100559
M100482
6
5
4
DESCRIPTION
QUILL, 650 TON, GDM 7 5/8
GEAR
LANDING COLLAR, 500T
14.5" DIAMETER BAR
3/16" PLATE
<Description>
QTY.
1
1
1
1
1
1
9-1/4" OD X 1.0" W.T. PIPE
BRG, TPRD ROL, THRUST
SLEEVE SEAL, QUILL, LOWER
BEARING, CYLINDRICAL ROLLER
BEARING, TAPERED ROLLER
RING, RETAINING
LINER, UPPER STEM
SEAL
CAPSCREW,SOCKET HEAD, 1-1/4-7UNC X 4.50, DH2
SETSCREW, 3/8-24 UNF X 0.63 CUP POINT
SETSCREW, 1/2-20UNF X 1IN, CUP POINT
O-RING, 3 7/8 INCH ID
WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE
1/16'' ALUMINUM OVAL, WIRE ROPE CLIP
1
1
1
1
1
1
1
1
20
6
3
2
9
10
3
2
1
D
C
B
B
GDS International
TITLE:
A
QUILL ASSY
SIZE DWG. NO.
B
A600003
7
6
5
4
3
2
REV
01
SHEET 2 OF 2
SCALE: 1:12 WEIGHT:
8
A
1
8
5
6
7
4
ITEM NO.
1
2
D
52.00
A
C
6
PART NUMBER
E100727
3
M500270-003
M500331
4
5
6
A500255
A500231
A500252
7
8
9
10
11
12
13
2
3
1
DESCRIPTION
MOTOR, AC, VERT DRILLING,1150 HP
QTY.
1
4
SHIM MOTOR MOUNT BTM - TOP DRIVE CORE
PLENUM, GE B20 GDM500
M500289
M104035
M500335
M500530
M500613
N100495
312211.0608
1
SEAL RING HOUSING ASSEMBLY, GE B20
ASSY, MOTOR, DISC BRAKE
ASSY, BLOWER, 15HP, 575V, 3600
1
1
1
HUB, GE20B-GF30DA MOTOR SIDE
SEAL RING, GE B20
SHAFT, MAIN ENCODER, GDM
GDM 500 - GEAR CASE VENT MOUNT
INSERT, AC PLENUM
1024 PULSE ENCODER WITH DOUBLE RECEPTICLE
SETSCREW, 3/8-16 UNC X 0.50 CUP POINT
1
1
1
1
2
1
2
D
C
5
6
5
88.09
10
12
9
1
B
13
B
1
3
3
11
2
7
4
8
A
UNLESS OTHERWISE SPECIFIED:
SECTION A-A
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/20/2015
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
12/18/13
DF
1/20/15
DGW
1/20/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ASSY
MOTOR
GDM 500
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: 974.05 LBS
DO NOT SCALE DRAWING
3
A500279
REV
1
8
5
6
7
4
2
3
1
SEE BOM FOR
SPARE PARTS
D
D
C
C
2
16
SECTION B-B
1
14 13
30.00
14 15
7
6
8
11 12
B
B
B
14.13
B
5
10 11
4
16
9
3
UNLESS OTHERWISE SPECIFIED:
2
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
4
6
1/21/2015
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
12/18/13
DF
1/21/15
DGW
1/21/14
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ASSY
MOTOR
DISC BRAKES
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 2
WEIGHT: 480.13 LBS
DO NOT SCALE DRAWING
3
A500231
REV
1
8
ITEM NO.
D
C
B
7
PART NUMBER
5
6
4
DESCRIPTION
QTY.
1
M500268
DISC, DISC BRAKE
1
2
M500238
HUB DISC
1
3
M500267
SHIMS, KIT, DISC BRAKE
1
4
M500274
DISC BRAKE HOUSING, DISC BRAKE ASSY
2
5
M500265
ADAPTER PLATE, DISC BRAKE
2
6
A500364
ASSY, CALIPER, BRAKE
2
7
M500275
DISC BRAKE COVER, DISC BRAKE ASSY
1
8
M500276
POST DISC BRAKE COVER, BRAKE ASSY
4
9
220102.1600
WASHER, NORD-LOCK, 1 IN, PAIR
4
10
016142.1650DH2
CAPSCR, SOCKETHEAD, M16 x 50, GR8.8, DH2
8
11
230101.1000
WASHER,LOCK,HI COLLAR 5/8
16
12
026211.1048DH2
CAPSCREW,SOCKET HEAD, 5/8-11UNC X 3.00, DH2
8
13
026211.1244DH2
CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.75, DH2
12
14
210202.1200
WASHER,LOCK,SPLIT,GR8, 3/4
16
15
026211.12124DH2
CAPSCREW, SOCKET HEAD, 3/4-10 X 7.75, DH2
4
16
008121.1656DH2
CAPSCREW,HEX HEAD, 1-8UNC X 3.50,DH2
4
SPARE
M102872
BRAKE PAD, BRAKE CALIPER, SKD-80
4
SPARE
S101565
SEAL KIT, BRAKE CALIPER, SKD80, STD-NITRILE
4
3
2
1
D
C
B
GDS International
TITLE:
A
ASSY
MOTOR
DISC BRAKES
A
SIZE PART/DWG NO.
B
A500231
WEIGHT: LBS
8
7
6
5
4
3
2
REV
01
SHEET 2 OF 2
1
8
D
ITEM NO.
1
2
3
4
5
6
7
8
PART NUMBER
P500001
M500299
008121.0824DH2
101112.0800
206101.0800
008121.1056DH2
008121.1032DH2
M100506
9
206101.1000
10
4
DESCRIPTION
BLOWER, ELIMINATOR, 15HP, 3600, 575V, STAINLESS STEEL
DUCT, BLOWER
CAPSCREW, HEX HEAD, 1/2-13UNC X 1.50, DH2
NUT,HEX,STOVER C 1/2-13
WASHER,FLAT,HARDENED,F436 Plain, 1/2
CAPSCREW,HEX HEAD, 5/8-11UNC X 3.5,DH2
CAPSCREW,HEX HEAD, 5/8-11UNC X 2.00,DH2
QUICK LINK, 3/8
QTY.
1
1
6
6
12
2
2
1
NUT,HEX,STOVER C 5/8-11
4
WASHER,FLAT,HARDENED,F436 PLAIN, 5/8
101112.1000
11
12
5
6
7
M100485
M100847
1
D
8
WIRE ROPE CRIMP, 3/16'' ALUMINUM
WIRE ROPE, 3/16" SS 7X19 WIRE STRAND
1
36 8 "
2
3
3
4
7
34 8 "
8
1
C
C
1
7
9
10
1
49 16 "
B
B
6
10
9
3
4
5
1
2
2
UNLESS OTHERWISE SPECIFIED:
A
01
REV.
RELEASE FOR MANUFACTURE
DGW 10/14/14
DESCRIPTION
INITIAL
8
7
6
DATE
5
ECN #
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
NAME
DRAWN
CHECKED
APPR.
DGW
12/18/13
DF
10/14/14
DGW
10/14/14
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ASSY,
BLOWER, 15HP
575V, 3600
A
SIZE PART/DWG NO.
B
FINISH
125AA Unless stated otherwise
3
A500252
REV
01
SCALE: DNS WEIGHT: 161.78 SHEET 1 OF 1
DO NOT SCALE DRAWING
4
GDS International
DATE
2
1
8
1.
2.
3.
4.
5.
D
C
6
7
5
NOTES:
IMPELLER BUSHING BOLTED ON HUB WITH 3X 3/8-16 UNC BOLTS
TORQUE HUB BOLTS TO 29 FT-LBS
IMPELLER & BOLTS ARE NOT SHOWN ITEM 4,7,10
ALL BOLTS SHOULD BE TIE WIRED
ALL MATERIAL IS STAINLESS STEEL
8
12X
14X
9
14X
6
4
ITEM NO.
PART NUMBER
1
P500001-02
2
P500001-04
3
P500001-01
3
3
2
3
1
DESCRIPTION
BLOWER HOUSING
MOTOR C-FACE WITH FEET 15 HP 3600 RPM 575 VOLT
INTAKE COVER
QTY.
1
1
1
4
P50000-03
IMPELLER
1
5
6
210202.0800
210202.0500
WASHER,LOCK,SPLIT,GR8, 1/2
WASHER,LOCK, SPLIT, GR8 5/16
16
14
7
210202.0600
WASHER,LOCK,SPLIT,GR8 3/8
3
8
9
10
11
12
13
008121.0824DH2
008121.0516DH2
008121.0620DH2
008121.0832DH2
108112.0800
108112.0500
CAPSCREW, HEX HEAD, 1/2-13UNC X 1.50" DH2
CAPSCREW,HEX HEAD, 5/16-18 UNC X 1.00 DH2
CAPSCREW,HEX HEAD,3/8-16UNC X 1.25,DH2
CAPSCREW,HEX,PLATED, GR8 1/2-13 UNC
NUT,HEX ,PLATED,GR8 1/2-13
NUT,HEX, PLATED, GR8 5/16-18
12
14
3
4
16
14
D
C
1
3
5
16X
2
B
B
11
4X
12
13
16X
14X
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
3
MODIFIED 3D MODEL TO ADD ALL THE BOLTS & WASHERS AND ADDED BOM
2/4/2015
HD
2
11/16" WAS 1/2"
7/28/2014
DGW
1
REV.
RELEASE FOR MANUFACTURING
DESCRIPTION
8
7
6
4/21/2014
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
4/21/2014
DF
1/21/2015
DGW
1/21/2015
GDS International
TITLE:
BLOWER ELIMINATOR
15 HP, 3600 RPM, 575 V
STAINLESS STEEL
THIRD ANGLE
PROJECTION
MATERIAL
SIZE PART/DWG NO.
SEE BOM
B
FINISH
125AA UNLESS STATED OTHERWISE
3
REV
P500001
WEIGHT: 125.40 LBS
DO NOT SCALE DRAWING
2
A
3
SHEET 1 OF 1
1
8
5
6
7
4
2
3
1
2
9
41.00
D
D
11
12
1
10
D
E
57.05
10
8
C
12
A
3
5
C
5
11
1
F
14
10
12
15
DETAIL D
SCALE 1 : 8
1
13
4
K
16
C
7
B
13
11
B
91.88
2
B
9
8
H
12
H
5
6
1
UNLESS OTHERWISE SPECIFIED:
5
A
PROPRIETARY AND CONFIDENTIAL
02
01
REV.
ADDED WELDED HINGE PIN, PAGE 2
<REV DESC>
DESCRIPTION
8
7
DETAIL E
SCALE 1 : 8
DETAIL K
SCALE 1 : 4
SECTION H-H
SCALE 1 : 24
6
9/24/14
JP
DGW 12/18/13
INITIAL
6
DATE
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
5
12
NAME
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
DRAWN
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DGW
12/18/2013
CHECKED
JP
9/24/14
ENG APPR.
JP
9/24/14
MFG APPR.
XXX
XX/XX/XX
Q.A.
XXX
XX/XX/XX
MATERIAL
GDS PART No.-Revision
A500277-02
4
GDS International
DATE
TITLE:
GUARD ASSEMBLY,
GDM 500
SIZE DWG. NO.
B
FINISH
02
SCALE: 1:18 WEIGHT: 392.69 SHEET 1 OF 3
DO NOT SCALE DRAWING
3
A500277
REV
2
1
A
8
5
6
7
4
3
2
1
1
3
17
D
AA
5
D
4
8
7
8
9
G
8
8
16
8
6
DETAIL A
SCALE 1 : 4
G
1
C
DETAIL C
SCALE 1 : 4
C
1/2 ROUND BAR
TYP
1/4
2
.25
CAGE HINGE
DETAIL B
SCALE 1 : 12
B
11
2
8
5
7
B
DETAIL AA
SCALE 1 : 6
1
11
3
GDS International
9
DETAIL F
SCALE 1 : 8
A
TITLE:
GUARD ASSEMBLY,
GDM 500
41.00
SIZE DWG. NO.
B
SECTION G-G
SCALE 1 : 12
8
7
A500277
SCALE: 1:1
6
5
4
3
2
REV
01
WEIGHT: 392.69 SHEET 2 OF 3
1
A
8
D
C
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
7
6
5
4
QTY.
M500448
M500449
M500533
220102.0800
008121.0644DH
DESCRIPTION
GUARD FRAME
DOOR, DS, CAGE ACCESS, GDM 500
PLATFORM, UPPER CAGE, GDM 500
ROD, PLATFORM MOUNTING, GDM 500
DEFLECTOR PLATFORM, GDM 500
LATCH, BTM PLATFORM, GDM 500
DOOR, ODS, CAGE ACCESS, GDM 500
PIN W/HEAD, 3/8 x 1 3/4"
BRACE, FRONT CAGE, GDM
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
CAPSCREW, HEX HEAD, 3/8-16UNC X 2.75, DRILLED
M500418
M500425
026211.1656DH2
101112.1600
104112.1200
M102322
M100734 NEW
220102.1600
208201.1200
MOUNT, LOWER CAGE, GDM 500
CAPSCREW, 12-POINT, 1-8 UNC X 3-3/4", GR8
CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2
NUT, HEX, STOVER 1-8
NUT, HEX, SLOTTED 3/4-10 UNC
COTTER PIN, 1/4" X 2"
1-1/2" DIA ROUND BAR, CUT TO 4-1/4" L
WASHER, NORD-LOCK, 1 IN, PAIR
WASHER,FLAT,Gr8, 3/4
2
10
4
4
4
2
2
10
2
PART NUMBER
M500401
M500412
M500426
M500427
M500434
M500447
3
2
1
1
1
1
1
1
2
1
10
1
4
4
D
C
B
B
GDS International
TITLE:
GUARD ASSEMBLY,
GDM 500
A
SIZE DWG. NO.
B
A500277
SCALE: 1:1
8
7
6
5
4
3
2
REV
01
SHEET 3 OF 3
WEIGHT:
1
A
1 of 2
2 of 2
8
5
6
7
4
2
3
ITEM NO.
PART NUMBER
1
M500100
2
3
4
5
D
N500002
N500003
220102.1400
008121.1424DH2
1
DESCRIPTION
PRXIMITY MOUNT BRACKET
QTY.
1
SENSOR, PROX INDUCTIVE, DC
CABLE, 5M, INDUCTIVE SENSOR
WASHER,LOCK,NORDLOCK,1 PAIR 7/8
CAPSCREW,HEX HEAD, 7/8-9UNC X 1.50,DH2
1
1
2
2
D
1
58"
3
C
C
2
1
B
B
5
4
3
28"
1
88"
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
02
MODIFIED FROM ORIGINAL VERSION
9/5/13
01
REFER TO TD125146 - ORIGINAL VERSION
7/18/12
REV.
DESCRIPTION
8
DATE
7
NAME
DATE
JAV
9/5/13
CHECKED
DF
12/3/14
APPR.
DF
12/3/14
UNLESS OTHERWISE SPECIFIED:
6
JAV
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
PROXIMITY SENSOR
MOUNT ASSEMBLY
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
02
SHEET 1 OF 1
WEIGHT: 1.32 LBS
DO NOT SCALE DRAWING
3
A500101
A
1
1 of 2
2 of 2
1 of 2
2 of 2
8
5
6
7
4
2
3
ITEM NO. PART NUMBER
12
D
12
42"
9
44 16 "
2
1
DESCRIPTION
QTY.
1
A500015
GDM 650/500 LINK COLLAR ASSEMBLY
1
2
A500160
ROTATING PLATE ASSY, LINKS ASSY
1
3
A500347
ELEV. TILT PLATE CYL. ASSY
2
4
5
6
A500348
A500349
A500162
LOAD COLLAR REAR ASSY, LINK ASSY
ELEVATOR TILT PLATE ASSY, LINK ASSY
LOAD COLLAR FRONT BRACKET ASSEMBLY
1
1
1
7
A500411
ELEVATOR LINK, ASSEMBLY, GDM
2
8
M500145
SPRING POST, LOAD COLLAR ASSY
24
9
M500146
SPACER, SPRING POST, LOAD COLLAR ASSY
24
10
M500148
SPRING, LOAD COLLAR ASSY
24
11
206101.2000
WASHER,FLAT,HARDENED,F436 Plain, 1 1/4
48
12
M500054
ROTATING PLATE LINK ASSY
1
C
D
C
6
12
1
4
B
B
1
92 8 "
5
9
10 11
8
3
7
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/21/2015
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
1/21/15
DGW
1/21/15
DF
1/21/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ASSY, LINK,
TOP DRIVE,
GDM 500
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: 3398.33 LBS
DO NOT SCALE DRAWING
3
A500355
REV
1
8
23
D
5
6
7
25 24
4
2
3
1
13 12
D
21
A
15
DETAIL A
SCALE 1 : 2
19
17
26
DETAIL C
SCALE 1 : 1.5
C
C
5
42"
B
3
37 16 "
7
4
9
2
8
3
20 21 22
10
18
B
B
11
36 16 "
C
16
SECTION B-B
SCALE 1 : 12
14
UNLESS OTHERWISE SPECIFIED:
B
A
20
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
11
PROPRIETARY AND CONFIDENTIAL
3
42 4 "
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/22/2015
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
1/22/15
DGW
1/22/15
DF
1/22/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
LINK COLLAR ASSEMBLY
GDM 650/500
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 2
WEIGHT: 2834.84 LBS
DO NOT SCALE DRAWING
3
A500015
REV
1
A
8
7
6
5
4
ITEM NO.
20
2
3
4
5
21
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
D
C
B
PART NUMBER
M500021
S500000
M500156
008121.0828DH2
220102.0800
M500053
M500304
008121.0424DH
220102.0400
M500157
M100917
008121.0616
220102.0600
M500058
M105001
M500636
108112.1600
M100491
H101598
M500165-060
M500165-134
M500165-250
M500314
230101.1600
026211.1672DH2
M500394
M100482
M100559
M100485
M100847
3
2
1
DESCRIPTION
LINK COLLAR FINAL MACHINING 500T
SEAL, SHAFT, RADIAL 9X11X.625
RETAINING RING, LOAD COLLAR SLEEVE, LINK ASSY
HEX HEAD, 1/2-13 UNC x 1 3/4 IN, GR 8 WIRED
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
LINK COLLAR TOP PLATE CORE ASSY
ROTARY SEAL ASSY
HEX HEAD CS, GR 8, 1/4- 20UNC x 1 1/2 DRILLED
WASHER,LOCK,NORDLOCK,1 PAIR 1/4
LOAD COLLAR SLEEVE
GREASE FITTING, 1/4 NPT, STRAIGHT
CAPSCREW, HEXHEAD, 3/8-16 X 1" GR. 8
WASHER,LOCK,NORDLOCK,1 PAIR 3/8
LATCH LOAD COLLAR, LOAD COLLAR ASSY
LINCH PIN - WITH LOCKING RING 1/4"
PIN - 1'' X 3'' W/ 1''-8 THREADED END
NUT,HEX,PLATED,GR8 1-8
EYEBOLT, SHLD TYPE, 3/8-16UNC X 1-1/4in
CAP, 3/8 ORFS
SPACER PLATE, .060, CORE ASSY
SPACER PLATE, .134, CORE ASSY
SPACER PLATE, .250, CORE ASSY
PLATE 2-3/4", ASTM A572, Gr50
WASHER,LOCK,HI COLLAR 1''
CAPSCREW,SOCKET HEAD, 1-8UNC X 4.50, DH2
PLATE, GUIDE, ANTI-ROTATION
1/16'' ALUMINUM OVAL, WIRE ROPE CLIP
WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE
WIRE ROPE CRIMP, 3/16'' ALUMINUM
WIRE ROPE, 3/16" SS 7X19 WIRE STRAND
QTY.
1
1
1
8
8
1
1
8
8
1
1
3
3
2
2
2
2
2
9
2
1
1
1
10
10
1
8
20FT
4
4FT
D
C
B
GDS International
TITLE:
A
LINK COLLAR ASSEMBLY
GDM 650/500
SIZE PART/DWG NO.
B
A500015
WEIGHT: LBS
8
7
6
5
4
3
2
A
REV
01
SHEET 2 OF 2
1
8
5
6
7
4
ITEM NO.
1
D
2
3
6
7
A
C
2
3
1
DESCRIPTION
QTY.
BRG, TURNTABLE, LINK ASSY
1
CAPSCREW,HEX HEAD, 7/8-9UNC X 4.00,DH2
18
WASHER,LOCK,NORDLOCK,1 PAIR 7/8
18
PART NUMBER
1
M500032
2
008121.1464DH2
3
220102.1400
4
M500159
BUSHING ROTATING PLATE SMALL, ROTATING PLATE ASSY
2
5
M500158
BUSHING ROTATING PLATE LARGE, ROTATING PLATE ASSY
2
6
026211.1464DH2
CAPSCREW, SOCKET HEAD, 7/8-9 UNC X 4.00 DH2
24
7
230101.1400
WASHER, LOCK, HI COLLAR
24
8
9
10
11
12
13
14
15
16
17
M500054
M100635
M100491
M100506
220102.0600
H500039
M100559
M100847
M103173
M100482
ROTATING PLATE LINK ASSY
GREASE FITTING, 1/8-27 NPT, STRAIGHT
EYEBOLT, SHLD TYPE, 3/8-16UNC X 1-1/4in
QUICK LINK, 3/8
WASHER,LOCK,NORDLOCK,1 PAIR 3/8
CLAMP, DOUBLE, 3/8
WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE
WIRE ROPE, 3/16" SS 7X19 WIRE STRAND
HOURGLASS SLEEVE ALUM, 3/16 IN (OVAL SLEEVE ALUM)
1/16'' ALUMINUM OVAL, WIRE ROPE CLIP
1
1
2
2
2
3
20FT
3 FT
4
6
D
C
8
12 11 10
B
13
13
B
9
5
DETAIL A
SCALE 1 : 4
UNLESS OTHERWISE SPECIFIED:
4
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/22/15
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
1/22/15
DGW
1/22/15
DF
1/22/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ROTATING PLATE ASSY,
LINKS ASSY
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 1
WEIGHT: 151.42 LBS
DO NOT SCALE DRAWING
3
A500160
A
1
8
7
5
6
4
ITEM NO.
1
2
3
4
5
6
7
D
8
6
9
10
5
2
3
PART NUMBER
M500563
M100131
M100329
M100635
220102.1600
008121.1644DH2
M500413
008121.0632DH2
206101.0600
101112.0600
1
DESCRIPTION
LOAD COLLAR REAR BRKT WLDMT
BRG, SPHER. PLAIN RADIAL, 1.38 x 2.188
RETNG RING, INT, 2.188 BORE, 0.049 THK
GREASE FITTING, 1/8-27 NPT, STRAIGHT
WASHER, NORD-LOCK, 1 IN, PAIR
CAPSCREW,HEX HEAD, 1-8UNC X 2.75,DH2
PIN W/HEAD 1.375 x 4.4375
QTY.
1
2
2
2
8
8
2
WASHER,FLAT,HARDENED,F436 PLAIN, 3/8
3/8-16 STOVER NUT
4
2
CAPSCREW, HEX HEAD, 3/8-16UNC X 2.75
D
2
C
C
B
B
7
8
9
10
4
UNLESS OTHERWISE SPECIFIED:
1
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTUE
DESCRIPTION
8
7
6
1/22/2015
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
1/22/15
DF
1/22/15
DGW
1/22/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
LOAD COLLAR
REAR ASSY
LINK ASSY
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500348
REV
1
8
5
6
7
4
A
ITEM NO.
D
1
B
2
3
PART NUMBER
1
DESCRIPTION
Default/QTY.
CYLINDER, LINK TILT
1
CYLINDER ROD END, GDM LINK TILT
1
GREASE FITTING, 1/8-27 NPT, STRAIGHT
BRG, SPHER. PLAIN RADIAL, 1.38 x 2.188
RETNG RING, INT, 2.188 BORE, 0.049 THK
SETSCREW, 3/8-16 UNC X 0.50 CUP POINT
1
1
1
1
1
H101555-1
2
H500112
3
4
5
6
M100635
M100131
M100329
312211.0608
7
H100723
PLUG, SOC HEX, 1/8,
1
8
H101970
ELL90º, MALE 3/8" ORFS, 3/4" ORB
2
SEAL KIT,LINK TILT,1-3/4'' ROD,GDM
-
SPARE PARTS H101555-2
D
8
C
C
C
3
2
6
B
B
DETAIL C
SCALE 1 : 4
7
4
5
DETAIL B
SCALE 1 : 4
DETAIL A
SCALE 1 : 4
A
01
REV.
RELEASE FOR PRODUCTION
DESCRIPTION
8
7
6
UNLESS OTHERWISE SPECIFIED:
MH
9/25/14
INITIAL
DATE
5
ECN #
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
NAME
DRAWN
MH
CHECKED
JP
APPR.
JP
09/25/2014
TITLE:
ELEV. TILT PLATE CYL. ASSY
THIRD ANGLE
PROJECTION
MATERIAL
SIZE PART/DWG NO.
B
FINISH
125AA Unless stated otherwise
3
A500347
2
REV
01
SHEET 1 OF 1
SCALE: DNS WEIGHT:
DO NOT SCALE DRAWING
4
GDS International
DATE
1
A
8
5
8
10
4
5
6
7
7
13 11
8
11
2
10 12
4
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
6
D
C
9
8
12 10
3
2
3
PART NUMBER
M500564
M500368
M500369
M500370
M500143
M500147
M500151
M100635
M500413
206101.0600
101112.0600
008121.0636DH
008121.0628DH
M100559
M100482
1
DESCRIPTION
ELEVATOR TILT PLATE 500T TOP DRIVE
BUSHING PIVOT TILT PLATE, TILT PLATE ASSY
BUSHING MID TILT PLATE, TILT PLATE ASSY
BUSHING LINK TILT PLATE, TILT PLATE ASSY
PIN ELEVATOR TILT PLATE, LOAD COLLAR ASSY
PIN ELEVATOR TILT PLATE UPPER, LOAD COLLAR ASSY
SPACER TILT PLATE, ROD EYE
GREASE FITTING, 1/8-27 NPT, STRAIGHT
PIN W/HEAD 1.375 x 4.4375
WASHER,FLAT,HARDENED,F436 PLAIN, 3/8
3/8-16 STOVER NUT
CAPSCREW,HEX HEAD, 3/8-16UNC X 2.25,DH
CAPSCREW, HEXHEAD, 3/8-16 X 1.5" GR. 8
WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE
1/16'' ALUMINUM OVAL, WIRE ROPE CLIP
QTY.
1
4
4
4
2
2
4
6
2
12
6
4
2
10
6
D
C
11
49"
1
30 2 "
B
13
8 16 "
5
1
9
6
9
6
1
NAME
DATE
DGW
9/22/14
CHECKED
DF
9/23/14
APPR.
DF
9/23/14
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
9/23/14
DGW
DATE
APPROVED
5
B
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ELEVATOR
TILIT PLATE ASSY
LINK ASSY
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500349
REV
1
8
5
6
7
4
ITEM NO.
D
5.50
4
2
3
PART NUMBER
1
DESCRIPTION
QTY.
1
M500168
LOAD COLLAR FRONT BRACKET WLDMT
1
2
M500161
BUSHING LOAD COLLAR BRACKET
2
3
008121.1636DH2
CAPSCREW,HEX HEAD, 1-8UNC X 2.25,DH2
8
4
220102.1600
WASHER, NORD-LOCK, 1 IN, PAIR
8
D
3
1
C
C
17.00
B
B
2
2
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
17.75
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
6/17/14
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
6/17/14
DGW
6/17/14
DF
6/17/14
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
LOAD COLLAR
FRONT BRACKET
ASSY
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: 71.06 LBS
DO NOT SCALE DRAWING
3
A500162
REV
1
8
6
7
5
4
ITEM NO.
3
1
D
2
3
PART NUMBER
1
DESCRIPTION
QTY.
1
M500481
ELEVATOR, LINK BRACKET, GDM
1
2
3
4
M100635
M100142
M500494
GREASE FITTING, 1/8-27 NPT, STRAIGHT
BRG, SPHERICAL, PLAIN RADIAL, 1.00 X 1.625
RETAINING RING, INTERNAL, 1.625
4
2
2
D
2
2
1
2
1
A
A
C
C
1.00
3
15.00
2
1
3
B
B
B
3
SECTION A-A
SCALE 1 : 2
1
DETAIL B
SCALE 1 : 1
4
UNLESS OTHERWISE SPECIFIED:
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR PRODUCTION
DESCRIPTION
8
4/22/14
JP
INITIAL DATE
7
6
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
5
NAME
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
DRAWN
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DATE
MH
4/21/2014
ENG APPR.
JP
4/21/2014
MFG APPR.
XXX
XX/XX/XX
Q.A.
XXX
XX/XX/XX
CHECKED
MATERIAL
GDS PART No.-Revision
TITLE:
ELEVATOR LINK,
ASSEMBLY, GDM
SIZE DWG. NO.
B
FINISH
3
A500411
SCALE: 1:4
DO NOT SCALE DRAWING
4
GDS International
2
REV
01
SHEET 1 OF 1
WEIGHT:
1
A
8
14
15
16
5
6
7
17 29
11
19
12
1
12
4
2
3
1
13
11
24
D
D
13
A
11
A
29 10
14
C
C
12
21
B
4
3
29 10
12
14
B
B
30 22
30 23
B
SECTION B-B
20
UNLESS OTHERWISE SPECIFIED:
21
A
20
5
6
9
2
7
18
8
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
4
SECTION A-A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
11/18/13
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
11/18/13
DF
11/5/14
DGW
11/5/14
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GRABBER ASSEMBLY
500T
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 2
WEIGHT: 1094.47 LBS
DO NOT SCALE DRAWING
3
A500345
A
1
8
C
B
5
6
4
3
1
2
3
4
5
6
M500546
M500547
M500548
M500549
S500016
S500017
BODY, GRABBER, 500 T
ROD, GRABBER
PLUG, BORE, GRABBER, 500T
PLATE, RETAINER, PLUG, GRABBER 500T
WIPER, ROD, SNAP-IN, 6.000"
POLYPAK SEAL, TYPE B, 6.0" ID x 6.5" OD x .562" WIDE
Default/
QTY.
1
1
1
4
1
1
7
S500018
SEAL, PISTON, CPS CAPPED T-SEAL, 9" OD
1
8
S500020
O-RING, 9-3/8" OD X 9" ID X 3/16" W
1
9
S500019
RING, WEAR, ROD, 6" ID X 6 1/4" OD X 1/2" W, 612F, ANGLE CUT
1
10
008121.0824DH2
CAPSCREW, HEX HEAD, 1/2-13UNC X 1.50, DH2
12
ITEM NO.
D
7
PART NUMBER
DESCRIPTION
11
H500008
ELL 45deg, MALE 3/8" ORFS, MALE 1/2 ORB
12
H101400
PLUG, SOCKET HEX, 1/2'' ORB
4
13
M500581
PLATE, STRAP, RETAINER
1
14
15
16
17
M500209
M500204
M500203
008121.0836DH2
GATE, GRABBER, 500 T
PIN GRABBER CLAMP
PIN LOCK, GRABBER ASSY
CAPSCREW,HEX HEAD, 1/2-13UNC X 2.25,DH2
1
2
2
4
18
19
20
21
22
23
24
25
26
27
28
29
30
S500021
H103771
M500181
M500182
008121.1236DH2
008121.1224DH2
A500254
M100482
M100559
A500105
A500102
220102.0800
220102.1200
RING, WEAR, PISTON, 9" OD X 8 3/4" ID X 1/2" W, 612F, ANGLE CUT
2 X 7'' ISO LIGHT DIE SPRING
BELL GUIDE REAR 7 IN, GRABBER ASSY
BELL GUIDE FRONT 7 IN, GRABBER ASSY
CAPSCREW,HEX HEAD, 3/4-10UNC X 2.25,DH2
CAPSCREW, HEX HEAD, 3/4-10UNC X 1.50, DH2
GRIPPER SPRING STABILIZER, GRABBER ASSY
FERRULE, 1/16, OVAL, ALUMINUM
WIRE ROPE, 1/16" SS ,7X7 SAFETY CABLE
GDM 650/500 TON ROD SIDE DIE BLOCK ASSEMBLY
GDM 650/500 TON GATE SIDE DIE BLOCK ASSEMBLY
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
WASHER,LOCK,NORDLOCK,1 PAIR 3/4
1
4
1
1
2
2
1
12
6
1
1
16
5
GATE SIDE
A500102
A500102
A500353
M500182
M500723
2
1
GRABBER CONFIGURATIONS
DIE BLOCKS
ROD SIDE
OPTION
A500103
SMALLEST
A500105
STANDARD
A500105
650 TON LWCV ONLY
STABBING GUIDES
M500181
7 INCH
M500722
9 INCH
D
2
C
B
GDS International
TITLE:
A
GRABBER ASSEMBLY
500T
SIZE PART/DWG NO.
B
A500345
WEIGHT: LBS
8
7
6
5
4
3
2
A
REV
01
SHEET 2 OF 2
1
8
5
6
7
4
ITEM NO.
1
2
3
4
D
3
38"
4
2
3
2
3
PART NUMBER
M500578
R100030
M500579
008121.0816DH2
1
DESCRIPTION
BLOCK, DIE, GRABBER
BLOCK, DIE, GRABBER
BLOCK, DIE, RETAINER
CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2
QTY.
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
4
1
2
2
4
5
220102.0800
6
M500553
PIN, BLOCK, DIE, GATE
1
7
8
M100559
M100482
WIRE ROPE, 1/16" SS, 7X7 SAFETY CABLE
FERRULE, 1/16, OVAL, ALUMINUM
2
4
5
D
6
1
C
C
7
68"
B
B
5"
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
11/4/2014
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
11/4/14
DGW
11/4/14
DF
11/4/14
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GDM 650/500 TON
GATE SIDE DIE
BLOCK ASSEMBLY
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 1
WEIGHT: 21.93 LBS
DO NOT SCALE DRAWING
3
A500102
A
1
8
3
1
5
6
7
5
2
4
ITEM NO.
1
2
3
4
5
6
7
8
9
10
3
D
PART NUMBER
M500578
M500550
M500551
R100030
M500580
220102.0800
008121.0816DH2
008121.0844DH2
M100482
M100559
4
A
7
1
DESCRIPTION
BLOCK, DIE, GRABBER- 4.000" X 6.625" OD
PIN, BLOCK, DIE, ROD
BLOCK, GUIDE, ROD, GRABBER, 500T
TONG DIE, 1/2 x 1 1/4 x 5 LONG
PLATE, RETAINER, DIE, ROD SIDE - 082-02-024 BLOCK
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2
CAPSCREW,HEX HEAD, 1/2-13UNC X 2.75,DH2
FERRULE, 1/16, OVAL, ALUMINUM
WIRE ROPE, 1/16" SS, 7 X 7 SAFETY CABLE
7
C
2
3
5
QTY.
1
1
2
2
2
8
4
4
8
4
D
2
C
3
8
6
1
7 16 "
B
B
3
38"
A
SECTION A-A
15
10 16 "
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURING
DESCRIPTION
8
7
6
1/27/2015
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
1/27/15
DF
1/27/15
DGW
1/27/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GDM 650/500 TON
ROD SIDE 3 1/2"
DIE BLOCK ASSY
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500103
A
1
8
5
6
7
4
5
D
3
2 16 "
3
6
8
1
1
ITEM NO.
1
2
3
4
5
PART NUMBER
M500585
R100030
M500567
M500551
M500550
DESCRIPTION
BLOCK, DIE, GRABBER
TONG DIE, 1/2 X 1-1/4 X 5 LONG TC DIE
PLATE, RETAINER, DIE ROD-SIDE FOR THE 8.5" OD DIE BLOCK
BLOCK, GUIDE, ROD, GRABBER, 500T
PIN, BLOCK, DIE, ROD
QTY.
6
008121.0820DH2
CAPSCREW,HEX HEAD,1/2-13UNC X 1.25,DH2
4
7
8
008121.0844DH2
220102.0800
CAPSCREW,HEX HEAD, 1/2-13UNC X 2.75,DH2
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
4
8
WIRE ROPE, 1/16" SS, 7X7 SAFETY CABLE
FERRULE, 1/16, OVAL, ALUMINUM
4
8
9
10
2
2
3
M100559
M100482
1
2
2
2
1
D
4
A
C
C
5
15
6 16 "
7
8
B
B
A
SECTION A-A
15
10 16 "
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
11/4/2014
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
11/4/14
DGW
11/4/14
DF
11/4/14
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GDM 650/500 TON ROD
SIDE 5 1/2 IN
DIE BLOCK ASSEMBLY
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 1
WEIGHT: 21.30 LBS
DO NOT SCALE DRAWING
3
A500105
A
1
8
5
6
7
1
4
ITEM NO.
1
2
3
4
5
6
7
8
2
D
2
3
PART NUMBER
M500585
M500568
R100030
M500553
220102.0800
008121.0816DH2
M100559
M100482
1
BOM Table
DESCRIPTION
BLOCK, DIE, GRABBER, 6.625" - 8.500"
PLATE, RETAINER, DIE, GATE SIDE FOR 6-5/8" - 8-1/2" OD
TONG DIE, 1/2 x 1 1/4 x 5 LONG
PIN, BLOCK, DIE, GATE, GRABBER 500T
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2
WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE
1/16" ALUMINUM OVAL, WIRE ROPE CLIP
QTY.
1
2
2
1
4
4
2
4
D
3
5"
6
A
C
3
2 16 "
5
4
C
2
15
6 16 "
B
B
NOTE:
LOWER WELL CONTOL VALVE (LWCV) USE ONLY.
1
2
A
SECTION A-A
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/28/2015
DGW
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DGW
1/28/15
DF
1/28/15
DGW
1/28/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GDM 650/500 TON
GATE SIDE 6.625-8.50
DIE BLOCK ASSY
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
01
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500353
A
1
8
5
6
7
4
ITEM NO.
1
2
3
4
5
D
10
11
5
1
10
6
7
8
9
10
11
12
13
11
1
2
5
9
2
3
PART NUMBER
M500323
M500321
M500322
M500324
M500395
220102.0800
008121.0820DH2
230101.1200
026211.1244DH2
208202.0800
101112.0800
M100559
M100482
1
DESCRIPTION
BASE STABILIZER, GRIPPER SPRING
STABILIZER SLIDE, GRIPPER SPRING
STABILIZER SLIDE INSERT, GRIPPER SPRING
CAP STABILIZER, GRIPPER SPRING
SPRING, COMPRESSION, GRIPPER
QTY.
1
1
1
1
2
WASHER,LOCK,NORDLOCK,1 PAIR 1/2
CAPSCREW,HEX HEAD,1/2-13UNC X 1.25,DH2
WASHER, LOCK, HI COLLAR 3/4"
CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.75, DH2
WASHER,FLAT,Gr8, SAE, YZ, 1/2
NUT,HEX,STOVER C 1/2-13
WIRE ROPE, 1/16'' SS, 7 X 7 SAFETY CABLE
FERRULE, 1/16, OVAL, ALUMINUM
2
2
2
2
2
2
6
20
3
C
C
2
7
SECTION A-A
SCALE 1 : 3
4
4
4
3
D
7
5
6
10
A
INSERT OPTIONS
M500322
STANDARD
M500724
LARGE
11
A
3
B
B
10 11
3
2
1
9
8
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
1
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
NAME
DATE
JP
1/6/14
CHECKED
DGW
1/28/15
APPR.
DGW
1/28/15
UNLESS OTHERWISE SPECIFIED:
6
1/28/2015
JP
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
GRIPPER SPRING
STABILIZER,
GRABBER ASSY
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500254
REV
1
1 of 1
8
7
5
6
4
ITEM NO.
41.00
2
D
2
3
PART NUMBER
1
M500616
2
3
4
5
6
7
M100623
M500310
230101.1000
026211.1032DH2
026211.1656DH2
230101.1600
1
DESCRIPTION
QTY.
BONNET 500T TOP DRIVE JOLIET MOTOR
1
ADAPTER, S PIPE
SHIMS, S-TUBE ADAPTER, TOP DRIVE ASSY
WASHER,LOCK,HI COLLAR 5/8
CAPSCREW,SOCKET HEAD, 5/8-11UNC X 2.00, DH2
CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2
WASHER,LOCK,HI COLLAR 1''
1
1
8
8
20
20
D
1
C
C
2
A
4
5
3
35.50
B
B
6
A
7
34.27
UNLESS OTHERWISE SPECIFIED:
SECTION A-A
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
01
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/27/15
DF
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
DF
1/27/15
DGW
1/27/15
DF
1/27/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
BONNET ASSY
GDM
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
01
SHEET 1 OF 1
WEIGHT: 1000.93 LBS
DO NOT SCALE DRAWING
3
A500370
REV
1
8
7
5
6
4
2
3
1
D
D
C
C
B
B
NAME
DATE
WJB
1/22/2015
CHECKED
-
-
APPR.
-
-
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
1
REV.
RELEASE FOR DATABOOK
DESCRIPTION
8
7
6
1/22/2015
WJB
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
ASSY, HYDRAULIC
GDM 500
-
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
1
SHEET 1 OF 1
WEIGHT: LBS
DO NOT SCALE DRAWING
3
A500230
A
1
8
5
6
7
4
ITEM NO.
1
2
3
4
5
6
7
8
D
2
3
PART NUMBER
A500240
M500098
M500228
220102.1000
008121.1028DH2
M500069
M500279
H100662
1
DESCRIPTION
BLOCK INTERFACE ASSY
PIN LOAD SIDE PLATES 500T TOP DRIVE CORE
KEEPER LOAD PIN, CORE ASSY
WASHER, LOCK, NORDLOCK, 5/8"
CAPSCREW, HEX HEAD, 5/8-11 UNC X 1.75, DH2
SIDE LOAD PLATE, GDM
BUSHING, BLOCK INTERFACE ASSY
PLUG, SOCKET HEX, 1/2'' ORB
QTY.
1
4
4
8
8
2
2
4
D
1
8
C
A
7
C
6
3
B
B
2
B
NAME
DATE
JAV
1/2/14
CHECKED
-
-
APPR.
-
-
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
2
REDRAWN
1
RELEASE
REV.
DESCRIPTION
8
7
6
1/21/2015
WJB
1/2/14
JAV
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
4
5
DETAIL B
SCALE 1 : 4
DRAWN
DETAIL A
SCALE 1 : 4
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
BLOCK INTERFACE
ASSEMBLY, WITH SIDE
PLATES
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
2
SHEET 1 OF 1
WEIGHT: 3347.37 LBS
DO NOT SCALE DRAWING
3
A500329
A
1
8
5
6
7
4
ITEM NO.
8
D
7
2
3
PART NUMBER
1
DESCRIPTION
QTY.
2
1
M500384
2
M500223
PIN BLOCK INTERFACE. BLOCK INTERFACE ASSY
500T
RETAINER, SIDE, BLOCK INTERFACE ASSY 500T
3
M500279
BUSHING, BLOCK INTERFACE ASSY
2
4
M500070
COUNTER BALANCE BEAM
1
5
008121.1636DH2
008121.1636DH2
8
6
220102.1600
WASHER, NORD-LOCK, 1 IN, PAIR
8
7
101112.1200
NUT,HEX,STOVER C 3/4-10
2
8
008121.1280DH2
CAPSCREW,HEX HEAD, 3/4-10UNC X 5.00,DH2
2
2
D
C
C
5
1
2
6
4
B
B
3
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
A
PROPRIETARY AND CONFIDENTIAL
1
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
NAME
DATE
WJB
1/21/14
CHECKED
-
-
APPR.
-
-
UNLESS OTHERWISE SPECIFIED:
1/21/2015
WJB
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
BLOCK INTERFACE
ASSEMBLY
-
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
REV
1
SHEET 1 OF 1
WEIGHT: 995.16 LBS
DO NOT SCALE DRAWING
3
A500240
A
1
8
7
5
6
4
ITEM NO.
1
2
3
4
5
6
SPARE PARTS
SPARE PARTS
SPARE PARTS
D
2
3
PART NUMBER
H800000
M100635
M500413
H101030
008121.0628DH
101112.0600
M102871
H800000-1
312211.0608
1
DESCRIPTION
CYLINDER, HYDRAULIC 5IN BORE X 10IN STROKE
GREASE FITTING, 1/8-27 NPT, STRAIGHT
PIN W/HEAD 1.375 x 4.4375
ELL 90°, MALE 1/2 ORFS, MALE 3/4 ORB
CAPSCREW, HEX HEAD, 3/8-16UNC X 1.75, DH
NUT,HEX,STOVER C 3/8-16
PIN/CLEVIS SET, CYLINDER, COUNTERBALANCE
GDM STAND JUMP CYLINDER SEAL KIT
SETSCREW, 3/8-16 UNC X 0.50 CUP POINT
1
2
3
5
QTY.
1
2
2
2
2
2
-
D
6
C
C
4
B
B
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
LOCATION OF ASSEMBLY
A
PROPRIETARY AND CONFIDENTIAL
1
REV.
RELEASE FOR MANUFACTURE
DESCRIPTION
8
7
6
1/21/2015
WJB
DATE
APPROVED
5
ECN #
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
4
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
DRAWN
CHECKED
APPR.
NAME
DATE
WJB
1/21/15
DF
1/27/15
WJB
1/27/15
GDS International
TITLE:
THIRD ANGLE
PROJECTION
MATERIAL
STANDJUMP
ASSEMBLY
-
A
SIZE PART/DWG NO.
B
FINISH
125AA UNLESS STATED OTHERWISE
2
1
SHEET 1 OF 1
WEIGHT: 3393.46 LBS
DO NOT SCALE DRAWING
3
A500024
REV
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
Drawing No.
05-MAIN-PWR
09-PWR-GDP
Revision
02
01
10-GDP-PLC
01
17- ENC
18-PRO-INX
19-PLC-TD-2
20-PLC-TD-2
21-OP-INT
01
01
01
01
01
22/PLC-ACRACK-3
24-CONOUTPUT
25-CON-3RD
30-E-STOP
31-HPU
32-OP-INT
33-BLOW
34-TD-ENA
35-TD-ENC
39-BU-WRENCH
40-HANDLER
41-LINK
42-IBOP
43-BRAKE
48-AC-TEMP
60-ELEV
61-ZONE
62-SLIDER
DRIVER HOUSE
101-SCR-DC
02
Description
MAIN POWER DISTRIBUTION
120/24V POWER DISTRIBUTION GLOBAL
DRILLING PANEL
PLC RACK CONFIGURATION GLOBAL
DRILLING PANEL
ENCODER SCHEMATIC
10C/12- INTERCONNECTION
TOP DRIVE RACK 1 CONFIGURATION
TOP DRIVE RACK 1 CONFIGURATION
OPERATOR INTERFACE TERMINAL
SCHEMATIC
CONSOLE RACK 3 CONFIGURATION
01
CONSOLE OUTPUTS SCHEMATIC
0
02
01
01
01
01
01
01
01
0
0
0
01
01
00
00
01
01
CONSOLE 3RD PARTY SCHEMATIC
E-STOP/LOCKOUT- AC/DC SCHEMATIC
HPU SCHEMATIC
LUBE CONTROL SCHEMATIC
BLOWER CONTROL SCHEMATIC
TOP DRIVE ENABLE SCHEMATIC
TOP DRIVE SPEED CONTROL SCHEMATIC
BACK UP WRENCH CONTROL
HANDLER CONTROL SCHEMATIC
LINK TILT CONTROL SCHEMATIC
IBOP SCHEMATIC
BRAKE CONTROL SCHEMATIC
AC MOTOR TEMPRATURE SCHEMATIC
ELEVATOR SCHEMATIC
PLC RACK CONFIGURATION
SLIDER SCHEMATIC
DRIVER HOUSE SCHEMATIC
SCR HOUSE SCHEMATIC
GDM650 Rev. 8
135
501
GDP
600V MCC
Main Breaker
MS
BLOWER
MS
L1
T1
L3
T1
L1
T1
503
L2
T2
L2
T2
L2
T2
504
L3
T3
L1
T3
L3
T3
505
THERMAL TRIP: 16 Amps
MAGNETIC TRIP: 450 Amps
LUBE PUMP
MS
MCC BUS
CB1
506
WHITE
2
LINE MONITOR
NO
732
C
730
TB11
1
509
L1
L2
L3
510
511
2
4
T1
L1
BLUE
L2
T2
L2
T2
L1
T3
L3
T3
THERMAL TRIP: 3.5 Amps
MAGNETIC TRIP: 55 Amps
5
T1
6
WHT-BLK
7
RED-BLK
8
9
918
10
734A
512
513
UV Trip CB1
A1
0030
11
RL 1
SCR E-Stop
705B
734
Orange
GREEN
24V
NC
514
3015
Console
E-stop
3
ORANGE
L3
508
515
BLACK
TB70
1
RED
THERMAL TRIP: 100 Amps
MAGNETIC TRIP: 100 Amps
12
TB23
4
A2
TB 23:5 /936
MOTOR
HEATER
13
LUBE
HEATER
15
DC ONLY
Brown
516
RL 1
SCR E-Stop
Relay
517
TB14
518
16
BLACK
WHITE
RED
14
WHT-BLK
120 V (N)
526
TB3
650
1
651
2
T1
9
ORN-BLK
10
BLU-BLK
11
BLK-WHT
12
RED-WHT
13
GRN-WHT
14
BLU-WHT
15
BLK-RED
T1
T1
L2
T2
L2
T2
T2
L3
T3
L3
T3
T3
TB20:1
907
TB21:1
924
L1
T1
L1
T1
T1
L2
T2
L2
T2
T2
L3
T3
L3
T3
T3
THERMAL TRIP: 25A
MAGNETIC TRIP: 400A
16
MTR5
528
HPU1
20 HP
1760 RPM
19.3 A - 575V
CAB 20
GREEN
MTR6
WHITE
BLACK
529
CB **
120 V (L)
120 V (N)
TB4
1
2
3
BLACK
L1
WHITE
N
GREEN
G
L1
SOLA
UPS
M
THERMAL TRIP: 25A
MAGNETIC TRIP: 400A
N
HPU2
20 HP
1760 RPM
19.3 A - 575V
G
L2
L1
T1
L1
T1
M
L2
T1
L1
T1
L3
T1
L1
T1
LUBE PUMP
2 HP
1750 RPM
2.7 Amp
8
GRN-BLK
L1
3
527
537
7
RED-BLK
M
525
536
CAB 49
6
3010
L1
120 V (L)
535
5
BLUE
CAB 19
524
534
4
ORANGE
523
533
3
GREEN
522
532
LOCAL BLOWER
15 HP
3550 RPM
13.8 Amp
2
206
4
521
531
AUX MTR J
TB90
CAB 48
1
CAB 22
CAB 23
11
520
14
205
3
519
530
TOPDRIVE
MAST
502
507
SERVICE
LOOP
MAST
500
HPU COOLER
2 HP
1750 RPM
2.7 Amp
MOTOR
HEATER
LUBE
HEATER
901
902
903
904
905
TB 20
120V AC
906
907
TB3-1 120V AC (L) / 523
1F
600
PS1
POWER SUPPLY
120 VAC/24 VDC
TB 20:1 / 1027 PLC
1A
#12 AWG
908
909
10A
650
2F
3F
10A
#12 AWG
C
4F
606
5F
608
10A
910
TB 22
24VDC(+)
606
RDY
L AC(L)
NO
N AC(N)
24VDC +
G
24VDC -
1A
6F
911
726
10A
106
10A
3027
740
913
650
PS2
POWER SUPPLY
120 VAC/24 VDC
2A
10F
914
#12 AWG
#12 AWG
5A
915
608
5A
12F
916
609
626
917
13
658
RDY
L AC(L)
740
2A
742
5A
NO
728
2A
2A
24VDC +
742
G
24VDC -
743
TB 22:5 /3102 HPU SENSORS
6F
710
TB 22:6 / 3151 HPU1 STATUS
7F
712
8F
714
TB 22:8 / 3163 HPU2 STATUS
9F
716
TB 22:9 / 1735 ENCODER SELECT
10F
718
11F
720
12F
F12
13F
142
14F
730
1A
107
N AC(N)
708
2A
#14 AWG
C
11F
5F
2A
14
2A
918
5A
15
919
TD 24V PS1 / 1804
4F
8F
9F
TD 24V PS2 / 1805
2A
744
2A
702
10A
5A
656
2F
3F
741
7F
3027
700
5A
746
5A
912
1F
TB 22:7 / 3021 CONSOLE PLC
TB 22:10 / 3269 LUBE STATUS
TB 22:11 / 3369 BLOWER STATUS/ CT
TB 22:12 / MICROBOX
TB 22:13 / 3416 HEATER OPTION
E-STOP POWER
5A
15F
920
650
TB3-1 120V AC (L) / 523
921
658
1
922
F
726
605A 120V AC (N) 926
728
651
925
1
651
601
/ 920
PLC PS (N) / 1028
605
605A
603
2
106
107
/ 920
607
TB 23
0V DC RETURN
741
609
TB11:4 / 3023
3143
938
711
705A
GDP PLC M1
2
I:1/0.1
1020 24V POWER SUPPLY #2
701
705
2
703
RL6 - A2 / 3145
TD RET PS1 / 1806
RL5 - A2 / 3117
TB9-4 / 1806
#14 AWG
932
5
RL8 - A2 / 3372
715
705B
705
3
713
RL2 - A2 / 1732
RL3 - A2 / 3011
6
3160
936
937
RL3:43 / 3151 HPU2 STARTER
900
RL3:33 / 3143 HPU1 STARTER
908
RL3:63 / 3360 BLOWER STARTER
906
RL3:53 / 3260 LUBE STARTER
705
1
743
4
3365
935
903
1
I:1/0.0
1019 24V POWER SUPPLY #1
GDP PLC M1
TB11:6 / 3018
3
932
934
726
20
TB3:2 / 526
930
933
17
#12 AWG
928
931
16
19
TB3-2 120V AC (N) / 524
929
2
TB 21
120V AC(N)
924
927
2 amp
630A
120V AC (N) 926
18
923
926
CB3
605
3260
UV/ 515
0030
705C
705E
4
705F
705D
0030
621
5
6
RL2 - A2 / 1732
TB21:11 / 3421
TORQ,RPM
1001
1002
752
1003
753
ETHERNET PIN-OUT
1004
M
L+
CAB 30
CAB 31
1005
1006
1 - WHITE / GREEN
2 - GREEN
3 - WHITE / ORANGE
4 - BLUE
5 - WHITE / BLUE
6 - ORANGE
7 - WHITE / BROWN
8 - BROWN
MANAGED ETHERNET
SWITCH
2119
2119
1928
6GK5310-0BA00-2AA3
1
8
1007
1008
754
754
754
24 VDC
1113
1009
RACK 0 GDP
GDP-PS
RACK 0 GDP
GDP-CPU
RACK 0 GDP
GDP-1
RACK 0 GDP
GDP-2
RACK 0 GDP
GDP-3
DIGITAL INPUT
1011
#1
1012
#2
L1+
1013
I-1/0.0
2
106
24V PS#1
924
1
O-1/0.0
GDP-5
8 ANALOG INPUT
8 ANALOG OUTPUT
#4
#5
#3
L1+
2
135
TD VFD E-STOP/LOCKOUT
3011
1
O-2/2.0
2
181
HOUR METER
3421
754
754
RACK 0 GDP
GDP-4
L1
L1
1
2
AI-1/0
1014
I-1/0.1
3
107
PROFIBUS
PORT
1015
I-1/0.2
4
115
24V PS#2
926
O-1/0.1
AUTO SLIDER REV
4202
O-1/0.2
3
4
134
139
BLOWER START
3362
O-2/2.1
LUBE PUMP START
3262
O-2/2.2
3
SPARE
4
3
C
SPARE
4
1016
I-1/0.3
5
114
SLIDER ENABLE O/P
4205
O-1/0.3
5
137
HPU COOLER START
3162
O-2/2.3
5
SPARE
5
1017
I-1/0.4
6
112
BLOWER CT
3369
O-1/0.4
6
132
HPU #1 START
3145
O-2/2.4
6
SPARE
6
1021
1022
753
L+
M
ETHERNET
PORT
L+
1025
7
133
HPU #2 START
3157
O-2/2.5
7
SPARE
I-1/0.6
8
100
TD HPU E-STOP
3119
O-1/0.6
8
138
SLIDER ENABLE
3422
O-2/2.6
8
SPARE
I-1/0.7
9
750
M
1026
120V AC
907
120V AC (N)
925
600
603
L1
N
GND
L+
M
7
C
8
TD LUBE PUMP RUN
3269
102
TD BLOWER RUN
3369
I-1/1.1 13
108
TD HPU OIL LEVEL
3104
103
L1+
754
O-1/0.7
9
HORN
3413
L1+
754
10
O-1/1.0 12
754
136
900
SCR FORWARD
901
SCR REVERSE
9
SPARE
9
10
10
O-2/3.0 12
754
11
O-1/1.1 13
O-2/2.7
Comp +
SPARE
12
AI-1/8
SPARE
13
TD HPU#1 RUN
3150
O-1/1.2 14
902
SCR 40 AMP FIELD
O-2/3.2 14
C
SPARE
754
755
1030
I-1/1.4 16
I-1/1.5 17
104
111
113
I-1/1.6 18
TD LOCKOUT / E-STOP
3035
SCR FIELD LOSS
SPARE
I-1/1.7 19
M
TD HPU#2 RUN
3162
SPARE
20
O-1/1.3 15
903
O-1/1.4 16
SCR 15 AMP FIELD
SPARE
O-1/1.5 17
SPARE
O-1/1.6 18
SPARE
O-1/1.7 19
M
SPARE
20
O-2/3.4 16
SPARE
O-1/3.5 17
SPARE
O-2/3.6 18
SPARE
O-2/3.7 19
M
SPARE
20
14
15
(-)
(+)
16
17
B
18
AI-1/16
19
165A
(+)164B
(-)
10
165B
11
(+)164C
AO-1/4
CH 3
SLIDER TORQUE
LIMIT
3107
CH 0
TD TORQUE SIGNAL
THIRD PARTY 0
CH 1
TD RPM SIGNAL
THIRD PARTY 0
(-)
14
165C
15
(+)164D
CH 2
TD TORQUE SIGNAL
THIRD PARTY 1
3522
149
(-)
(-)
3529
149
AO-1/6
(-)
18
149
23
CH 4
INCLINEOMETER
3107
AO-1/8
165D
(+)
(-)
26
CH 3
TD RPM SIGNAL
THIRD PARTY 1
3529
CH 4
TD TORQUE SIGNAL
THIRD PARTY 2
149
(+)
27
CH 5
SPARE
AO-1/10
(-)
149
(+) 880
AI-1/12
M
AO-1/2
CH 2
SLIDER RPM SP
3107
(-)
(+)
(+)164A
3522
7
149
(+)
AI-1/10
SPARE
O-2/3.3 15
6
CH 1
SPARE
M - ana
11
O-2/3.1 13
(+)
11
L+
SIEMENS 6ES7321-1BH02-0AA0
751
101
I-1/1.0 12
I-1/1.3 15
M
1029
O-1/0.5
I-1/1.2 14
1024
1028
HPU COOLER RUN
3164
AI-1/6
1023
1027
105
SIEMENS 6ES7331-7KF02-0AB0
1020
M
7
SIEMENS 6ES7322-1BH01-0AA0
1019
I-1/0.5
SIEMENS 6ES7322-1HH01-0AA0
SIEMENS 6ES7307-1KA02-0AA0
1018
3
149
(-)
AI-1/4
SIEMENS 6ES7315-2EH14-0AB0
L+
(-)
754
754
1
CH 0
HPU PRESSURE
OPTION
AO-1/0
AI-1/2
752
(+)
SIEMENS 6ES7322-5HF00-0AB0
RACK 0 GDP
1010
(-)
CH 6
SCR TORQUE
FEEDBACK
149
(+) 881
(-)
CH 7
SCR RPM
FEEDBACK
149
20
(+)
(-)
CH 5
TD RPM SIGNAL
THIRD PARTY 2
30
31
AO-1/12
(+) 882
(-)
34
0VDC
35
(+) 883
AO-1/14
(-)
38
M
0VDC
CH 6
SCR
TORQUE LIMIT
REFERENCE
CH 7
SCR
RPM LIMIT
REFERENCE
20
1031
1032
1033
1034
1035
1036
1037
1037
755
755
755
755
755
0 VDC
1132
1001
1002
1003
1004
1005
1006
1007
1008
1009
RACK 0 GDP
1010
GDP-6
1011
#6
1012
1013
L1+
754
24 VDC
1009
21
3
197
WHITE
4844
4
196
RED
4842
1015
5
197
1016
6
198
RED
4843
1017
7
200
WHITE
4849
8
199
RED
4847
1019
9
200
1020
10
201
RED
4848
11
203
WHITE
4854
12
202
RED
4852
13
203
14
204
RED
4853
15
556
WHITE
16
557
RED
RED
1014
CH 0
GRID TEMP 1
1018
CH 1
GRID TEMP 2
SIEMENS 6ES7311-7PF01-0AB0
1021
1022
1023
1024
1025
1026
1027
CH 2
ROOM TEMP
CH 3
HPU TEMP
1028
17
1029
18
557
1030
M
40
1031
1032
1033
1034
1035
1036
1037
1037
0 VDC
1033
755
1700
1701
1702
1703
GDP
1704
TD TB1
1705
1
TB2:1
1707
2
TB2:2
1708
3
TB2:3
1709
4
TB2:4
1710
5
TB2:5
6
TB2:6
7
TB2:7
1714
8
TB2:8
1715
9
TB2:9
1716
10
TB2:10
1706
1711
1712
1713
1717
1718
1719
+VDC
1720
VFD
TD 309TB8
GDP TB2
TD TB2
1
1
+VDC
1721
0VDC
2
1722
801
3
1723
1724
2
800
TO VFD DRIVE
SIG(A)
CHANNEL A
SIG(A\)
11
12
4
5
802
803
MAST J BOX
TD TB2
TD AUX BOX
TD TB2
1
1
RED
CAB 33
BLACK
2
2
3
3
4
4
YELLOW
5
5
YELLOW/WHITE
6
6
7
7
BLUE
8
8
BLUE/WHITE
CHANNEL A
TD ENCODER
CAB 33
1725
6
1726
1727
1728
SIG(B)
CHANNEL B
SIG(B\)
13
7
14
8
1729
1730
804
805
CHANNEL B
9
9
10
10
1731
1733
1734
1735
1736
1737
715A
1732
NOTE:
***VFD TO GDP SHIELDS TO BE GROUNDED AT VFD***
***ISOLATED AT GDP***
***NOTE : GDP TO ENCODER SHIELDS GROUNDED AT GDP / ISOLATED AT TD***
DRILL FLOOR
MAST
SERVICE LOOP
1801
MAST CONTROL J-BOX
1802
GDP
TD 24V S1 / 907
700
TD TB9
1
TOPDRIVE
TD PLC J-BOX
TB71
CAB13 BLACK
1
CAB 43 BLACK
TD R1 13
1 I-0.0
1803
1804
D1 TB30
788
1
363
TD 24V S2 / 908
702
2
WHITE
2
WHITE
366
D2
2
1805
1806
TD RET S1 / 928
1807
TD RET S2 / 929
701
703
TD R1 13
2 I-0.1
3
4
RED
3
GREEN
4
RED
3
GREEN
4
789
24 VDC
5
1808
5
1809
6
ORANGE
TB70 / 516
5
TB70 / 517
6
6
BLUE
7
1810
8
1811
1812
9
7
WHT-BLK
7
WHT-BLK
10
1813
8
RED-BLK
8
RED-BLK
1814
1815
1816
9
10
GRN-BLK
ORN-BLK
9
10G
1817
11
1818
12
1819
1820
1821
1822
1823
1824
1825
1826
1827
1828
1829
1830
1831
1832
1833
1834
1835
1836
1837
1838
GRN-BLK
ORN-BLK
0 VDC
1900
MODULE #1
MODULE #2
MODULE #3
MODULE #4
MODULE #5
MODULE #6
MODULE #7
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
1901
1902
1903
ETHERNET
24V
0V
1
DO1
5
DO2
1
1904
DO1
5
HNDLR ROTATE
FORWARD
Q8.0
1905
320
322
24V
24V
DO2
1
HNDLR ROTATE
REVERSE
Q8.1
DO1
5
HNDLR UNLOCK
Q9.0
STAND JUMP
Q9.1
334
316
24V
24V
DO2
1
DO1
5
IBOP CLOSE
Q10.0
IBOP OPEN
Q10.1
314
312
24V
24V
DO2
1
DO1
5
BUW CLOSE
Q11.0
BUW OPEN
Q11.1
310
308
24V
24V
DO2
1
DO1
5
LINK TILT
EXTEND
Q12.0
326
328
24V
24V
DO2
1
LINK TILT
RETRACT
Q12.1
DO1
5
HYDRAULIC
OIL COOLER
Q13.1
324
332
24V
24V
DO2
1
LINK TILT
FLOAT
Q13.0
5
BRAKE
Q14.0
BRAKE DUMP
Q14.1
304
306
24V
24V
1906
+
1907
+
2
6
2
7
3
6
2
7
3
6
2
7
3
6
2
7
3
6
2
7
3
6
2
7
3
6
2
7
3
6
1908
1909
1910
-
-
3
1911
0V
1912
0V
321
323
PE
PE
0V
0V
335
317
PE
PE
0V
0V
315
313
PE
PE
0V
0V
311
309
PE
PE
0V
0V
327
329
PE
PE
0V
0V
325
333
PE
PE
0V
0V
7
305
307
PE
PE
1913
PE
1914
4
PE
8
4
8
4
8
4
8
4
8
4
8
4
8
4
8
1915
1916
1917
1918
1919
WAGO 750-375
TB30:7
TB30:1
WAGO 753-508
WAGO 753-508
WAGO 753-508
WAGO 753-508
WAGO 753-508
WAGO 753-508
WAGO 753-508
0V
MODULE #8
MODULE #9
MODULE #10
MODULE #11
MODULE #12
MODULE #13
MODULE #14
24V
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
2-DO 24V DC
RACK 1 TOP-DRIVE
16-DI 24V DC
RACK 1 TOP-DRIVE
4-AI 4-20mA
RACK 1 TOP-DRIVE
1920
DI1
DO1
1923
DO2
24V POWER
SUPPLY #2
DO1
DO2
DO1
DO2
DO1
DO2
DO1
363
366
DI3
DI4
DO2
AI1
3
1
5
TANK VENT
Q15.0
1
SPARE
Q15.1
5
1MM MANIFOLD
COLD WEATHER
Q16.0
1
2.5MM MANIFOLD
COLD WEATHER
Q16.1
344
1000
5
ELEVATOR
OPEN
Q17.0
1
ELEVATOR
CLOSE
Q17.1
1002
330
5
SPARE
Q18.0
1
SPARE
Q18.1
5
SPARE
Q19.0
332
352
355
DI5
DI6
5
24V
24V
2
24V
6
24V
2
24V
6
24V
2
24V
6
24V
2
24V
6
WEIGHT
PROX SWITCH
DI7
6
DI8
PURGE PRESSURE
SWITCH
DI9
0V
0V
0V
0V
0V
0V
0V
0V
DI10
10
0V
AI3
SPARE
3
7
3
7
3
7
3
7
3
3
DI11
1001
1003
331
333
PE
4
PE
PE
8
4
PE
PE
8
4
PE
PE
8
4
PE
PE
8
4
409
SPARE
DI13
PE
DI14
13
8
HYDRAULIC
SYS PRESS
12
SPARE
1933
7
SPARE
DI12
11
1932
AI4
SPARE
7
1931
345
6
SPARE
9
0V
M
2
8
7
1929
1934
M
375
1928
1930
SPARE
6
24V
2
5
SPARE
TD HEIGHT
PROX SWITCH
1926
1
PH LOCK
SENSOR
SPARE
Q19.1
AI2
4
AIR PRESSURE
SWITCH (AC ONLY)
1925
1927
2
24V POWER
SUPPLY #1
1922
1924
DI2
1
1921
M
14
SPARE
4
M
8
SPARE
0V
1935
DI15
1936
15
DI16
16
SPARE
1937
1938
1939
1940
1941
WAGO 753-508
WAGO 753-508
WAGO 753-508
WAGO 753-508
WAGO 753-508
SPARE
WAGO 750-1405
WAGO 753-455
MODULE #15
MODULE #16
MODULE #17
MODULE #18
MODULE #19
MODULE #20
MODULE #21
4-AI 4-20mA
RACK 1 TOP-DRIVE
4-AI 4-20mA
RACK 1 TOP-DRIVE
2/4 CHANNEL RTD
RACK 1 TOP-DRIVE
2/4 CHANNEL RTD
RACK 1 TOP-DRIVE
INCREMENTAL ENCODER INTERFACE
RACK 1 TOP-DRIVE
INCREMENTAL ENCODER INTERFACE
RACK 1 TOP-DRIVE
END MODULE
RACK 1 TOP-DRIVE
2000
2001
2002
2003
AI1
AI2
1
2004
AI1
5
HYD RETURN
PRESS
HYD TEMP
2005
411
407
M
M
AI2
1
AI1
5
LUBE OIL
FLOW
401
956
M
M
AI2
1
ELEVATOR
SIGNAL CLOSED
AI1
5
LUBE OIL
TEMP
432
434
M
M
AI2
1
BRAKE
TEMP
A
5
MOTOR
RTD 1
417
423
M
M
A/
1
MOTOR
RTD 3
24V
5
0V
1
A
5
A/
1
PIPE HANDLER
ENCODER
24V
5
1
0V
5
TOP DRIVE
MOTOR RPM PROX
440
441
B
B/
346
347
N1
N2
2006
2007
6
2
6
2
6
2
2008
431
435
AI3
AI4
6
2
418
424
AI3
AI4
6
2
3
7
3
4
8
4
2
442
B
B/
N1
6
2
6
2
7
3
7
3
8
4
8
4
N2
6
443
2009
2010
2011
AI3
AI4
3
AI3
7
LUBE PRESS
AFTER FILTER
LUBE PRESS
B4 FILTER
2012
405
403
M
M
AI4
3
7
SPARE
3
SPARE
7
AMBIENT
TEMP
3
SPARE
LTCH GATE
7
MOTOR
RTD 2
LTCH GATE
7
SPARE
429
420
2013
2014
2015
4
M
8
0V
4
M
M
8
M
M
8
4
M
REF
8
4
SHLD
REF
SHLD
8
0V
428
421
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
2032
2033
2034
2035
2036
2037
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
(DC Only)
24V
24V
0V
0V
2101
2102
OPERATOR INTERFACE PANEL
2103
2104
2105
2106
2107
2108
SIEMENS HMI
SIMATIC PANEL PC
IPC 677C
2109
2110
2111
2112
2113
ETHERNET
2114
2115
2116
2117
2118
2119
2120
ETHERNET / 1005
ETHERNET / 1005
2121
2122
2123
2124
2125
2126
120V AC (L)
2127
120V AC (N)
2128
2129
2130
2131
2132
2133
2134
2135
2136
2137
2138
PROFI_BUS
CDL
DB15
L
N
G
2200
MODULE #1
MODULE #2
MODULE #3
MODULE #4
MODULE #5
MODULE #6
16-DI 24V DC
RACK 3 CONSOLE
16-DI 24V DC
RACK 3 CONSOLE
16-DI 24V DC
RACK 3 CONSOLE
4-DO 24VDC
RACK 3 CONSOLE
4-DO 24VDC
RACK 3 CONSOLE
4-DO 24VDC
RACK 3 CONSOLE
1
2201
24V
3213
3211
3
4
4
SLIDER
REVERSE
I4.1
8705
8706
4
DO1
4
5
2206
3
6
5
6
2
6
2208
3105
3104
7
8
7
8
TD IBOP OPEN
I2.7
2209
3100
3216
9
10
9
-
3
7
2212
3114
3117
11
12
11
PE
PE
13
14
13
8
2215
2216
3113
3116
15
16
15
12
24V
3206
3207
13
14
2
7
3
6
2
0V
7
3
0V
13
DO3
14
SPARE
I5.4
SPARE
I5.5
HNDLR BYP PL
Q4.2
15
16
DO3
8
3402
16
DO4
4
HPU ALARM PL
Q4.3
3301
LUBE OIL PL
Q5.2
DO4
4
3302
SPARE
I5.6
MODULE #8
MODULE #9
MODULE #10
MODULE #11
4-DO 24VDC
RACK 3 CONSOLE
4-AO 0-10V DC
RACK 3 CONSOLE
4-AO 0-10V DC
RACK 3 CONSOLE
4-AI 4-20mA
RACK 3 CONSOLE
END MODULE
RACK 3 CONSOLE
2222
AO1
SPARE
Q20.0
AO2
SPARE
Q20.1
AO1
5
RPM OUTPUT
PQW272
AO2
1
RPM SETPOINT
PQW274
AI1
5
RPM OUTPUT
3RD PARTY
PQW280
AI2
1
RPM OUTPUT
3RD PARTY
PQW282
3700+ 3701+
5
SLIDER
RPM SETPOINT
PIW288
SLIDER
TORQUE SETPOINT
PIW290
3600+ 3602+
8700
8702
M
M
2225
2226
24V
24V
2
2227
M
6
M
2
2228
M
6
M
2
3700- 3701-
6
2
3600- 3602+
6
8702
8704
AI3
AI4
2229
0V
2230
0V
3
AO3
AO4
3
7
2231
AO3
AO4
3
7
3
7
TORQUE OUTPUT
TORQUE SETPOINT
3RD PARTY
PQW278
PQW284
TORQUE OUTPUT
PQW276
TORQUE OUTPUT
3RD PARTY
PQW286
3702+ 3703+
7
SPARE
PIW292
SPARE
PIW294
3601+ 3603+
2232
2233
2234
DO3
SPARE
Q20.2
4
DO4
M
8
2235
SPARE
Q20.3
M
4
M
8
0V
M
4
M
8
0V
4
M
8
0V
3702- 3703-
3601- 3603-
WAGO 750-559
WAGO 750-559
2236
2237
2238
2239
2240
2241
WAGO 750-504
8
SPARE
I5.7
MODULE #7
1
DO4
3303
0V
5
4
16
24V
DO2
SPARE
Q6.2
16
15
2221
2224
MOTOR TEMP PL
Q5.3
WAGO 750-504
DO1
7
DO3
8
WAGO 750-504
1
0V
I5.3
14
WAGO 750-1405
2223
6
SPARE
3550 3551
WAGO 750-1405
2220
24V
0V
3204 3101
WAGO 750-1405
WAGO 750-375
24V
12
SPARE
I5.2
13
ELEVATOR
CLOSE
I5.7
24V
3650
12
I5.3
ELEVATOR
OPEN
I5.6
24V
ELEVATOR
CLOSED
Q6.1
3403
I5.1
14
15
6
0V
3
11
SPARE
I5.5
3500
SPARE
11
LIMIT INC
I5.4
3401
5
BRAKE PL
Q6.0
10
I5.1
LIMIT DEC
15
TD BRAKE
I3.7
24V
IBOP CLOSE PL
Q5.1
10
SPARE
I5.0
12
13
16
3300
2
3210
STANDJUMP
I3.6
2217
3205
11
11
HNDLR UNLOCK
JOYSTICK 2 - UP
I3.5
3400
HPU ON PL
Q5.0
SPARE
I4.7
9
TORQUE LIMIT
I5.2
14
DRILL ENABLED PL
Q4.1
0V
3106
DO2
1
8
9
RPM LIMIT
I3.3
HNDLR CW
JOYSTICK 2 RT
I3.4
10
8
SPARE
I4.6
10
I3.1
HNDLR CCW
JOYSTICK 2 - LT
3112
9
REV / FWD
SWITCH 7 - LT
I5.0
12
3115
3102
DO1
5
SPARE
I4.5
7
SPIN-IN / ZERO
JOYSTICK - LT
I4.7
3103
9
LINK TILT FLOAT
JOYSTICK 3 - RT
LINK TIL RET
JOYSTICK 3 - DN
I3.2
2213
SPIN-OUT / PRE
JOYSTICK - RT
I4.6
10
LINK TILT EXT
JOYSTICK 3 - UP
I3.0
8
DO2
1
6
SPARE
I4.4
7
7
DO1
5
ALARM PL
Q4.0
6
5
MK-UP / INC
JOYSTICK - UP
I4.5
3202
IBOP CLOSE
I2.6
5
6
BRK-OUT / DEC
JOYSTICK - DN
I4.4
8
SPARE
I4.3
6
3201
7
-
DO2
4
SPARE
I4.2
3107
5
HPU2 START
I2.5
+
BUW CLOSE
I4.3
3111
HPU1 START
I2.4
+
TORQUE / DRILL
I4.2
3203
5
2219
3
2
1
2205
4
3214
3
HNDLR BYPASS
I2.3
3200
2214
TRIP ENABLED
I4.1
3215
2
1
SLIDER
FORWARD
I4.0
3404
5
2204
2211
DRILL ENABLED
I4.0
3404
4
ALARM RESET
I2.2
2210
1
2
0V
3
2207
2
1
PRESSURE SW
I2.1
ETHERNET
1
2218
1
2
E-STOP
I2.0
2202
2203
2
1
WAGO 750-455
WAGO 750-600
WAGO 750-504
SPARE
Q6.3
2400
2401
2402
2403
2404
2405
2406
2407
2408
2409
2410
2411
2412
2413
2414
2415
2417
2418
2419
2420
2421
2442
DC R3 M4
O-0.1
5
3300
3300
DRILL ENABLED PL
G
0010
O-0.3
8
3301
3301
A
2445
0010
2446
2447
DC R3 M5
O-0.2
4
3302
3302
LUBE OIL PL
A
0010
8
A
0010
2449
3303
3303
MOTOR TEMP PL
2450
2451
DC R3 M4
O-0.0
1
3400
3400
ALARM PL
R
0010
2452
2453
DC R3 M5
O-0.0
1
3401
3401
HPU ON PL
R
0011
4
3402
3402
HANDLER BYPASS PL
R
0011
TB40:18 3035
1
2458
3403
3403
TD BRAKE PL
R
0011
2459
2460
DC R3 M5
5
2456
3500
3500
IBOP CLOSED PL
R
0011
2423
O-0.1
WHITE
3700-
BLACK
3701+
WHITE
3701-
BLACK
3701+
WHITE
3701-
BLACK
3700+
WHITE
3700-
BLACK
F5
WHITE
0005
BLACK
F5
WHITE
0006
BLACK
A
RPM OUTPUT
2211
Channel 0
RPM ANALOG
DC R3 M8
O-7/0-
2
B
RPM OUTPUT
2212
RPM DIGITAL
DC R3 M8
O-7/2+
5
A
RPM SETPOINT
2214
Channel 1
RPM DIGITAL
DC R3 M8
O-7/2-
6
B
RPM SETPOINT
2216
5
ELEV CLOSED PL
TORQUE ANALOG
DC R3 M8
O-7/4+
3
A
TORQUE OUTPUT
2218
Channel 2
TORQUE ANALOG
DC R3 M8
O-7/4-
4
B
TORQUE OUTPUT
2220
2461
2462
DC R3 M6
2422
3700+
2454
2457
DC R3 M6
O-0.1
1
2455
DC R3 M4
O-0.0
O-7/0+
2448
DC R3 M5
O-0.3
2443
2444
HPU ALARM PL
RPM ANALOG
DC R3 M8
3005
DC R3 M4
O-0.2
2416
2441
CONSOLE - TD MOTOR CONTROL JS
3650
3650
R
0011
2463
2464
2424
2465
2425
2466
2426
2467
2427
2468
2428
2469
2429
2470
2430
2471
2431
2472
2432
2473
2433
2474
2434
2475
2435
2476
2436
2477
2437
2478
TORQUE SETPOINT
DC R3 M8
O-7/6+
7
A
TORQUE SETPOINT
2222
Channel 3
TORQUE SETPOINT
DC R3 M7
O-7/6-
8
B
TORQUE SETPOINT
2224
RPM GAUGE
24V
3032
OV
3037
24V
3032
OV
3037
A
B
TORQUE GAUGE
A
B
CONSOLE - 3RD PARTY RPM / TORQUE
DC R3 M9
O-7/0+
1
3600+
BLACK
4-20mA RPM
ISOLATOR 1
1
RPM OUTPUT 0-10VDC
Channel 0
DC R3 M9
O-7/0-
2
3600-
BLACK
2
RPM OUTPUT 0-10VDC
4-20mA TRQ
ISOLATOR 2
DC R3 M9
O-7/0+
3
3601+
BLACK
1
TRQ OUTPUT 0-10VDC
Channel 2
DC R3 M9
O-7/0-
4
3601-
BLACK
2
TRQ OUTPUT 0-10VDC
4-20mA TRQ
ISOLATOR 1
24V
24V
OV
0V
F6
BLACK
0V
BLACK
7
8
4-20mA
ISOLATOR 2
24V
24V
OV
0V
F6
BLACK
0V
BLACK
4-20mA RPM
ISOLATOR 1
3
4
5
6
7
8
3RD PARTY
TB
640
BLACK
+
641
BLACK
-
642
BLACK
+
643
BLACK
-
644
BLACK
+
645
BLACK
-
646
BLACK
+
647
BLACK
-
1
2
3
4
4-20mA TRQ
ISOLATOR 2
3
4
5
6
5
6
7
8
3000
OPTIONAL
GDP
3001
DRIVE LOCKOUT
RL12
705
GDP PLC M0
O-0.0
3002
2
135
A1
1025 E-STOP / L.O. SIGNAL
3162
A2
24VDC
3003
CONSOLE
3004
3005
TD TB11
732
516
3006
1
TB23:4 / 935
734A
A2
LOCKOUT RELAY
RL3
TB23:7 / 933
901
901
3014
3017
901
A2
2
WHITE
2
2
3
4
205
111A
111
CP
3
4
CP
1
2 1
206
744
4
742
3
RED
3213
3
1
1
2
2 1
2
TOP DRIVE LOCK-OUT
PB1
740
1
2
3
4
I-2.0
TD LOCKOUT/E-STOP
744
GDP PLC M1
I-1/1.4
901
1025
16
111
E-STOP / L.O. SIGNAL
0V DC
TB23:6 / 931
711
24V DC
TB22:1 / 912
712
4
GREEN
4
5
ORANGE
5
AC ONLY
6
BLUE
6
FAULT RELAY
CR2A
7
WHITE/BLACK
7
8
RED/BLACK
8
9
GREEN/BLACK
9
3018
3019
3020
3021
A1+
A2-
0001
740
740
3022
3023
TD TB12
3
850
11
3024
4
851
14
10G
ORANGE/BLACK
10G
3025
3026
3027
1F
3028
2F
2A FUSE
F1
2A FUSE
F2
2A FUSE
F3
2A FUSE
F4
2A FUSE
F5
2A FUSE
F6
PLC 24V
2216
ETHERNET
3029
3030
3031
3032
3033
3034
3035
3036
3037
3F
4F
5F
6F
0V DC
17
18
19
20
0002
0010
0011
0034
0035
0036
0037
3005
INPUT 24V
3531
INPUT 24V
3402
GUAGE 24V
2470,2474
SPARE
PLC 0V
2218
21
2413
22
2225
23
2225
2225
2225
0038
0039
0040
R
E-STOP LIGHT
3033
PB2
TD TB14
DC R3 M1
A1
1
734
24VDC
CP 33 34 43 44
3013
3
713
CP 13 14 23 24
3012
3016
1
A1
TD TB14
3010
3015
BLACK
734
SCR E-Stop
RL1
705B
3009
3011
CAB 32
0010
732
DC ONLY
3007
3008
E-STOP
PB2
TB40
RPM METER 0V
3571
TORQUE METER 0V
3575
ETHERNET SWITCH 0V
3575
0010
2402
3034
GDP
3100
3101
3102
TD TB 10
708
+24VDC TB22:5F / 910
3105
1
TB1
CAB 82
BLK
RED
1
RL5
HPU
E-STOP
705
3153
A2
100A
A1
2
WHT
I-0.6
8
3145
2
3147
RED
BLUE
3
3108
GDP PLC M1
I-1.0
13
108
4
GREEN
BLK
4
5
3112
6
ORANGE
HPU OIL LEVEL
FS1
5
BLUE
6
7
7
HPU OIL TEMP
WHT
RED
RED
GDP PLC
15
HPU TEMP
557
16
M6
3116
8
RED-BLK
8
18
557
3117
9
3118
10
3119
GRN-BLK
14
11
4
3
132
O -0.4
HPU1
BREAKER
710
24 Vdc TB22:6F / 912
3120
103
103
13
34
3151
RL3
LOCKOUT
RELAY
903
24 Vdc TB22:17 / 920
14
RL7
HPU2
RELAY
RL7 A2 / 3153
GDP PLC M1
14
I -1.2
905
44
24
23
11
905A
GDP PLC M2
7
HPU2 START
133
O -0.5
A1
1014
705
705
RL6 A2 / 3146
714
HPU1
STARTER
RL8 A2 / 3363
714A
33
104
104
13
34
14
GDP PLC M1
15
I -1.3
3160
RL11
HPU COOLER
RELAY
905
24 Vdc 3152
11
5
137
O -0.3
A1
1013
HPU COOLER
BREAKER
710
24 Vdc TB22:6F / 912
A2
705E
A1
3166
TD PLC J-BOX
3126
3127
705
705
RL10 A2 / 1736
HPU COOLER
STARTER
ISO 1 A
105
105
13
34
14
GDP PLC M1
7
I -0.5
3128
3131
+
408 BROWN 24V
TB30:3
PT1
+
BLK
409
410 RED 24V
3136
3137
7
SIGNAL -
TD R1 M15 CH0
PT1
+
BLK
411
412 RED 24V
TB30:3
GND1
GND
T1
L2
T2
L2
T2
T2
3168
L3
T3
L3
T3
T3
L1
T1
L1
T1
T1
L2
T2
L2
T2
T2
L3
T3
L3
T3
T3
T1
L1
T1
THERMAL TRIP: 25A
MAGNETIC TRIP: 400A
3171
MTR5
1
SIGNAL -
3174
3177
3178
L1
MTR6
M
THERMAL TRIP: 25A
MAGNETIC TRIP: 400A
3175
3176
HPU1
20 HP
1760 RPM
19.3 A - 575V
CAB 20
3173
GND
-
T1
3167
3172
TB30:3
GND1
HYDRAULIC
RETURN
PRESSURE
L1
3170
TD R1 M14 CH3
HYDRAULIC
SYSTEM
PRESSURE
CAB 19
T1
L1
3169
3133
3135
SIGNAL -
GND
3132
3134
5
GND1
3129
3130
PT1
WHITE
407
-
HPU COOLER STATUS
1018
M
TD R1 M15 CH1
HYDRAULIC
TEMPERATURE
0 Vdc TB23:2 / 935
A2
RL11
710E
33
HPU COOLER
STARTER
910
14
GDP PLC M2
HPU COOLER START
3165
TOPDRIVE
HPU2 RUNNING STATUS
1017
MCC BUS
3125
0 Vdc TB23:2 / 931
A2
RL7
HPU2
BREAKER
24 Vdc TB22:8F / 914
A2
705B
A1
14
3157
3164
3124
HPU1 RUNNING STATUS
HPU2
STARTER
3160
3155
3156
RL5
HPU E-STOP
RELAY
904
43
3163
3123
TB23:3 / 930
1016
3150
3162
3122
0 Vdc TB23:2 / 931
A2
705
705
HPU1
STARTER
710A
33
3161
3121
A2
705A
A1
RL6
3159
10
902A
14
A1
3158
9
ORG-BLK
13
1013
3154
3114
902
34
HPU1
STARTER
3149
3153
6
WHT-BLK
RL6
HPU1
RELAY
GDP PLC M2
HPU1 START
3152
3113
556
901
33
3148
LEVEL SWITCH OPENS
ON LOW LEVEL
1021
3111
3115
900
24 Vdc TB22:17 / 920
RL5
HPU E-STOP
RELAY
3144
100
3
HPU LEVEL
SWITCH
RL3
LOCKOUT
RELAY
3146
1013
3107
3110
3143
GDP PLC M1
HPU E-STOP
GDP PANEL
3142
E-STOP
PB1
705
TB23:2 / 931
3106
3109
3141
BLK
3103
3104
HPU
HPU J-BOX
HPU2
20 HP
1760 RPM
19.3 A - 575V
M
L2
T1
L1
T1
L3
T1
L1
T1
HPU COOLER
2 HP
1750 RPM
2.7 Amp
3200
3241
3201
3242
TOP DRIVE
3202
3203
GEARCASE
3244
JBOX
3204
3245
TD R1 M17 CH 0
3205
3206
3243
WHT
WHT
CAB 76 432
LUBE OIL
TEMP
3207
RED
431
RED
433
RED
RTD7
1
MEAS LEAD (-)
2
MEAS LEAD (+)
3208
3246
3247
3248
3249
3209
LUBE OIL
TEMP
3250
3210
3251
3211
3252
3212
3253
3213
3254
TOPDRIVE
3214
3255
3215
3256
TD R1 M16 CH0
3216
3217
3218
LUBE OIL
FLOW
PT1
+
BLK
401
402 RED 24V
3221
3222
TB30:4
GND
TD R1 M15 CH3
LUBE PRESS
PT2
BEFORE
+
FILTER
BLK
403
404 RED 24V
3225
3226
7
SIGNAL -
TD R1 M15 CH2
406 RED 24V
BLK
TB30:4
GND3
GND
3260
RL3
L.O. AUX.
BLOCK
3
SIGNAL -
906
24 Vdc TB20:18 / 920
907
53
54
RL9
LUBE
RELAY
907
LUBE PUMP
STARTER
705D
907A
11
A1
14
A2
0 Vdc / TB23:3 936
3261
3263
GND
LUBE PRESS
PT3
AFTER
+
FILTER
GDP PANEL
3262
TB30:4
GND2
405
3257
3259
GND1
3223
3224
SIGNAL -
3258
3219
3220
1
GDP PLC M2
LUBE START
3265
3267
3227
3268
3228
3269
3229
3270
3230
3271
3231
3272
3232
3273
3233
3274
3234
3275
3235
3276
3236
3277
3237
3278
O-2/0.2
139
A1
RL8 / 3363
RL10/ 1736
RL9
LUBE PUMP
BREAKER
24 V TB22:10F / 914
A2 705
705
1020
3264
3266
4
718
718A
33
34
LUBE PUMP
STARTER
718A
11
101
14
GDP PLC M1
9
I-1/0.7
1014
LUBE RUNNING STATUS
3300
3341
3301
3342
3302
3343
3303
3344
3304
3345
3305
3346
3306
3347
3307
3348
3308
3349
OPTIONAL (SCR)
3309
3310
3350
FOR A DIFFERENTIAL
PRESSURE SWITCH SET AT 4.5" OF
WATER DECREASING
FOR A PRESSURE SWITCH SET AT
6" OF WATER DECREASING
TOPDRIVE
3311
3312
3313
3314
3315
3316
3317
T.D LOW AIR PURGE
PS2
3
TD R1 M13
352
4
351
PLC J-BOX
WHITE
3
I-0.2
3351
3352
3353
3354
3355
BLACK
SWITCH OPENS ON
LOW PRESSURE
3356
24V
T.D AIR PRESSURE PS
3357
GDP PANEL
3358
3318
3359
3319
3360
3320
3361
3321
3362
3322
3363
3323
3364
3324
3365
3325
3366
3326
3367
3327
3368
3328
3369
RL3
L.O. AUX.
BLOCK
908
24 Vdc TB20:19 / 918
GDP PLC M2
BLOWER START
909
63
3
O-0.1
RL8
BLOWER
RELAY
909
64
3370
3330
3371
3331
3372
3332
3373
3333
3374
3334
3375
3335
3376
3336
3377
3337
3378
A2
A2 705
RL9 A2 / 3263
RL8
BLOWER
BREAKER
720
720A
33
BLOWER
STARTER
720A
102
13
34
14
0 Vdc / TB23:4 / 935
RL7 A2 / 3154
705
GDP PLC M1
12
I-1.0
BLOWER RUNNING STATUS
1015
BLOWER
CT RELAY
720
112
1
3329
A1
14
A1
1015
24 Vdc TB22:11 / 915
705C
909A
11
134
BLOWER
STARTER
2
GDP PLC M1
6
I-0.4
1026
BLOWER CT RELAY STATUS
3400
CONSOLE
3401
3402
OFF
3031
3441
SW4
TRIP
3442
DRILL
DC R3 M2
3214
F4
3214
3403
3404
2
TRIP
3543
1922
3444
DC R3 M2
3215
F4
3443
I-0.1
3215
1
3445
I-0.0
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
3421
3422
3461
PLC_GDP_M3
O - 0.0
1013
2
181
HOUR METER
621
A1
A2
HOUR METER
HM A2 / 932
3462
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
3519
F4
F4
1
JS1-LEFT
3 3102
DC R3 M2
3102
8
I-4.7
3404
SPIN-IN / DRILL ZERO
F4
1
JS1-RIGHT
3 3103
3513
F4
1
DC R3 M1
3 3204
3204
8
DC R3 M2
3103
7
I-4.6
SPIN-OUT / PRESET
JS1-UP
F4
1
3 3104
DC R3 M2
3104
6
I-4.5
MAKE-UP / INCREASE
F4
F4
JS1-DOWN
1
3 3105
GDP
DC R3 M2
3105
5
I-4.4
BREAK-OUT / DECREASE
SW7-LEFT
DC R3 M2
4247
F4
F4
3106
3106
9
I-5.0
DRILL REV / FWD
F4
SW 5
DC R3 M2
3544
4242
F4
F4
3107
3107
4
O-0+
3
164A
1
TO DRILLING / MUDLOGGER
RECORDER
RIG
MUDLOGGER +
TORQUE
Channel 0
I-4.3
BUW CLOSE
F4
TD TB 13
GDP PLC M5
GDP PLC M5
O-0 -
6
165A
2
TORQUE
MUDLOGGER SUPPLIED BY CUSTOMER
SW 7
DC R3 M2
F4
3502
F4
3111
3111
3
I-4.2
TORQUE / DRILL
F4
TD TB 13
GDP PLC M5
O-2+
7
164B
3
RECORDER / MUDLOGGER
RIG
MUDLOGGER +
RPM
Channel 1
GDP PLC M5
O-2 -
SW 7
DC R3 M2
F4
F4
3205
3205
10
10
165B
4
RPM
SUPPLIED BY CUSTOMER
I-5.1
DC R3 M2
F4
MUDLOGGER -
RPM LIMIT SELECT
221
SW 7
3206
3206
11
I-5.2
TORQUE LIMIT SELECT
SW 7
TD TB 13
GDP PLC M5
O-4+
11
164C
5
TO DRILLING / MUDLOGGER
RECORDER
RIG
MUDLOGGER +
TORQUE
DC R3 M2
F4
3207
3207
12
I-5.3
LIMIT DECREASE
SW 7
DC R3 M2
F4
3208
3208
13
Channel 2
GDP PLC M5
O-4 -
14
165C
6
TORQUE
MUDLOGGER SUPPLIED BY CUSTOMER
I-5.4
LIMIT INCREASE
SW X
DC R3 M1
3028
F3
F3
3200
3200
3
I-2.2
ALARM RESET
SW 7
TD TB 13
GDP PLC M5
O-6+
15
164D
7
RECORDER / MUDLOGGER
3201
3201
5
I-2.4
HPU1 START
SW 7
DC R3 M1
4000
F3
F3
3202
3202
6
I-2.5
HPU2 START
RIG
MUDLOGGER +
RPM
DC R3 M1
F3
Channel 3
GDP PLC M5
O-6 -
RPM
18
165D
I-3.6
STANDJUMP
2212
F4
8
MUDLOGGER SUPPLIED BY CUSTOMER
CONSOLE
3900
3901
3902
3941
BUW
CLOSED
R3
MOD7 DO/1
877
A1+
3903
3942
0VDC
TB 23
A2-
3943
3944
3904
3945
11
3905
3906
14
3946
3947
DRY CONTACTS
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
3926
3927
3928
3929
3966
TOPDRIVE
PLC J-BOX
3967
BUW GRIPPER OPEN
SOL10A
TD R1 M4
O-0.1
5
O-0.1
7
308
309
CAB 54 BLACK
2-H
+
-
WHITE
3971
BUW GRIPPER CLOSE
SOL10B
3931
3933
3969
3970
GREEN
3930
3932
3968
O-0.0
1
O-0.0
3
310
311
CAB 55 BLACK
WHITE
GREEN
2-H
+
-
3972
3973
3974
3934
3975
3935
3976
3936
3977
3937
3978
4000
4001
CONSOLE - TD PIPE HANDLER CONTROL JOYSTICK
JS2-LEFT
3536
F3
3112
12
I-1.3
JS2-RIGHT
3113
3113
13
JS2-UP
4005
3116
3116
14
JS3-UP
4302
3114
S1-1
4009
3114
9
S1-2
3115
3115
11
S2-2
4011
F3
3117
3117
DC R3 M1
4053
DC R3 M1
F3
3203
3203
4018
4
I-0.3
4
I-0.3
4019
TB30:9
4020
TB30:3
356
0V
354
24V
4023
4064
4025
HANDLER UNLOCK
4026
O-0.0
3
HANDLER UNLOCK
SOL02B
2-H
+
-
CAB 53 BLACK
335
WHITE
4067
GREEN
4068
4028
4029
4030
TD R1 M1
HANDLER ROTATE FORWARD
4031
O-0.0
1
O-0.0
3
320
321
4033
4035
4036
4037
CAB 60 BLACK
2-H
-
+
WHITE
TD R1 M1
HANDLER ROTATE REVERSE
O-0.1
O-0.1
5
7
322
CAB 61 BLACK
323
WHITE
GREEN
4070
4071
4072
GREEN
4032
4034
4066
4069
HANDLER ROTATE FORWARD
SOL09A
4073
HANDLER ROTATE REVERSE
SOL09B
2-H
+
-
YEL/WHT
442
BLU
443
BLU/WHT
A
/A
2
6
B
ENCODER
/B
Z
/Z
8
13G
GND
+
A
/A
B
/B
4065
334
4027
441
4062
4063
1
5
YEL
4059
4022
O-0.0
I-5
SHIELD
4061
TD R1 M2
1
TD R1 M18A
4055
BRWN
BLU
4024
I-5
TD R1 M18B
4060
BLK
4021
0V
440
4058
HANDLER LOCK SENSOR
PROX2
355
-
-
TOP DRIVE
TD R1 M13
1024 PPR
+ DUAL OUTPUT
4057
PLC J-BOX
HANDLER LOCK STATUS
RED
BLK
347
TD R1 M18A
4054
4056
HANDLER BYPASS
4016
CAB 74
I-1.1
LT FLOAT
4014
346
4051
4052
4013
4017
4050
I-1.2
10
5
4049
LT RETRACT
JS3 - RIGHT
I-5
I-5
I-1.0
DC R3 M1
F3
S2-1
4048
LT EXTEND
JS3-DOWN
1
I-5
DC R3 M1
F3
I-5
4047
UNLOCK
4007
PIPE HANDLER ENCODER
24V
TD R1 M18B
4046
I-1.5
4006
4015
4045
DC R3 M1
F3
PLC J-BOX
4044
I-1.4
PH RIGHT
4004
4012
4043
DC R3 M1
F3
4003
4010
4042
PH LEFT
4002
4008
4041
DC R3 M1
3112
4074
4075
4076
4077
4078
Z
/Z
4100
4101
4102
4103
CONSOLE
CONSOLE - TD PIPE HANDLER CONTROL JS
4104
4105
4106
JS3-UP
F3
4302
1
3
DC R3 M1
3114
3114
4108
F3
1
JS3-DOWN
3
F3
1
JS1-RIGHT
3
4111
3115
4113
4114
4115
4116
4117
TOPDRIVE
PLC J-BOX
TD R1 M5
4120
O-0.1
5
4121
0V DC
7
4124
4125
4126
4127
4130
4131
4132
4133
4134
4135
4136
4137
328
329
LINK TILT RETRACT
CAB 64 BLACK
LINK TILT RETRACT
SOL03B
2-H
+
WHITE
GREEN
LINK TILT EXTEND
TD R1 M5
O-0.1
1
326
CAB 63 BLACK
0V DC
3
327
WHITE
LINK TILT EXTEND
SOL03A
2-H
+
GREEN
LINK TILT FLOAT
TD R1 M6
O-0.0
1
0V DC
3
4128
4129
11
I-3.2
11
14
DRY CONTACTS
DC R3 M1
3117
3117
10
I-3.1
LINK TILT FLOAT
4112
4123
A2-
LINK TILT RETRACT
4110
4122
A1+
DC R3 M1
3115
4109
4119
I-3.0
MOD7 DO/4
LINK TILT EXTEND
4107
4118
9
R3
LINK TILT
FLOAT ENGAGED
879
0VDC
LINK TILT FLOAT
324
CAB 62 BLACK
325
WHITE
GREEN
SOL04A
2-H
+
CONSOLE
CONSOLE
4200
4241
4201
4242
4202
4243
4203
4244
4204
4245
4205
4246
4206
4247
4207
4248
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
4223
4264
4224
4265
4225
4266
4226
4267
4227
4268
4228
4269
4229
4270
4230
4271
4231
4272
4232
4273
4233
4274
4234
4275
4235
4276
4236
4277
4237
4278
F3
3514
IBOP CONTROL VALVE
SW3
DC R3 M1
CLOSE
OPEN
A1
3216
A2
8
I-2.7
IBOP OPEN SW
DC R3 M1
F3
3511
3100
B1
B2
TD R1 M3
5
O-0.2
7
0V DC
IBOP CONTROL VALVE
OPEN
SOLENOID "A"
312
313
CAB 56 BLACK
(OPTIONAL)
2-H
+
-
WHITE
GREEN
IBOP OPEN
IBOP CONTROL VALVE
CLOSE
SOLENOID "B"
O-0.3
0V DC
IBOP CLOSE
1
314
CAB 57 BLACK
3
315
WHITE
GREEN
I-2.6
IBOP CLOSE SW
TOPDRIVE
PLC J-BOX
7
2-H
+
-
(OPTIONAL)
4300
CONSOLE
TOP DRIVE BRAKE
SW8
OFF
ON
4301
4302
4303
DC R3 M1
F3
4008
3101
1
2
4304
4305
4306
4307
4308
4309
4310
TOPDRIVE
4311
4312
PLC J-BOX
4313
4314
TOP DRIVE BRAKE
TD R1 M7
SOL01B
1
O-0.0
BLACK
304
2-H
+
4315
4316
4317
3
0V DC
-
WHITE
305
TOP DRIVE BRAKE
GREEN
4318
4319
4320
4321
TOP DRIVE BRAKE DUMP
TD R1 M7
O-1/0.3
SOL01C
5
BLACK
306
2-H
+
4322
4323
4324
7
0V DC
-
WHITE
307
TOP DRIVE BRAKE
DUMP VALVE
GREEN
4325
4326
4327
4328
TD R1 M17
MEAS LEAD (-)
6
CAB 78
WHT
434
BRAKE
TEMP
4329
4330
4331
4332
4333
4334
4335
4336
4337
16
I-3.7
T.D BRAKE SW
MEAS LEAD (+)
BRAKE
TEMP
5
RED
435
4800
4801
4841
PLC J-BOX
MOTOR AC 5GEB20
4802
4803
4804
4805
4843
+AI 1
1
417
WHT
TD R1 M18 CH0
2
4844
WHT
TD R1 M18 CH0
-AI 1
418
RED
A
RTD
4806
4808
4809
WHT
4810
RED
4849
SPARE
RTD
4811
+AI 3
3
WHT
TD R1 M18 CH1
-AI 3
4
4854
420
421
RED
B
RTD2
4859
WHT
4819
RED
4820
SPARE
RTD
4860
4861
4821
4862
+AI 2
5
423
WHT
TD R1 M18 CH2
-AI 2
6
4863
WHT
TD R1 M18 CH2
424
RED
C
RTD2
4825
4864
4865
4866
4826
4827
4856
4858
WHT
4818
4824
4855
4857
4817
4823
4851
4853
WHT
TD R1 M18 CH1
4816
4822
4850
4852
4812
4815
4846
4848
WHT
4814
4845
4847
4807
4813
4842
4867
WHT
4828
WHT
4829
RED
4868
SPARE
RTD
4869
4870
4830
4871
4831
4872
4832
4873
4833
4874
4834
4875
4835
4876
4836
4877
4837
4878
CONSOLE
4200
4201
4241
TOPDRIVE
4242
F3
ELEVATOR CONTROL VALVE
SW
A1
4202
15
I-5.6
ELEVATOR OPEN SW
4244
WEIGHT SENSOR
LIMIT SWITCH
TD R1 M13
WEIGHT SENSOR SW
I-0.5
6
375
4205
GND
376
4206
TB30:4
374
GND
24V
BLU
BLK
4245
4246
DC R3 M2
4247
F3
3551
B1
4207
3550
A2
4243
4203
4204
DC R3 M2
CLOSE
OPEN
GRN
B2
4248
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
4223
4264
4224
4265
4225
4266
4226
4267
4227
4268
4228
4269
4229
4270
4230
4271
4231
4272
4232
4273
4233
4274
4234
4275
4235
4276
4236
4277
4237
4278
TOPDRIVE
PLC J-BOX
TD R1 M10
O-17.0 1
0V DC
3
ELEVATOR CONTROL VALVE
OPEN
SOLENOID "A"
330
331
ELEVATOR OPEN
BLACK
WHITE
GREEN
16
I-5.7
ELEVATOR CLOSE SW
2-H
+
(OPTIONAL)
-
2000
2001
2002
2003
2004
MODULE #1
MODULE #2
MODULE #3
MODULE #4
MODULE #5
16-DI 24V DC
RACK 4 CONSOLE
4-DO 24VDC
RACK 4 CONSOLE
4-AI 4-20mA
RACK 4 CONSOLE
INCREMENTAL ENCODER INTERFACE
RACK 4 CONSOLE
END MODULE
RACK 4 CONSOLE
1
2005
2006
2007
2
1
2
MUD PUMP
RUN STATUS
DW ANTI COLLISON
PROX SW
ETHERNET
24V
3750
3751
3
4
0V
DO1
3
1
5
2008
2009
DO2
AI1
AI2
A
A/
24V
0V
4
TD CALIBRATION
SW
UPPER LIMIT
OVER RIDE
3752
3753
5
6
1
5
ANTI COLLISION
RELAY
1
CUT AND SLIP
5
1
LT BAILS
INCLINOMETER
5
5
955
950
5
1
DRAWORKS
ENCODER
951
954
6
ZONE MNGMT
BYPASS
2010
+
2011
+
2
0V
3754
7
6
8
0V
2
7
M
6
M
2
B
6
952
9
2014
DO3
7
11
6
953
AI3
7
3
8
4
AI4
LTCH GATE
7
3
7
3
8
4
8
4
7
UPPER LIMIT
INDICATION PL
12
11
2016
DO4
3
2015
N2
10
-
3
2
10
9
-
N1
6
8
2012
2013
B/
2
12
2017
PE
2018
4
13
PE
8
14
13
0V
14
4
0V
M
2019
M
REF
SHLD
8
0V
15
2020
16
15
16
2021
WAGO 750-375
2022
WAGO 750-1405
WAGO 750-504
WAGO 750-455
WAGO 750-637-000-0001
WAGO 750-600
(OPTION)
2023
TB24/0V
2A FUSE
7F
F7
2024
2025
2026
+VDC
0VDC
2027
954
955
MOD1-B
MOD1-B
WHITE
RED
TD R4 M3 CH0
2028
2029
2030
2031
2032
2033
2034
2035
2036
2037
DRAWORKS
ENCODER
SIG(A)
CHANNEL A
SIG(A\)
950
951
MOD1-A
SIGNAL
1
GREEN
BLACK
MOD1-A
YELLOW
BLUE
SIG(B)
CHANNEL B
SIG(B\)
952
953
MOD1-A
MOD1-A
BLACK
24V
ZONE MNGMNT
BYPASS
SW
TB30:2
WHITE
INCLINOMETER
W/ GATEWAY
DC R4 M1
F4
F4
F4
3754
3754
5
I-0.5
ZONE MGMT BYPASS
CONSOLE - TD MOTOR CONTROL JS SLIDER
CONSOLE - SLIDER RPM / TORQUE
4-20mA RPM
ISOLATOR 1
5
6
3RD PARTY
TB
642
BLACK
643
BLACK
3
1
JS1-LEFT
3 3102
DC R3 M2
3102
8
JS1-RIGHT
1
3
3900
3901
4
1
1
2
DC R3 M2
3 3104
4-20mA TRQ
ISOLATOR 2
6
SLIDER TB
3900
JS1-UP
5
I-4.7
SPIN-IN / DRILL ZERO
3104
6
I-4.5
3902
3
MAKE-UP / INCREASE
646
BLACK
647
BLACK
7
JS1-DOWN
1
3
8
SW7-LEFT
3903
3901
DC R3 M2
3106
3106
9
I-5.0
DRILL REV / FWD
3902
TOP DRIVE BRAKE
SW8
OFF
ON
DC R3 M1
3101
1
2
16
I-3.7
T.D BRAKE SW
3903
4
(OMRON) INVERTER CUBICLE
TD TB8
+VDC
790
1
0VDC
2
SHIELD
3
SIG(A)
CHANNEL A
SIG(A\)
4
SHIELD
6
7
SHIELD
9
1
791
2
3
820
4
821
5
SIG(B)
CHANNEL B
SIG(B\)
GDP PANEL
TD TB2
5
6
822
7
823
8
8
9
10
734
LOCK-OUT
CR1A
10
0V
INPUT CUBICLE
TD TB6
852
1
TD TB3
1
852
A1+
BLK
TD TB12
852
1
11
2
853
2
853
WHT
2
14
853
744
FAULT RELAY
CR2A
A1+
A2-
TD TB5
GDP CPU
PROFIBUS PLUG
8
PROFIBUS PLUG
VFD DRIVE
(NODE 3)
RED
RED
SH
GRN
GRN
CAB006
ON
GRN
RED
3
850
RED
851
GRN
3
850
11
9
851
4
4
RTD01
SH
1015
SIEMENS CPU
850
WHT
OFF
RED
SH
PROFIBUS PLUG
BRAKING MODULE
(NODE 4)
RED
RED
WHT
ON
RED
GRN
6
7
ORG
BLU
WHT/BLK
5
6
7
RTD02
RED
SH
5
8
9
10
BLK/RED
BLK/GRN
BLK/GRN
TB 23
A2-
8
9
10
851
14
TB12:3
GDP
(IDS) SCR HOUSE
Forward
RL13
R0
MOD2 DO/12
900
A1+
0VDC
TB 23
TB14
A2-
1
SCR ONLINE
3010
11
R0
MOD2 DO/13
14
Reverse
RL14
901
0VDC
A1+
11
A2-
205
E-STOP
206
REVERSE
866
TRQ LIMIT
R0
MOD2 DO/14
A1+
R0
R0
MOD2 DO/15
R0
MOD5 AO/35
TRQ FDBK
R0
MOD4 AI/16
882
883
880
A2-
14
R0
MOD4 AI/18
TB 11:2
881
734
40AMP
873
15AMP
874
A2-
14
2
2
40
TB8-5
3
RED
3
41
PC1-38
4
42
C-6
6
7
8
9
10
12
13
14
15
16
120V
11
PC1-44
11
15 Amp
RL16
903
0VDC
A1+
MOD5 AO/31
RPM REF
RPM FDBK
11
39
5
865
14
40 Amp
RL15
902
0VDC
1
WHITE
4
FORWARD
SCR FIELD LOSS
R0
MOD1 DI/17
TB 21:4
TB 23
113
120N
COMMON
TB6
BLACK
17
18
19
20
21
GREEN
ORANGE
BLUE
WHITE-BLK
RED-BLK
GREEN-BLK
ORANGE-BLK
BLUE-BLK
BLACK-WHT
RED-WHT
GREEN-WHT
BLUE-WHT
BLACK-RED
WHITE-RED
ORANGE-RED
BLUE-RED
RED-GREEN
5
6
7
CT
H2
FORWARD
709
REVERSE
128 128
L2
FIELD SUPPLY
TB1
TB2
15
5
14
4
200
130 130
10
161 PC1-7
11
162 PC1-29
12
156 156
13
792 RL2-23
(2.66V/1000A)
3
40AMP
715
15AMP
716 FS TB1-5
17
706 RL1-24
0
200
(5.0V/1500V)
714
16
3
2
4
1
+
FIELD SETTINGS
18
793 RL2-24
19
703 T4-14
20
159 PC1-27
21
L1
730 PC1-36
9
15
600V
708
8
14
H1
DEFAULT 60A (TORQUE)
FIELD 1 40A (DRILL MODE)
FIELD 2 18A (HIGH SPEED)
MOTOR
FIELD
GDP
+VDC
TD TB1
1
0VDC
2
POWER PLC 1
TD TB9
BLK
+VDC
WHT
3
PR2 BLK / 1826
CHANNEL A
PR2 WHT / 1827
TO TOP DRIVE
4
5
RED
7
8
PR4 BLK / 1832
GRN
ORG
BLU
2
703
4
WHT/BLK
GRN/BLK
ORG/BLK
734
1
TD RET S1 / 928
WHT
852
TD RET S2 / 929
RED
3
5
GRN
6
ORG
7
BLU
8
WHT/BLK
9
RED/BLK
10
GRN/BLK
1
11
FAULT RELAY
CR2A
TD TB5
0001
851
9
A2A1+
2
4
744
850
14
5
8
11
6
823
RED/BLK
LOCK-OUT
CR1A
TD TB3
853
2
A2A1+
14
701
3
LOCKOUT
TD TB12
BLK
TD 24V S2 / 908
822
10
PR4 WHT / 1833
TD 24V S1 / 907
702
821
9
CHANNEL Z
NOT CONNECTED
700
820
6
PR3 BLK / 1829
CHANNEL B
PR3 WHT / 1830
1
003
7
8
9
11
ORG/BLK
10
12
13
E-STOP
TD TB 10
BLK
14
15
WHT
708
1
2
+24VDC TB22:5F / 910
RL5
HPU
E-STOP
100A
A1
2
I-1/0.0
TB23:2 / 931
RED
1
GRN
3
GDP PLC M1
108
4
12
BLU
I-1/1.0
HPU LEVEL
SWITCH
1021
4
ORG
WHT/BLK
6
GRN/BLK
WHT/BLK
7
7
O-4/2 -
1017
RPM
11
O-4/4+
14
O-4/4 -
15
O-4/6+
1021
RPM
18
O-4/6 -
1022
RPM
10
556
GDP PLC
8
RED/BLK
15
8
557
16
M6
HPU TEMP
18
9
GRN/BLK
10
9
557
ORG/BLK
120 V (N)
TB3
2
RED
3
ORANGE
650
1
651
2
TB20:1
907
TB21:1
924
BLUE
WHITE-BLK
3
POWER PLC 2
TD TB11
BLK
GREEN
1
RED-BLK
732
GREEN-BLK
BLACK
RED
GRN
TB4
1
2
3
BLACK
L1
WHITE
N
GREEN
G
2
3
111A
744
4
711
0001
L1
SOLA
UPS
ORG
N
BLU
G
L2
WHT/BLK
5
6
ORANGE-BLK
732
712
LOCKOUT RELAY
RL3
BLUE-BLK
BLACK-WHT
TB12:3
TB23:6 / 931 0V DC
TB12:4
RED-WHT
GREEN-WHT
TB22:1 / 912 24V DC
BLUE-WHT
BLACK-RED
WHITE-RED
7
ORANGE-RED
GDP CPU
PROFIBUS PLUG
HMI
RED/BLK
PROFIBUS PLUG
VFD DRIVE
(NODE 3)
RED
RED
SH
GRN
GRN
GRN
RED
GRN/BLK
ORG/BLK
SH
ON
BLUE-RED
RED-GREEN
4
6
7
8
9
10
SH
PROFIBUS PLUG
BRAKING MODULE
(NODE 4)
RED
SH
GRN
ON
14
R0
MOD2 DO/13
R0
206
865
FORWARD
866
REVERSE
882
883
880
MOD2 DO/14
R0
12
14
MOD4 AO/3
MOD4 AO/7
R0
RPM REF
R0
TRQ FDBK
15
MOD3 AI/18
R0
MOD2 DO/15
R0
18
19
20
10
11
40 Amp
RL12
0VDC
902
A1+
RPM FDBK
14
TB 11:2
873
40AMP
874
15AMP
11
15 Amp
RL13
0VDC
903
A2-
16
17
A1+
TRQ LIMIT
R0
MOD3 AI/16
734
13
14
A2-
A2881
11
Reverse
RL11
0VDC
901
11
21
OFF
MOD2 DO/12
A1+
3010
205
A1+
120V
113
MOD1 DI/17
R0
8
9
Forward
RL10
900
A2-
5
WHITE
WHT
0VDC
1
WHITE
10
GREEN
120 V (L)
TB 23
TB14
BLACK
CAB006
RPM
10
9
6
ORG/BLK
SIG(B)
CHANNEL B
SIG(B\)
O-4/2+
1016
1020 TORQUE
165D
8
O-4/0 -
1019 TORQUE
164D
7
RED/BLK
5
165C
6
5
BLU
1015
SIEMENS CPU
7
164C
2
SIG(A)
CHANNEL A
SIG(A\)
6
3
5
O-4/0+
1015 TORQUE
165B
4
ORG
0VDC
164B
3
GRN
+VDC
TO VFD DRIVE
CAB 25
2
RED
HPU E-STOP
3
1014 TORQUE
165A
1013
ENCODER VFD
TD TB2
+VDC
WHT
GDP PLC M1
100
164A
1
3153
705
***NOTE : GDP TO ENCODER SHIELDS GROUNDED AT GDP / ISOLATED AT TD***
3rd Party
TD TB13
BLK
705
A2
120N
TB 21:4
SCR FIELD LOSS
14
11
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
Project Description
Drawing Package Version
Customer Name
Page Total
No. Pages
Name
1
1
Index
2
1 159105E020
3
1 159105E200
4
14 159105E308
9/18/2014
159105
800HP Top Drive House
11
Global Drilling Support
Description 1
Drawing Package
DIAGRAM ‐ POWER SYSTEM ONE‐LINE
DIAGRAM ‐ LIGHTING PANEL
DIAGRAM ‐ STANDALONE A1000 VFD
Description 2
WITHOUT GEN CONTROLS
Doc Class
ELECTRICAL
ELECTRICAL
ELECTRICAL
18
22
23
4
1
1
159105E309 DIAGRAM ‐ TOP DRIVE
159105M001 EQUIPMENT OUTLINE ‐ POWER CONTROL HOUSE
159105M002 ELEVATION ‐ LINE UP, 800HP TOP DRIVE
ELECTRICAL
MECHANICAL
MECHANICAL
24
27
32
34
37
3
5
2
3
2
001.028.112
001.052.117.
001.029.006.
001.039.194
001.039.195
MECHANICAL
MECHANICAL
MECHANICAL
MECHANICAL
MECHANICAL
HOUSE ‐ ACCESSORIES, TOP DRIVE
PLUG PANEL MAIN LEFT
PLUG PANEL ‐ TOP DRIVE,
CUBICLE ‐ MODEL 07010 INPUT, STAND ALONE DRIVE,
CUBICLE ‐ MODEL 07103 CONVERTER/INVERTER, 3 POLE (1 FUTURE), SAD,
PRECABLE ASSEMBLY
86.0 HIGH X 24.0 WIDE X 34.0 DEEP
86.0 HIGH X 50.0 WIDE X 34.0 DEEP
166
Revision Description
INITIAL RELEASE
Swaped 30 amp breaker to 15 amp breaker.
REMOVED TB32 1,2 FROM SH 10
CHANGED CUSTOMER RTD CONNECTIONS TO
INTERNAL, 309TB8 TO TB8
INITIAL RELEASE
INITIAL RELEASE
UPDATED DRAWING TO REFLECT CHANGES TO
PLATE
INITIAL RELEASE
INITIAL RELEASE
REMOVED ITEM 321
REMOVED ITEM 266 AND ITEM 267
Revision
Number
A
B
E
C
A
A
C
A
A
E
D
Drawing Package Index
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
NOTES:
1.
THE MAIN PLUG PANEL IS REMOVABLE. IT IS TO BE INSTALLED USING 3/8-16 SS
HARDWARE, WHICH SHALL BE DRILLED AND TAPPED INTO THE WALL SIDING. THE
HOUSE AND PLUG PANEL ARE TO BE SEALED USING A CAULK SUITABLE FOR EXTERIOR
APPLICATIONS WITH MINIMAL SHRINKAGE AFTER CURING. THE COLOR OF THE CAULK
SHALL MATCH THE HOUSE.
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.
3.
THE TRANSFORMER SHALL BE BOLTED TO THE MEMBERS ON THE PORCH AS SHOWN
USING SS HARDWARE.
4.
THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.
5
CUSTOMER INSTALLED EQUIPMENT.
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
C
3/27/2014 STD-AC-ECN-20140327-01
JIMENEZ,M
BRAATZ,J
FRENCH,J
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
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
REV
DATE
REVISION NOTE
DRAWN
CHKD
APPR
HOUSE - ACCESSORIES,
TOP DRIVE
PHONE: (703)849-1900
FAX:
(713)849-4666
transmitted to the recipient for limited purposes only, and remains the property
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159105
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.028.112
1/ 3
REV:
C
25
INPUT
5
62
320
63
5
60
X2
61
61
X2
60
LF2
321
PLAN VIEW
B
C
100
LF1
240
CONVERTER/
INVERTER
344
1
10LDP1
A
D
321
320
320
A/C 1
240
321
700
A/C 1
A/C 2
GLAND PLATE
THIS SIDE
A/C 2
ADDED HOLE SIZES
TO TRANSITION PLATE
5
120 10T1
C
64 343
WEST ELEVATION
(LESS CUST. EQUIP.)
B
A
64 343
D
EAST ELEVATION
SOUTH ELEVATION
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
HOUSE - ACCESSORIES,
TOP DRIVE
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159105
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.028.112
2/ 3
REV:
C
26
702 600
200
240
CONVERTER/
INVERTER
323
100
INPUT
CONVERTER/
INVERTER
120
201
SECTION A-A
SECTION C-C
200
10DISC1,2 2X
INPUT
323
80
2X 340
320
321
2X 342
1
5
201
10RECPT1,2 2X 260
SECTION B-B
2X 340
SECTION D-D
2X 341
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
HOUSE - ACCESSORIES,
TOP DRIVE
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159105
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.028.112
3/ 3
REV:
C
27
700
700
701
SEE PLUG
PANEL DETAIL
LEFT SIDE VIEW
FRONT VIEW
9510 N. HOUSTON ROSSLYN
HOUSTON, TX 77088
TITLE:
PLUG PANEL - TOP DRIVE,
PRECABLE ASSEMBLY
PHONE: ( 703) 849-1900
FAX:
( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
A
REV
1/10/2014 STD-AC-ERO-20140110-01
DATE
REVISION NOTE
BAKER, M.
DRAWN
BRAATZ, J. FRENCH, J.
CHKD
APPR
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159286
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.029.006
1/ 2
REV:
A
28
ROW A
ROW B
ROW C
ROW D
ROW E
ROW F
ROW G
1
21
1
300
1
708
3
23
708
2
1
1
711
2
1
303
20
711
2
301
4
2
709
23
707
3
2
22
3
302
709
711
5
2
303
3
710
23
3
3
303
4
4
40
40
50
50
706
705
704
703
702
PLUG PANEL DETAIL
9510 N. HOUSTON ROSSLYN
HOUSTON, TX 77088
TITLE:
PLUG PANEL - TOP DRIVE,
PRECABLE ASSEMBLY
PHONE: ( 703) 849-1900
FAX:
( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
A
REV
1/10/2014 STD-AC-ERO-20140110-01
DATE
REVISION NOTE
BAKER, M.
DRAWN
BRAATZ, J. FRENCH, J.
CHKD
APPR
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159286
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.029.006
2/ 2
REV:
A
29
30
31
32
33
34
35
36
NOTES:
1.
THE MAIN PLUG PANEL IS REMOVABLE. IT IS TO BE INSTALLED USING 3/8-16 SS
HARDWARE, WHICH SHALL BE DRILLED AND TAPPED INTO THE WALL SIDING. THE
HOUSE AND PLUG PANEL ARE TO BE SEALED USING A CAULK SUITABLE FOR EXTERIOR
APPLICATIONS WITH MINIMAL SHRINKAGE AFTER CURING. THE COLOR OF THE CAULK
SHALL MATCH THE HOUSE.
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.
3.
THE TRANSFORMER SHALL BE BOLTED TO THE MEMBERS ON THE PORCH AS SHOWN
USING SS HARDWARE.
4.
THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.
5
CUSTOMER INSTALLED EQUIPMENT.
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
C
3/27/2014 STD-AC-ECN-20140327-01
JIMENEZ,M
BRAATZ,J
FRENCH,J
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
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
REV
DATE
REVISION NOTE
DRAWN
CHKD
APPR
HOUSE - ACCESSORIES,
TOP DRIVE
PHONE: (703)849-1900
FAX:
(713)849-4666
transmitted to the recipient for limited purposes only, and remains the property
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159105
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.028.112
1/ 3
REV:
C
37
INPUT
5
62
320
63
5
60
X2
61
61
X2
60
LF2
321
PLAN VIEW
B
C
100
LF1
240
CONVERTER/
INVERTER
344
1
10LDP1
A
D
321
320
320
A/C 1
240
321
700
A/C 1
A/C 2
GLAND PLATE
THIS SIDE
A/C 2
ADDED HOLE SIZES
TO TRANSITION PLATE
5
120 10T1
C
64 343
WEST ELEVATION
(LESS CUST. EQUIP.)
B
A
64 343
D
EAST ELEVATION
SOUTH ELEVATION
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
HOUSE - ACCESSORIES,
TOP DRIVE
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159105
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.028.112
2/ 3
REV:
C
38
702 600
200
240
CONVERTER/
INVERTER
323
100
INPUT
CONVERTER/
INVERTER
120
201
SECTION A-A
SECTION C-C
200
10DISC1,2 2X
INPUT
323
80
2X 340
320
321
2X 342
1
5
201
10RECPT1,2 2X 260
SECTION B-B
2X 340
SECTION D-D
2X 341
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
HOUSE - ACCESSORIES,
TOP DRIVE
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159105
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.028.112
3/ 3
REV:
C
39
40
41
42
43
44
700
700
701
SEE PLUG
PANEL DETAIL
LEFT SIDE VIEW
FRONT VIEW
9510 N. HOUSTON ROSSLYN
HOUSTON, TX 77088
TITLE:
PLUG PANEL - TOP DRIVE,
PRECABLE ASSEMBLY
PHONE: ( 703) 849-1900
FAX:
( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
A
REV
1/10/2014 STD-AC-ERO-20140110-01
DATE
REVISION NOTE
BAKER, M.
DRAWN
BRAATZ, J. FRENCH, J.
CHKD
APPR
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159286
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.029.006
1/ 2
REV:
A
45
ROW A
ROW B
ROW C
ROW D
ROW E
ROW F
ROW G
1
21
1
300
1
708
3
23
708
2
1
1
711
2
1
303
20
711
2
301
4
2
709
23
707
3
2
22
3
302
709
711
5
2
303
3
710
23
3
3
303
4
4
40
40
50
50
706
705
704
703
702
PLUG PANEL DETAIL
9510 N. HOUSTON ROSSLYN
HOUSTON, TX 77088
TITLE:
PLUG PANEL - TOP DRIVE,
PRECABLE ASSEMBLY
PHONE: ( 703) 849-1900
FAX:
( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
A
REV
1/10/2014 STD-AC-ERO-20140110-01
DATE
REVISION NOTE
BAKER, M.
DRAWN
BRAATZ, J. FRENCH, J.
CHKD
APPR
of Omron. It may not be reproduced, in whole or in part, without the written
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
FUO:
159286
PO#/CUSTOMER
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.029.006
2/ 2
REV:
A
46
47
48
49
50
1
Drawing Package Index
Project Number
Project Description
Drawing Package Version
Customer Name
Page Total
No. Pages
Name
1
1
Index
2
1 159286E020.
3
1 159286E200.
9/18/2014
159286
1200 HP Top Drive House
13
Global Drilling Support
Description 1
Drawing Package
DIAGRAM‐POWER SYSTEM ONE‐LINE
DIAGRAM‐LIGHTING PANEL
4
14
159286E308. DIAGRAM‐STANDALONE A1000 VFD
18
22
23
26
28
33
36
4
1
3
2
5
3
2
159286E309.
159105M001.
001.034.527.
001.034.525.
001.052.117.
001.039.194.
001.024.995.
DIAGRAM‐TOP DRIVE
EQUIPMENT OUTLINE ‐ POWER CONTROL HOUSE
HOUSE ‐ ACCESSORIES, TOP DRIVE, 1200 HP
PLUG PANEL ‐ TOP DRIVE,
PLUG PANEL MAIN LEFT
CUBICLE ‐ MODEL 07010 INPUT, STAND ALONE DRIVE,
CUBICLE ‐ MODEL 07103 CONVERTER/INVERTER, 3 POLE, SAD,
Description 2
Doc Class
ELECTRICAL
ELECTRICAL
Revision Description
WITHOUT GEN CONTROLS
ELECTRICAL
INITIAL RELEASE
Changed 200CB4 from 30A to 15A.
Chng to rev D (sht. 1), chng tb5 5/6 to 6/7 (sht. 8),
rmv tb 47/tb63/tb16/tb32 (sht. 10)
PRECABLE ASSEMBLY
ELECTRICAL
MECHANICAL
MECHANICAL
MECHANICAL
MECHANICAL
MECHANICAL
MECHANICAL
(Sheet 4) RTD dashed wires were changed to solid
INITIAL RELEASE
ADDING ITEM 800
INITIAL RELEASE
INITIAL RELEASE
REMOVED ITEM 321
ADDING LEXAN COVER
86.0 HIGH X 24.0 WIDE X 34.0 DEEP
86.0 HIGH X 50.0 WIDE X 34.0 DEEP
229
Revision
Number
A
B
D
D
A
B
A
A
E
D
Drawing Package Index
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
NOTES:
1.
THE MAIN PLUG PANEL IS REMOVABLE. IT IS TO BE INSTALLED USING 3/8-16 SS
HARDWARE, WHICH SHALL BE DRILLED AND TAPPED INTO THE WALL SIDING. THE
HOUSE AND PLUG PANEL ARE TO BE SEALED USING A CAULK SUITABLE FOR EXTERIOR
APPLICATIONS WITH MINIMAL SHRINKAGE AFTER CURING. THE COLOR OF THE CAULK
SHALL MATCH THE HOUSE.
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.
3.
THE TRANSFORMER SHALL BE BOLTED TO THE MEMBERS ON THE PORCH AS SHOWN
USING SS HARDWARE.
4.
THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.
5
CUSTOMER INSTALLED EQUIPMENT.
6
MODIFY PART 220.45.925 AS NEEDED IN INPUT CUBICLE.
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
B
9/20/2013 STD-AC-ECN-20130920-01
BROWN,K
BRAATZ,J
ROYSE, M
A
8/27/2013 STD-AC-ERO-20130821-02
BROWN,K
BRAATZ,J
FRENCH,J
REV
DATE
REVISION NOTE
DRAWN
CHKD
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
APPR
HOUSE - ACCESSORIES,
TOP DRIVE, 1200 HP
PHONE: (703)849-1900
FAX:
(713)849-4666
FUO:
159286
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.034.527
1/ 3
REV:
B
801
24
X2 703
INPUT
5
6
62
320
63
5
C
100
LF1
60
X2
61
240
CONVERTER/
INVERTER
61
X2
60
LF2
321
344
PLAN VIEW
1
2
B
10LDP1
A
D
321
320
320
A/C 1
240
321
700
A/C 1
A/C 2
GLAND PLATE
THIS SIDE
A/C 2
5
120 10T1
C
64 343
WEST ELEVATION
(LESS CUST. EQUIP.)
B
A
D
SOUTH ELEVATION
64 343
EAST ELEVATION
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
HOUSE - ACCESSORIES,
TOP DRIVE, 1200 HP
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
FUO:
159286
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.034.527
2/ 3
REV:
B
25
702 600
200
240
CONVERTER/
INVERTER
323
100
INPUT
CONVERTER/
INVERTER
120
201
SECTION A-A
SECTION C-C
200
10DISC1,2 2X
INPUT
323
80
2X 340
320
321
2X 342
1
5
201
10RECPT1,2 2X 260
SECTION B-B
2X 340
SECTION D-D
2X 341
9510 N. HOUSTON ROSSLYN TITLE:
HOUSTON, TX 77088
HOUSE - ACCESSORIES,
TOP DRIVE, 1200 HP
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
FUO:
159286
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.034.527
3/ 3
REV:
B
26
700
700
701
SEE PLUG
PANEL DETAIL
LEFT SIDE VIEW
FRONT VIEW
9510 N. HOUSTON ROSSLYN TITLE:
PLUG PANEL - TOP DRIVE
PRECABLE ASSEMBLY
HOUSTON, TX 77088
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
A
REV
transmitted to the recipient for limited purposes only, and remains the property
8/21/2013 STD-AC-ERO-20130821-02
DATE
REVISION NOTE
BROWN,K
DRAWN
BRAATZ,J
CHKD
FRENCH,J
APPR
FUO:
159286
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.034.525
1/ 2
REV:
A
27
R
O
W
G
R
O
W
F
R
O
W
E
21
30
0
30
0
40
50
20
2
1
22
3
40
50
3
4
70
6
71
1
1
71
1
2
2
22
2
R
O
W
A
1
20
1
30
2
30
2
21
1
30
1
30
1
R
O
W
B
R
O
W
C
R
O
W
D
71
1
70
8
1
70
8
2
70
9
3
70
9
3
2
70
7
3
4
5
71
0
3
4
70
5
70
3
70
4
70
2
PLUG PANEL DETAIL
9510 N. HOUSTON ROSSLYN TITLE:
PLUG PANEL - TOP DRIVE
PRECABLE ASSEMBLY
HOUSTON, TX 77088
PHONE: (703)849-1900
FAX:
(713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
FUO:
159286
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON
SHEET NO:
DRAWING NO:
001.034.525
2/ 2
REV:
A
28
29
30
31
32
33
34
35
36
37
7
Section
650/850 T O N T O P D R I V E MANUAL REV 0
HPU-WILSON
254
GDS International
Hydraulic Power Unit
Part Number 15H14028
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
To our Valued Customers
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
and components and been carefully assembled by our experienced technicians.
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
me or a member of our staff.
If you have other applications for fluid power or fluid connector
Products, please contact your local Wilson Company sales associate, or call
our Main Office at 832-467-0001.
Thank you again for electing Wilson Company as your source for
fluid power equipment.
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
HYD. POWER UNITS
Maintenance & Installation
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, specification, 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 merchandise 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 information contained or described on this publication. Further, we reserve the right to revise or otherwise make product
improvements at any time without notification.
WARNING - USER RESPONSIBILITY
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS 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 or system options for further investigation
by users having technical expertise.
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
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
General Information
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.
4
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
General Information
STARTUP PROCEDURE FOR
NEW INSTALLATIONS
• Read and understand the instruction manual.
• Identify components and their function.
• Visually inspect components and lines for possible damage.
• Insure that all necessary ports are properly connected.
• Check reservoir for cleanliness. Drain and clean as required.
• Check fluid level and fill as required with filtered fluid to a minimum ISO cleanliness level of 20/18/14.
• Fill pump case with clean oil prior to starting.
• If pump is mounted vertically with the shaft up, bleed the air out the D1 drain port
located near the mounting flange.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature.
• Reduce pressure settings of compensator and relief valve. Make sure accurate
pressure readings can be made at appropriate places.
• If solenoids in system, check for actuation.
• Jog the pump drive. Check for proper shaft rotation. Make sure pump fills properly.
• Start the pump drive.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines especially in pump and motor inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds,
system shocks, and air in fluid.
• Equipment is operational.
Typical Ajustment Ranges and Initial Settings (unless customer specified at time of order)
Function
Adjustment range
Pressure compensators
"C0"
80-280 bar (1160-4060 PSI)
"C1"
20-80 bar (290-1160 PSI)
"AM"
80-280 bar (1160-4060 PSI)
Load sense pressure
"L0"
8-35 bar (116-500 PSI)
Differential pressure
"AM"
37 bar (540 PSI)
Maximum Volume stop
018
100-40%
028
100-40%
045
100-20%
060
100-30%
075
100-35%
100
100-50%
140
100-50%
Minimum Volume stop
018
0-68%
028
0-40%
045
0-40%
060
0-50%
075
0-45%
100
0-45%
140
0-25%
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Adjustment value
Recommended or Initial Setting
40 bar/turn (580 PSI/turn)
18.6 bar/turn (260PSI/turn)
40 bar/turn (580 PSI/turn)
Factory supplied at minimum
Factory supplied at minimum
Factory supplied at minimum
28 bar/turn (410 PSI/turn)
24 bar (350 PSI)
Adjustment not recommended
Factory Set do not adjust
9% per turn (1.6 cc/turn)
8.2% per turn (2.3 cc/turn)
7.5% per turn (3.4 cc/turn)
6.8% per turn (4.1 cc/turn)
6.2% per turn (4.65 cc/turn)
5.5% per turn (5.5 cc/turn)
4.8% per turn (6.72 cc/turn)
100%
100%
100%
100%
100%
100%
100%
10% per turn (1.8 cc/turn)
9% per turn (2.6 cc/turn)
8.2% per turn (3.7 cc/turn)
4.6% per turn (2.76 cc/turn)
4.3% per turn (3.23 cc/turn)
3.9% per turn (3.9 cc/turn)
3.3% per turn (4.62 cc/turn)
0%
0%
0%
0%
0%
0%
0%
5
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Trouble Shooting
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.
Effect of Trouble
Possible Cause
air in fluid
noisy pump
cavitation in
rotating group
misaligned shaft
mechanical fault in pump
Fault Which Needs Remedy
leak in inlet line
low fluid level
turbulent fluid
return lines above fluid level
gas leak from accumulator
excessive pressure drop in the inlet line from a pressurized reservoir
inlet line strainer acting as air trap
fluid too cold
fluid too viscous
fluid too heavy
shaft speed to high
inlet line too small
inlet strainer too small
inlet strainer too dirty
operating altitude too high
inlet pressure too low
faulty installation
distortion in mounting
axial interference
faulty coupling
excessive overhung loads
piston and shoe looseness or failure
bearing failure
incorrect port plate rotation
eroded or worn parts in the displacement control
air in fluid
see noisy pump above
cavitation
see noisy pump above
cogging load
worn relief valve
worn compensator
slow response in check
valves
excessive decompression
energy rates
barrel blow-off
mechanical considerations
needed repairs
replace
excessive line
capacitance (line volume,
compensator instability
line stretch, acumulator
effects)
reduce line size or lengths
erosion on barrel ports
and port plate
pressure shocks
replace or relocate
improve decompression control
rotating group worn, excessive case pressure
eliminate hose
6
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Trouble Shooting
Effect of Trouble
Possible Cause
excessive loads
contaminant particles
in fluid
high wear in pump
improper fluid
improper repair
unwanted water in fluid
excessive pump leakage
relief valve
compensator
heating of fluid
pump too large for
fluid needs
heat exchanger
reservoir
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Fault Which Needs Remedy
reduce pressure settings
reduce speeds
improper filter maintenance
filters too coarse
introduction of dirty fluid to system
reservoir openings
improper reservoir breather
improper line replacement
fluid too thin or thick for operating temperature range
breakdown of fluid with time/temperature/heating effects
incorrect additives in new fluid
destruction of additive effectiveness with chemical aging
incorrect parts
incorrect procedures, dimensions, finishes
condensation
faulty breather/strainer
heat exchanger leakage
faulty clean-up practice
water in makeup fluid
recheck case drain flow and repair as required
fluid too thin
improper assembly, port timing
set too low (compared to load or to compensator)
instability caused by back pressure, worn parts
set too high (compared to relief)
worn parts
select smaller pump displacement
water turned off or too little flow
water too hot
fan clogged or restricted
efficiency reduced by mud or scale deposits
intermittent hydraulic fluid flow
too little fluid
improper baffles
insulating air blanket that prevents heat rejection
heat pickup from adjacent equipment
7
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
P1/PD 28cc, Model Ordering Code
028 P
Pump
Series
S
Open Circuit
Displacement
28cc/rev.
(1.71 in³/rev)
Mounting
& Ports
Shaft Single
Options Shaft
Seal
5
Mobile
PD
Industrial
Fluorocarbon
Additional
Seal Material
Control
Design Control Options
Configuration
Letter Options
S
SAE B Pilot SAE Work Ports
with SAE Aux Ports
A
SAE B Pilot Metric Work Ports
with BSPP Aux Ports
M
ISO - 100MM Pilot Metric Work Ports
with Aux Ports
B
ISO - 100MM Pilot Metric Work Ports
with BSPP Aux Ports
Shaft Options
01
Splined shaft - SAE B-B 15T
02
Keyed shaft - SAE B-B 1” Dia.
04
ISO keyed 25MM Dia.
08
Splined shaft - SAE B 13T
R
Clockwise
Port
Orientation
L
Counterclockwise
Mobile (P1)
S
Industrial (PD)
Thru-Drive
Mounting
Pad/Coupling
Port
Type
Pressure limiter
1160.30 - 4061.05 PSI (80 - 280 bar)
Paint
C1
Pressure limiter
290.08 - 1160.30 PSI (20 - 80 bar)
L0
Load sensing 145.04-435.11 PSI ∆P
(10-30 bar ∆P) with pressure limiter
1160.30 - 4061.05 PSI (80 - 280 bar)
L2
Load sensing 145.04-435.11 PSI ∆P
(10-30 bar ∆P) with bleed & pressure limiter
1160.30 - 4061.05 PSI (80 - 280 bar)
AN*
Pilot operated pressure limiter with
ISO4401 interface & SAE 4 Vent Port
AM
Pilot operated pressure limiter with
mechanical adjustment and SAE 4 Vent Port
AE
Pilot operated pressure limiter with
mechanical and electrical adjustment 12 VDC
AF
Pilot operated pressure limiter with
mechanical and electrical adjustment 24 VDC
##
See chart below for electronic control options
*Not functional control as such
Additional Control Options
E
End Ports
R
Side ported with ripple chamber
T
Side ported with through drive
Adjustable Displacement Stops*
(For E & R Port Orientation Only)
0
None
1
Adjustable maximum displacement stop
2
Adjustable minimum displacement stop
3
Adjustable maximum and minimum
displacement stop
*Not available with Thru-Drive
Port Type
0
Flange Ports
2
Threaded Ports
Thru-Drive Mounting Pad/Coupling
0
No Thru-Drive
A
SAE 82-2 (A), 16 (A), 9T coupling
0
No other options
H
SAE 82-2 (A), 19 (--), 11T coupling
2
Displacement sensor **
B
SAE 101-2 (B), 22 (B) , 13T coupling
Q
SAE 101-2 (B), 25 (B-B), 15T coupling
00
No Paint
PB
Black Paint
** mandatory with "W**", "X**",
"Y**", "Z**" "*D*" and "*Y*"
Paint
Electronic Control Options
#
#
0
No ECU
D
Proportional displacement control
Y
Proportional pressure
and displacement control
P
Electronic valve with zero displacement default
T
Electronic valve with max displacement default
S
Electronic valve with zero displacement default and hydromechanical Pmax
U
Electronic valve with max displacement default and hydromechanical Pmax
W
Electronic valve with zero displacement default (CANBUS compatible)
Y
Electronic valve with max displacement default (CANBUS compatible)
X
Electronic valve with zero displacement default and hydromechanical Pmax (CANBUS compatible)
Z
Electronic valve with max displacement default and hydromechanical Pmax (CANBUS compatible)
*** W, X, Y and Z only available with *D* and *Y*
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Special
Features
Port Orientation
C0
Shaft Rotation
M
Adjustable
Displacement
Stops
Control Options
Mounting & Ports
Configuration
00
Shaft
Rotation
Pump Series
P1
A
9
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Typical Characteristics
Technical Data
Model
Maximum Displacement, cm3/rev
cu.in./rev
Outlet Pressure – Continuous, bar
psi
Intermittent*, bar
psi
Peak, bar
psi
P1 Maximum Speed (1.3 bar abs inlet), rpm
P1 (1.0 bar abs inlet), rpm
P1 (0.8 bar abs inlet), rpm
PD Maximum Speed (1.0 bar abs inlet), rpm
PD (0.8 bar abs inlet), rpm
Minimum Speed, rpm
Inlet Pressure – Maximum, bar
psi
Rated, bar
psia
Minimum, bar
psia
Case Pressure – Peak, bar
P1/PD 018
18
1.10
P1/PD 028
28
1.71
3600
3300
2900
3400
3200
2900
P1/PD 045
45
2.75
P1/PD 060
P1/PD 075
60
75
3.66
4.58
280
4000
320
4500
350
5000
3100
2800
2700
2800
2500
2400
2400
2200
2100
1800
1800
600
10 (gage)
145
1.0 absolute (0.0 gage)
14.5
0.8 absolute (-0.2 gage)
11.6
4.0 absolute (3.0 gage)
and less than 0.5 bar above inlet pressure
2.0 absolute (1.0 gage)
and less than 0.5 bar above inlet pressure
-40 to +95
-40 to +203
6 to 160
5000 (for cold starting)
5
Rated, bar
Fluid Temperature Range, °C
°F
Fluid Viscosity – Rated, cSt
Max. Intermittent, cSt
Min. Intermittent, cSt
Fluid Contamination – Rated, ISO
Maximum, ISO
SAE Mounting – Flange
ISO Mounting - Flange
SAE Keyed Shafts
ISO Keyed Shafts
SAE Spline Shafts
Weight – End Port, kg (lb)
Side Port, kg (lb)
Thru-Drive, kg (lb)
Moment of Inertia kg·mm2
Moment of Inertia Thru-Drive kg·mm2
P1/PD 100
100
6.01
P1/PD 140
140
8.54
2500
2100
1900
2400
2100
1800
127-4 (C)
125 mm
38-1, CC
40 mm
152-4 (D)
180 mm
44-1, D
50 mm
20/18/14
82-2 (A)
80 mm
19-1, A
20 mm
9T, A
11T, A
13.4 (29.5)
14.2 (31.3)
—
760
NA
101-2 (B)
100 mm
25-1, BB
25 mm
13T, B
15T, BB
17.7 (39.0)
18.1 (40.0)
22 (48)
1555
1618
21/19/16
127-2 (C) or 127-4 (C)
125 mm
125 mm
32-1, C
32-1, C
32 mm
32 mm
101-2 (B)
100 mm
25-1, BB
25 mm
13T, B
15T, BB
23 (50)
24 (52)
27 (59)
3208
3268
14T, C
14T, C
17T, CC
13T, D
29 (64)
30 (67)
34 (75)
4548
4687
30 (66)
31 (68)
35 (77)
5041
5207
51 (112)
53 (117)
55 (121)
12027
12402
66 (145)
67 (147)
82 (180)
21400
22343
*Intermittent pressure is defined as less than 10% of operation time, not exceeding 6 successive seconds.
Typical Control Reponse Times*
Typical Control
Response Time (ms)
Control Description
”C” Pressure Limiter
”L” Load Sensing
”A” Pilot Operated
Control
Pump Operating Condition
018
028
045
060
075
100
Maximum Displacement to Zero
25
25
25
37
21
26
30
Zero Displacement to Maximum
80
80
106
119
89
108
125
Maximum Displacement to Zero
40
40
30
54
40
43
45
Zero Displacement to Maximum
70
70
120
186
97
189
280
Maximum Displacement to Zero
25
25
46
43
37
39
40
Zero Displacement to Maximum
80
80
131
125
115
123
130
* Based on NFPA testing standards
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
15
140
For max volume stops:
Pump Size % Stroke reduction per turn
P*060 6.76
P*018
9
P*075
6.2
P*028
8.2
P*100
5.5
P*045
7.5
P*140
4.8
Control Adjustment Sensitivity:
• Load Sense 28 Bar/Turn
• Pressure Compensator 80 to 280
bar range (C0) = 40 Bar/Turn
• Pressure Compensator 20 to 80
bar range (C1) = 18.6 Bar/Turn
• Pressure compensator (AM) 10 to 40
bar range = 20 Bar/Turn
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
18cc & 28cc Pump Exploded View
1
25
3
41
26
4
5
7
8
11
9
27
14
13
42
15
44
45
12
28
19
20
43
31
21
31
22
32
32
23
33
34 35
24
46 47
38
39
40
16
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Parts
ITEM #
1
3
4*
5
7
8*
QTY
4
1
1
2
1
3
018 PART #
028 PART #
045 PART #
210 x209
210 x 211
361-12229-0
Contact Factory for port block ordering information
2050V-7
2160V-7
675-00162-0
108X2V
108X2V
108X2V
299X67
324-30014-0
324-30014-0
605-10077-0
605-10077-0
605-10077-0
03E-94415-0
03E-94969-0
03E-94339-0
03E-94414-0
03E-94970-0
03E-94340-0
03E-94413-0
03E-94969-0
03E-94341-0
03E-94416-0
03E-94970-0
03E-94342-0
9
1
03E-94963-0
03E-94376-0
03E-95374-0
03E-94964-0
03E-94377-0
03E-95080-0
03E-94965-0
03E-94378-0
03E-95374-0
03E-94966-0
03E-94379-0
03E-95375-0
10*
2
**
**
695-00912-0
11
1
03E-94427-0
03E-94390-0
03E-94355-0
12
1
03E-94428-0
03E-94391-0
03E-94354-0
13
1
03E-94430-0
03E-94393-0
03E-94356-0
14
1
03E-94427-0
03E-94390-0
03E-94353-0
15
1
03E-94426-0
03E-94389-0
03E-94352-0
19
1
256X521
256X525
356-65144-0
20
1
787635
03E-94387-0
03E-94350-0
21
2
786996
03E-94388-0
03E-94351-0
22
3
787000
03E-94386-0
03E-95903-0
23
1
03E-94717-0
03E-94375-0
03E-94338-0
24
1
787002
03E-94385-0
03E-94348-0
25
1
786994
03E-94384-0
03E-94347-0
26
9
789641
S2E-18415-0
S2E-18413-0
03E-94409-0
03E-94372-0
03E-94335-0
03E-94411-0
03E-94374-0
03E-94337-0
03E-94410-0
03E-94373-0
03E-94948-0
03E-94806-0
03E-94900-0
03E-94908-0
03E-94800-0
03E-94903-0
03E-94923-0
27
1
03E-94801-0
03E-94904-0
03E-94922-0
03E-94718-0
**
**
**
**
**
03E-94804-0
03E-95166-0
03E-94990-0
03E-94762-0
03E-95492-0
03E-95197-0
28
1
S2E-19079-0
S2E-18414-0
S2E-18412-0
31
2
03E-94359-0
03E-94359-0
03E-94359-0
32
2
03E-94432-0
03E-94395-0
03E-94358-0
33
1
**
**
**
108X6
108X8
488-35055-0
34
2
Consult Parker Rep.
Consult Parker Rep.
35*
2
695-00908-0
695-00908-0
695-00910-0
38*
1
787140
P2-060-3304
620-82125-5
39
1
256X535
256X544
356-65158-0
40
1
see separate compensator ordering information
41
2
324-30024-0
324-30024-0
324-30014-0
42
1
216-10013-0
789814
230-82227-0
43
1
230-82514-0
789815
230-82516-0
44
1
256X222
256X222
356-65159-0
45
1
256X544
256X544
356-65144-0
46
1
108X4
108X4
108X4
47*
1
695-00904-0
695-00904-0
695-00904-0
* denotes Item is included in the seal kit
18
DESCRIPTION
Socket head cap screw
Port Block
Port block O-Ring
Boss Plug (not shown)
Port Plate Pin
O-Ring
Port plate, clockwise, industrial (PD)
Port plate, counter clockwise, industrial (PD)
Port plate, clockwise, mobile (P1)
Port plate, counter clockwise, mobile (P1)
Port plate, CW, industrial (PD), ripple chamber
Port plate, CCW, industrial (PD), ripple chamber
Port plate, clockwise, mobile (P1), ripple chamber
Port plate, CCW, mobile (P1), ripple chamber
Bias and control rod O-ring
Bias Guide
Bias Piston
Bias Spring
Control guide
Control piston
Retaining ring, internal
Barrel hold down spring
Barrel hold down washer
Barrel hold down pin
Barrel
Spherical washer
Retainer plate
Piston and shoe assembly
01 shaft option, no thru drive
01 shaft option with thru drive
02 shaft option, no thru drive
02 shaft option with thru drive
04 shaft option, no thru drive
04 shaft option with thru drive
06 shaft option, no thru drive
06 shaft option with thru drive
08 shaft option, no thru drive
08 shaft option with thru drive
Cam
Bearing retainer Orifice
Cam bearing
Housing (not sold seperatley)
Plug, SAE ORB
Plug, BSPP
Plug, ISO
SAE O-ring
Shaft Seal
Seal Retainer
Compensator
Cover dowel pin
Port block bushing
Cylindrical roller bearing
External retaining ring (shaft)
Internal retaining ring (housing)
Boss plug
O-ring
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Electronic Control Exploded View
Torque to 5 ft-lbs (6.8 Nm)
22
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Electronic Control Parts
RDEC Parts list
Part #
DESCRIPTION
03E-95420-0
Rotary Position sensor
210X73
Socket head cap screw
234X7
Washer
03E-95249-0
Position sensor spacer
03E-95201-0
Shaft position connector 18 and 45 thru 75
03E-95545-0
Shaft position connector 28
03E-95205-0
Shaft position connector 100 and 140
85
1
789764
Seal
86
1
675-00904-0
O-Ring Seal
87
1
108X4V
O-Ring boss plug
88
1
S13-40266-0
Check Valve
89
1
S2E-19182-5
External Servo Assembly*
90
1
03E-95347-0
External servo manifold
91
1
S2E-19174-5
Maximum pressure valve CCW
S2E-19173-5
Maximum pressure valve CW
92
12
605-10069-0
O-Ring Seal
93
1
517-00178-5
Proportional valve 0 disp default CW
517-00180-5
Proportional valve max disp default CW
517-00179-5
Proportional valve 0 disp default CCW
517-00181-5
Proportional valve max disp default CCW
94
8
350-10167-0
Lock Washer
95
4
361-07360-8
Socket head cap screw**
210x105
Socket head cap screw***
210x110
Socket head cap screw****
96
1
325-36002-0
Roll Pin
97
1
S13-40266-0
Check Valve
98
1
03E-94859-0
Cam pin
99
1
S2E-19190-0K
Position sensor mating connector
100
1
S2E-19254-0
Electronic control unit (not shown)
101
1
S2E-19192-5K
Pressure sensor kit UNC threads(not shown)
S2E-19523-5K
Pressure sensor kit BSPP threads (not shown)
102
1
S2E-19191-0K
Prerssure sensor mating connector (not shown)
103
1
S2E-19179-0
12 Pin cable assembly
104
1
S2E-19259-0
CAN communication cable
105
1
S2E-19180-0
Control communcation cable
106
1
1210694
Standard Coil
107
1
121459
Gasket
* Item 89 includes items 86, 87, 88, 90, 92 and 96
** Used on control options S/X/U/Z
*** Used on pumps without overcenter capability (P) and control options P/W/T/Y
*** Used on pumps with over center capability (X) and control options P/W/T/Y
ITEM #
80
81
82
83
84
QTY
1
2
2
1
1
Displacement Sensor Installation
After engaging
slot toshaft
pin, slot to pin,
Aftershaft
engaging
hold sensorhold
flushsensor
to pump
padto pump pad
flush
and rotate toand
align
screw
slots
rotate to align screw slots
to screw holes.
Secure
withSecure
screwswith screws
to screw
holes.
& washers, &
2 places.
washers, 2 places.
After engaging
slot toshaft
pin, slot to pin,
Aftershaft
engaging
hold sensorhold
flushsensor
to pump
padto pump pad
flush
and rotate toand
align
screw
slots
rotate to align screw slots
to screw holes.
Secure
withSecure
screwswith screws
to screw
holes.
& washers, &
2 places.
washers, 2 places.
Final Position Final Position
Final Position Final Position
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
23
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Case to Inlet Check Valve
198±8 Nm
(146±6 ft-lbs)
50
51
52
53
CASE TO INLET CHECK VALVE
Item No
Qty
018, 028, 045
060, 075, 100, 140
Description
50
1
314-10002-0
314-10000-0
Hollow Set Screw
51
1
03E-94720-0
03E-93931-0
Check Valve Poppet
52
1
03E-94721-0
03E-93987-0
Spring
53
1
03E-94722-0
03E-93988-0
Check Valve Stop
24
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Volume Stop Control
57
60
61
59
58 57
56
55
54
Minimum and Maximum Volume Stop
Item #
Qty
018
028
045
060
075
100
140
362-11045-0
Description
54
1
55
1
334-00013-0
334-00011-0
Adjusting Screw
Locknut, Adjusting Screw
56
1
03E-93181-0
03E-93181-0
Volume Stop Plug
57
1
695-00908-0
695-00908-0
O-ring, Volume Stop Plug
58
1
618-15023-0
618-15023-0
Back Up Ring
59
1
695-00011-0
695-00011-0
O-ring, Volume Stop Rod
60
1
61
1
Not Shown
1
03E-94736-0
03E-95170-0
03E-93262-0
488-35018-0
Volume Stop Rod
488-35018-0
03E-95217-0
03E-95358-0
03E-93262-0
KIT
S2E-19203-5
S2E-19204-5
S2E-19114-5
KIT
S2E-19608-5
S2E-19609-5
**
S2E-18987-5K
Minimum Volume Stop Rod
S2E-18988-5K
Use Above Kit
Maximum and minimum volume stops use the same components except where noted.
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
25
Plug(No Volume Stop)
Adjustable Volume Stop
Adjustable Minimum Volume Stop
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Seal Kits and Parts Kits
70
Thru Drive Pad
Coupling #70
Thru Drive Couplings
018
028
045
060
075
100
140
O-ring
SAE A, 9 Tooth
S2E-19538-0 S2E-19364-0 03E-94942-0 03E-93278-0 03E-93278-0 03E-94274-0 03E-93947-0 695-00237-0
SAE A, 11 Tooth
S2E-19726-0 S2E-19391-0 03E-94943-0 03E-94724-0 03E-94724-0 03E-94657-0
**
695-00237-0
SAE B, 13 Tooth
**
S2E-19365-0 03E-94945-0 03E-93277-0 03E-93277-0 03E-94273-0 03E-93946-0 695-00243-0
SAE BB, 15 Tooth
**
S2E-19409-0 03E-94361-0 03E-93279-0 03E-93279-0 03E-94272-0 03E-93945-0 695-00243-0
SAE C, 14 Tooth
**
**
**
SAE CC, 17 Tooth
**
**
**
**
**
SAE D&E, 13 Tooth
**
**
**
**
**
Seal Kits
03E-93276-0 03E-93276-0 03E-94271-0 03E-93944-0
03E-94270-0 03E-93943-0
**
695-00251-0
695-00251-0
03E-93942-0 695-00259-0
018
028
045
060
075
100
140
S2E-18709-5K
S2E-19118-5K
S2E-19066-5K
S2E-18697-5K
S2E-18004-5K
S2E-18460-5K
S2E-18158-5K
Note: Seal kits contain all the seals required for any pump configuration.
26
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Parts Kits
Rotating Group
Kits
018
028
045
060
075
100
140
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
Ripple Chamber
S2E-19205-0K
S2E-19209-0K
S2E-19235-0K
**
**
**
**
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/
Ripple Chamber
S2E-19206-0K
S2E-19210-0K
S2E-19236-0K
**
**
**
**
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/
Ripple Chamber
S2E-19207-0K
S2E-19211-0K
S2E-19126-0K
**
**
**
**
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
w/ Ripple Chamber
S2E-19208-0K
S2E-19212-0K
S2E-19127-0K
**
**
**
**
060
075
100
140
S2E-19033-5
S2E-18720-5
S2E-18888-5
S2E-18963-5
**
**
**
S2E-18721-5
S2E-18759-5
S2E-18739-5
Rotating Group Kit includes barrel s/a, pistons, retainer, washer, pins, port plate
Torque Limiter Control Kits
Torque Limiter Kit for AMT Control
045
S2E-19102-5
Torque Limiter Kit for ALT Control
Torque Limiter Kit for L0T
See Note
**
**
Torque Limiter Kits includes cartridge assembly, tubing and fittings.
Note: AM control can be converted to an AL control with conversion kit S2E-19117-0.
European customers will receive a solid spool in this kit. US customer will receive a set screw to plug orifice in spool.
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
27
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
“C” Compensator
Outer spring used C0 only.
Inner spring used for both
C0 and C1 versions.
NOTE: Individual parts are not available.
The compensator is sold as a complete assembly only.
Compensator Part Number
Rotation
C0
80 - 280 bar (1150 - 4000 psi)
C1
20 - 80 bar (300 - 1150 psi)
CW
S2E-17904-5 T
S2E-18285-5 T
CCW
S2E-17905-5 T
S2E-18286-5 T
Item
no.
Quantity
1
1
2
1
Spool
3
1
Spring seat
4
1
Outer spring
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
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
Description
NOTES / Tightening Torque
Compensator body CW rotation
Compensator body CCW rotation
C0 versions only
115 ± 7 N-m (85 ± 5 ft-lbs)
30
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Compensator Procedures
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.
Compensator Disassembly:
Measure and record the extension of the two pressure adjusting screws.
1.
COMPENSATOR INSPECTION
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 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.
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 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.
COMPENSATOR SPRING FREE LENGTH
Type
Item
Number
C*/L*
5
Main compensator spring - inner
Free height: 25.9±0.5mm (1.020±0.020 in.)
C0/L0/L2
4
Main compensator spring - outer
Free height: 39±0.7mm (1.535±0.028 in.)
L*
17
Load Sense spring
Free height: 14±0.4mm (0.551±0.016 in.)
R*
6
Bias spring
Component
Tolerances
Reference item numbers on page 26.
32
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Compensator Procedures
COMPENSATOR ASSEMBLY
NOTE: instructions
are for load
COMPENSATOR
ASSEMBLY
COMPENSATOR
COMPENSATOR
ASSEMBLY
ASSEMBLY
sense compensator.
for other
compensator types disregard steps
NOTE:
are
for
NOTE:
NOTE:
instructions
instructions
are
for load
load
relatedinstructions
to extra spool
assembly.
sense
other
sensecompensator.
compensator.
compensator.For
for
for other
compensator
types
disregard
steps
compensator
compensator types
types disregard
disregard steps
steps
related
to
extra
spoolassembly.
assembly.
related
related to
to extra
extra spool
spool
assembly.
Carefully clean and dry all parts prior to assembly. Use caution to insure that
spools and other parts are not damaged during cleaning process. Use clean oil to
lubricate seals and spools for easier assembly.
Carefully clean
clean and
and dry
dry all
all parts
parts prior
prior to
to assembly.
assembly. Use
Use caution
caution to
to insure
insure that
that
Carefully
spools
and other
other
parts
areall
not
damaged
during
cleaning
process.
Useplugs
cleanand
oil to
to
spools
and
are
not
damaged
during
process.
Use
clean
oil
1. Remove
andparts
discard
o-rings.
Install
newcleaning
o-rings on
SAE boss
lubricate
seals
and
spools
for
easier
assembly.
lubricate
seals
and
spools
for
easier
assembly.
seal pistons.
1.
Remove
and film
discard
alltoo-rings.
o-rings.
Install
newmain
o-rings
on SAE
SAE boss
boss
plugs
and
1.
and
discard
Install
new
o-rings
on
and
2. Remove
Apply a light
of oilall
the o-ring
on the
compensator
sealplugs
piston.
seal
pistons.
seal
pistons.
Install the main compensator seal piston in the main compensator spring
cap.
2. Apply
Apply aa light
light film
film of
of oil
oil to
to the
the o-ring
o-ring on
on the
the main
main compensator
compensator seal
seal piston.
piston.
2.
Install
the
main
compensator
seal
piston
in
the
main
compensator
spring
Install
the
main
compensator
seal
piston
in
the
main
compensator
spring
3. Place inner compensator spring on seal piston. Install the outer compensator
cap.
cap.
spring over the inner spring on the seal piston. Position the spring seat over
the springs. Insert this assembly into the main compensator housing bore.
3. Place
Place
inner
compensator
springspring
on seal
seal
piston.
InstallNm
the (125-135
outer compensator
compensator
3.
inner
spring
on
piston.
Install
the
outer
Torque
the compensator
main
compensator
cap
to 169-183
ft.-lb.).
spring over
over the
the inner
inner spring
spring on
on the
the seal
seal piston.
piston. Position
Position the
the spring
spring seat
seat over
over
spring
the
springs.
Insert
this
assembly
into
the
main
compensator
housing
bore.
the
springs.
Insert
this
assembly
into
the
main
compensator
housing
bore.
4. Apply a light film of oil on the main compensator spool (the longer of the 2
Torque
the
main
compensator
spring
cap
to opposite
169-183 Nm
Nmmain
(125-135
ft.-lb.).
Torque
main
compensator
spring
to
169-183
(125-135
ft.-lb.).
spools).the
Insert
the
spool into the
spoolcap
bore
the
compensator
Main Outer Spring
Main
Main Outer
Outer Spring
Spring
spring assembly in the compensator body. The rounded end of the spool
4. Apply
Apply
light
film of
of oil
oil on
on
the
main
compensator
spool
(the
longer
of the
the
4.
light
film
main
compensator
spool
(the
longer
of
22
seat.
Install
a new
o-ring
shouldaabe
installed
first
sothe
it will
contact
the spring
spools).
Insert
the
spool
into
the
spool
bore
opposite
the
main
compensator
spools).
Insert
the
spool
into
the
spool
bore
opposite
the
main
compensator
on the hardened SAE boss fitting and place it into the port. Torque fitting to 4
spring
assembly
in
the compensator
compensator body.
body. The
The rounded
rounded end
end of
of the
the spool
spool
spring
assembly
the
±
0.5 Nm
(37 ± 5in
in-lb).
should be
be installed
installed first
first so
so itit will
will contact
contact the
the spring
spring seat.
seat. Install
Install aa new
new o-ring
o-ring
should
on
the
hardened
SAE
boss
fitting
and
place
it
into
the
port.
Torque
fitting
to
fitting
to 44
on
the
hardened
SAE
boss
fitting
and
place
it
into
the
port.
Torque
5. Apply a light film of oil to the o-ring on the load sense seal piston. Install the
±load
Nm
±± 55 in-lb).
± 0.5
0.5sense
Nm (37
(37
in-lb). seal piston seat in the load sense spring cap.
compensator
Install the load sense spring over the seal piston. Position the spring seat
5.
aa light
film
of
the
o-ring
the
load
sense
seal
piston.
Install
5. Apply
Apply
light
filmInstall
of oil
oil to
to
the
o-ring on
oninto
thethe
load
sense
seal
piston.
Install the
the
over the
spring.
this
assembly
load
sense
bore
of the
load
sense
seal
seat
in
load
load
sense compensator
compensator
seal piston
piston
seat
in the
thespring
load sense
sense
spring
cap.(26-28
compensator
housing. Torque
the load
sense
cap tospring
35-38 cap.
Nm
Install
Install
the load
load sense
sense spring
spring over
over the
the seal
seal piston.
piston. Position
Position the
the spring
spring seat
seat
ft. lb.).the
over
over the
the spring.
spring. Install
Install this
this assembly
assembly into
into the
the load
load sense
sense bore
bore of
of the
the
housing.
the
load
spring
to
Nm
compensator
housing.
Torque
thesense
load sense
sense
spring cap
cap
to 35-38
35-38
Nm (26-28
(26-28
6. compensator
Apply
a light film
of oil Torque
to
the load
compensator
spool
(the shorter
of
ft.
lb.).
ft.
lb.).
the 2 spools). Insert the spool into the spool bore opposite the load sense
spring assembly. The spool should be installed with the rounded end in first
6.
aa light
film
of
to
load
sense
compensator
spool
(the
shorter
6. Apply
Apply
light
filmthe
of oil
oil
to the
the
load
sense
compensator
spool
(theon
shorter
of
so
it will
contact
load
sense
spring
seat.
Install a new
o-ring
the of
the
2
spools).
Insert
the
spool
into
the
spool
bore
opposite
the
load
sense
the
2
spools).
Insert
the
spool
into
the
spool
bore
opposite
the
load
sense
hardened SAE boss fitting and place it into the port. Torque fitting to 4 ± 0.5
spring
spring assembly.
assembly. The
The spool
spool should
should be
be installed
installed with
with the
the rounded
rounded end
end in
in first
first
Nm (37 ± 5 in-lb).
so
so itit will
will contact
contact the
the load
load sense
sense spring
spring seat.
seat. Install
Install aa new
new o-ring
o-ring on
on the
the
SAE
boss
fitting
place
into
port.
Torque
to
hardened
SAEon
boss
fitting and
and
place
into the
theand
port.
Torque
fitting
to 44 ±± 0.5
0.5
7. hardened
Install
o-rings
remaining
SAE
bossititfittings
install
intofitting
housing.
Nm
(37
±
5
in-lb).
Nm
(37
±
5
in-lb).
Torque SAE-2 fittings to 4 ± 0.5 Nm (37 ± 5 in-lb).
7.
7. Install
Install o-rings
o-rings on
on remaining
remaining SAE
SAE boss
boss fittings
fittings and
and install
install into
into housing.
housing.
Torque
Torque SAE-2
SAE-2 fittings
fittings to
to 44 ±± 0.5
0.5 Nm
Nm (37
(37 ±± 55 in-lb).
in-lb).
Load Sense Spool
Load Sense
Spring
Main Compensator
Inner Spring
Load
Load Sense
Sense
Spring
Spring
Main
Main Compensator
Compensator
Inner
Inner Spring
Spring
Load Sense
Sense Spool
Spool
Load
Main Compensator Spool
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Main Compensator
Compensator Spool
Spool
Main
33
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
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
procedures previously
listed
do not solve the problem.
Disassembly and reassembly
should be performed
in a clean
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
reassembly should be performed in a clean environment.
compression and bodilyDisassembly
injury mayand
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
replaceparts
the spring
unless
necessary.
After disassembly, the internal
should
beabsolutely
coated with
a film of clean oil and
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
It is recommended
that the length
the protruding
of the compensator
adjusting screws, on the control
40 be measured
andofnoted
as thisportion
information
adjusting screws, on the control 38 be measured and noted as this information
will prove useful during assembly.
will prove useful during assembly.
Care must be taken to avoid
damaging
or contaminating
machined
Caredropping,
must be taken
to avoid dropping,
damaging or the
contaminating
the machined
parts and the control valve.
parts and the control valve.
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.
1.
Identify the pump from information on the data tag. Figure 1
Identify the pump from information on the data tag. Figure 1
Figure 1
34
Figure 1
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
PUMP DISASSEMBLY
Continued
2.
Drain fluid from housing. Fluid drained from pump should be disposed of
properly.
2. 3.
Drain
fluidpump
frominhousing.
drained
fromwhile
pump
should main
be disposed
Mount
fixture toFluid
prevent
movement
removing
housing of
bolts
properly.
3. 4.
Mount
pumpbolts
in fixture
prevent
movement
whileonremoving
housing
Remove
holdingtothe
compensator
assembly
the pump main
housing.
bolts
Additional fluid may drain out of the passages when the compensator is
4.
5.
removed. Set compensator aside for later disassembly and inspection
Remove bolts holding the compensator assembly on the pump housing.
Additional
may attaching
drain outthe
of port
the passages
the compensator is
5.
Removefluid
the bolts
block to thewhen
main housing.
removed. Set compensator aside for later disassembly and inspection
6.
Carefully remove the port block. Use caution to avoid dropping the port
Remove
attaching
thebias
portspring
block- piston
to theassembly
main housing.
plate. the
Notebolts
the location
of the
and the control
6.
piston assembly.
The
control
piston,
piston
biasdropping
spring may
Carefully
remove the
port
block.
Usebias
caution
toand
avoid
theremain
port
in pump when port block is removed. Remove and discard the three white
plate.
Note
the
location
of
the
bias
spring
piston
assembly
and
the
Teflon seals on the port block. These seals should be replaced each timecontrol
piston
The control piston, bias piston and bias spring may remain
the assembly.
pump is disassembled.
in pump when port block is removed. Remove and discard the three white
7.
Remove
piston
andThese
the bias
piston
- spring
Teflon
sealsthe
oncontrol
the port
block.
seals
should
beassembly.
replaced each time
rotation change only, do not disassemble further, proceed to
the NOTE:
pump isFor
disassembled.
7.
Remove the control piston and the bias piston - spring assembly.
8.
Remove
the tapered
roller bearing
shim from the
end of
the shaft.
For rotation
change
only, docone
not and
disassemble
further,
proceed
to
NOTE:
step 14.
8.
step 16.
9.
Position the pump horizontally and remove the rotating group. Avoid
from theand
barrel
if possible.
This will group.
assist inAvoid
separating
the pistons
the pump
horizontally
remove
the rotating
Position
identifying
an barrel
individual
piston and
borewill
during
component
thedamage
pistonsbetween
from the
if possible.
This
assist
in
separating
inspection.
identifying
damage between an individual piston and bore during component
inspection.
10.
Remove the drive shaft.
NOTE: Forashaft
no further disassembly
Proceed
045 pump
turn housing
8a. If completing
sealchange
changeonly,
or complete
overhaul onisarequired.
to assembly procedure step 5.
over and remove the snap ring and shaft seal from the housing before moving
on to
step 9.the cam by rotating it 90 degrees and carefully extracting it from the
11.
Remove
9.
pump cam
housing.
the large
pocket
under
fromNote
housing.
See
Figure
2 the cam fits on the pressure
Remove
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
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
35
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
PUMP DISASSEMBLY
Continued
10. Remove cam bushing screws and cam bushings from pump.
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.
Proceed to inspection section of this manual.
36
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
PUMP INSPECTION PROCEDURES
COMPENSATOR INSPECTION
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
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 severelydamaged, 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 dimension exceeds the allowable limit, the barrel needs to be replaced. Examine
the barrel face for scratches and gouges. The barrel canbe reworked if dimensions 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. Anymarks 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.
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.
37
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
Chart 1
Rework Limits
Item Number
Component
018 Part No
028 Part No
045 Part No
13
Page 16 & 17
Bias Spring
03E-94430-0
78.3 mm
03E-94393-0
87.5 mm
03E-94356-0
116.4 mm
20
Page 16 & 17
Barrel Spring
787635
41.4 mm
03E-94387-0
39.5 mm
03E-94350-0
48.3 mm
789519
Max End Play
0.10 mm
S2E-18415-0
Max End Play
0.07 mm
S2E-184130-0
Max End Play
0.10 mm
Min Shoe
Flange
Thickness
2.97 mm
Min Shoe
Flange
Thickness
3.98 mm
Min Shoe
Flange
Thickness
4.98 mm
26
Page 16 & 17
23
Page 16 & 17
Piston
Barrel
03E-94717-0
03E-94375-0
03E-94338-0
Tolerances
Free Height +/- 0.2mm
Free Height +/- 0.2mm
Measure OD in 3 places,
top, middle and bottom.
Measurement should
not vary by more than
0.01 mm
End Play between piston
and shoe should not
exceed value shown
Measure piston bore ID
in 3 places , top, middle,
bottom. Measurement
should not vary by more
than 0.01 mm.
Max material to be
removed by lapping is
.0051 mm
4
Page 28 & 30
P Max
Compensator
Spring-Outer
03E-93158-0
39 mm
Free Height : +/- 0.7mm
5
Page 28 & 30
P Max
Compensator
Spring- Inner
03E-93159-0
26 mm
Free Height : +/- 0.5mm
17
Page 28
Load Sense
Spring
03E-93825-0
14 mm
Free Height : +/- 0.4mm
38
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
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)
3.
10. With the average, use chart 2 to determine the correct shim to install in the
spring was removed during disassembly process, install
If barrel hold down
pump.
three pins to slots in barrel spline (45 Size only). Petroleum jelly can be used
to hold pins in
while
remaining
parts.
(Figure
4) Place
barrelinstall
11.place
If barrel
holdinstalling
down spring
was removed
during
disassembly
process,
three
pins
to slots
in barrel
spline.washer
Petroleum
jelly
can down
be used
to holdand
pins in
on fixture with pin
side
down.
Install
backup
and
hold
spring
while
installing remaining
parts.
(Figure
Place snap
barrel ring.
on fixture with
second back up place
washer.
Compress
spring in
press
and4)install
pin side down. Install backup washer and hold down spring. Compress
Caution: Make sure
snap
ringand
is properly
seated
in groove
prior
removing
spring
in press
install snap
ring. Caution:
Make
suretosnap
ring is
barrel from press.
properly seated in groove prior to removing barrel from press.
Figure 4
4.
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Apply a light film of oil into the piston CHART
bores. 2Lightly lubricate the spherical
surface
the bores in the hold
Meof
asuthe
red guide
differenball.
tial Install the nine pistons into
Shim
downminimum
plate. Install
the spherical
guide ball
into
down
plate. While
maximum
thickness
018
partthe
# hold028
part #
045 part #
holding the guide ball against the hold down plate, install the pistons into the
barrel.
39
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
PUMP ASSEMBLY PROCEDURES
Continued
Chart 2
Pump
Pump
Control and bias
guide torque045
of the
guide
nine pistons
Install the surface
locating
pin
on ball.
theInstall
portthe
block
face. into the bores in the hold
6.
For 045: Apply
Grade
T down
to guide
threads
and allow
holdingLoctite
the guidePrimer
ball against
the hold
plate, install
the pistons
into theto dry.
barrel.
Install unlubricated
o-rings on the control guide and bias guide. Apply Loctite
271 to 14.
guide
threads.
For
hand
rotation
Install
the locating
pinleft
on the
port block
face. the bias guide is installed nearest 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
(figure
5B.)
Torque
the Loctite
control
and bias
unlubricated
on the pin
control
guide and
bias
guide. Apply
271to
threads.inFor
left hand
the bias
guide
is installed
to the
guides as guide
specified
Chart
2. rotation
For 018,
028:
The
guidesnearest
are identical
and
dowel pin (figure 5A.) For right hand rotation the control guide is installed
press fit into
the holes. (Not shown in picture below)
nearest to the dowel pin (figure 5B.) Torque the control and bias guides as
Chart 3
Control and bias
guide torque
018
Press Fit
028
Press Fit
045
142 Nm (105 ft lbs)
13. Apply a light film of oil into the piston bores. Lightly lubricate the spherical
5.
down plate. Install the spherical guide ball into the hold down plate. While
specified in Chart 3.
Bias Piston
Guide
Locating pin
045 Picture
Control Pistonfrom the chart (see step 11.) Install the
23. Install bearing spacer as determined
Guide
rear bearing
on
the
drive
shaft.
Figure 5A
Figure 5B
Pump
045
Port Block with Left
Chart 4
Housing bolt
torque
Port Block with Right
Hand configuration
24 Confirm
that compensator rotation, portHand
plateconfiguration
rotation, control and bias
piston location indicate same direction of rotation.
16. Apply light oil film to control piston and install it in the control guide bore.
NOTE: The 140 had a lubrication hole in the piston. Confirm that the hole is
25 facing
Carefully
install
the
assembled
block
housing.
light
oil film
to
control
piston
andport
install
iton
inthe
thepump
control
guidePress
bore.the
the port
block.
The
control guide
has
nonsymmetrical
lubrication
port block
compress
the bias
spring
and
housing
Tighten the
grooves.
Thetoend
with the closest
grooves
must
beinstall
installed
towards bolts.
the
lightport
oilblock.
film
the pattern
bias piston.
Install
theblock
biasdoes
spring
the bias
bolts
in ato
cross
to insure
the port
notand
get cocked
on the
7.
Apply
8.
Apply
housing.
When port
block
is seated on the housing, torque bolts in a cross
piston in the
bias piston
guide
bore.
9.
piston
in theof
bias
piston guidejelly
bore. to the back surface of the port plate.
Apply a light
layer
petroleum
Install the
port
plate
on
the
port
block,
lining
the ofslot
on the
port housing.
plate
26.
Install
o-ring
seals
and
assembled
compensator
on
of pump
18. Apply a light layer of petroleum jelly to the
backup
surface
theside
port
plate.
Pumpthe
rotation
is on
indicated
by arrow
housing.
Torque bolts
Install
port plate
the
block,
liningon
upcompensator
the slot on the port
plate with
with the locating
pin.
(Refer
to port
Figure
6)
lightas
oilspecified
film to the bias
piston.
17. Apply
pattern
in chart
4. Install the bias spring and the bias
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.
Industrial
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
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:
and
quantity
The large pocket on the bottom surface
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 port plates
Figure 6
CW port plates
Dowel
10. Install the large o-ring in the groove on the port block. Install the three teflon
o-rings on the pressure communication ports of the port block.
CCW
40
CW compensator
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Maintenance
Chart 4
PUMP ASSEMBLY PROCEDURES
Housing bolt
Continued Pump
torque
045
23. Install bearing spacer as determined from the chart (see step 11.) Install the
rear bearing on the drive shaft.
Confirm
that compensator
rotation,
port
plate
controlThe
andchamfer
bias
11. 24
Install
the cam
bearings in the
cradle
area
ofrotation,
the housing.
on
piston location indicate same direction of rotation.
the back of the bearing must face the outer wall of the housing. Use Loctite
Grade
“T” or
suitable
onthe
screws
mating
threads
Primer
25
Carefully
install
theother
assembled
portprimer
block on
pumpand
housing.
Press
the in
housing.
Apply
Loctite #242
(usespring
sparingly)
to screw
threads
install
port block
to compress
the bias
and install
housing
bolts. and
Tighten
the
orifice
screws
to hold
bearings
inthe
place.
screws
to cocked
3.4 ± 0.25
bolts
in a cross
pattern
to insure
port Torque
block does
not get
on the
Nmhousing.
(33 ± 3 When
in-lb).port block is seated on the housing, torque bolts in a cross
pattern as specified in chart 4.
12. Place thin film of clean oil on cam bearing surfaces. Install cam in housing.
For Install
045, the
cam
must
tilted to permit
entry into
theofhousing.
(Figure 2)
26.
o-ring
seals
andbe
assembled
compensator
on side
pump housing.
NOTE:
The
largeispocket
on by
thearrow
bottom
surface of the
cam must
bebolts
on the
Pump
rotation
indicated
on compensator
housing.
Torque
to 5side
0.25
in-lb).
same
as Nm
the (45
three3pressure
communication holes on the main housing.
Pump rotation does not affect the assembly of the cam.
13. 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
Industrial portproperly
plates in the front bearing.
Chart 3
Pump
Housing bolt
torque
018
51 Nm (38 ft lbs)
028
70 Nm (52 ft lbs)
045
85 Nm (63 ft lbs)
14. Confirm that compensator rotation, port plate rotation, control and bias
piston location indicate same direction of rotation.
noteblock
slot length
on the pump housing. Press the
15. Carefully install the assembled port
and quantity
and install housing bolts. Tighten the
port block to compress the bias spring
bolts in a cross pattern to insure the port block does not get cocked on the
housing. When port block is seated on the housing, torque bolts in a cross
Mobile port plates
pattern as specified in chart 3.
16. Install o-ring seals and assembled compensator on side of pump housing.
Pump rotation is indicated by arrow on compensator housing. Torque bolts
to 5 ± 0.25
Nm (45
± 3plates
in-lb). (See Figure 7)
CCW
port
CW port plates
Dowel
CCW
CW compensator
Figure 7
CCW pump with
compensator
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
41
CW pump with
compensator
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Assembly Tools
T1 Seal Installation Tool
133 mm
(5.250 in)
18.5 mm
(0.728 in)
D
8.0 mm
(0.3150 in)
A
DIA
B
DIA
3.0 mm
(.12 in)
RADIUS
31.2 mm
(1.250 in)
DIA.
C
DIA
1.5 mm x 45 ˚ TYP.
(.06 in X 45 ˚ )
U-CUT
T1 Seal installation tool
A
B
C
D
(018)
2.250
1.62
1.18
0.406
(028)
2.250
2.00
1.378
0.447
A
T3 Seal Guard
B
C
30˚
D
F
+0.05 / -0.00mm
DIA BORE (+0.002 / - 0.000 in)
E +/- 0.05mm
DIA. (+/- 0.002 in)
BLEND RADIUS
& POLISH O.D.
T3
SealModel
Guard
Pump
018 (018 SAE)
“01”, “02”, “04” Shafts
018 (018 ISO)
“06” Shaft
(028 SAE)
028 / 045
“01”, “02”, “04” Shafts
(028 ISO)
018/028/045
“08” Shaft
(045 SAE)
A
76.20 mm
3.00 in.
B
50.80 mm
2.00 in.
C
19.05 mm
0.75 in.
76.20 mm
3.00 in.
50.80 mm
2.00 in.
19.05 mm
0.75 in.
76.20 mm
3.00 in.
50.80 mm
2.00 in.
76.20 mm
3.00 in.
50.80 mm
2.00 in.
D
D
EE
28.82 mm
1.135 in.
FF
20.45 mm
0.805 in.
15°
28.82 mm
1.135 in.
16.76 mm
0.66 in.
19.05 mm
0.75 in.
15°
38.10 mm
1.50 in.
26.00 mm
1.024 in.
19.05 mm
0.75 in.
15°
28.82 mm
1.135 in.
22.50 mm
0.885 in.
15°
(045 ISO)
42
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Assembly Tools
T2 Front Bearing P1/PD45 Installation Tool
T2 Front Bearing P1/PD045 Installation Tool
mm
( in )
89.75
( 3.53)
20.00
177.80
(0.787)
(7.00)
50.80
( 2.00)
29.92
( 1.178)
25.40
(1.00)
T5 Rear
Installation
Tool
T5Bushing
Rear Bushing
Installation
Tool
A
38
(1.5)
B 29
(1.14)
38
(1.5)
101.60
( 4.00)
mmmm
( in )
(in)
102
(4.0)
19.05
( 0.75)
B
A
38.10
13
( 1.50)
(.5)
12.7
( 0.5)
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Pump Size
A
3.71 mm
0.146 in.
B
19.9 mm
0.772 in.
028
4.00 mm
0.157 in.
21.6 mm
0.85 in.
045
4.00 mm
0.157 in.
24.1 mm
0.95 in.
018
43
25.40
( 1.00)
50.80
25
( 2.00)
(1.0)
Medium Pressure Axial Piston Pumps
P1/PDoil
Maintenance
018,
028,TEST
045PROCEDURE
Pump Test ProcedureTest criteria based on hydraulic
PUMP
ISO 32 per Parker HF-0 specifications.
Bulletin HY28-2665-02/SVC/EN
PUMP
TEST
PROCEDURE
PUMP
TEST
PROCEDURE
PUMP TEST PROCEDURE
Oil temperature: 50°C ± 2°C (120°F ±10°F). NOTE: insure that the hydraulic
system does not overheat during this test procedure.
Operating
speed:
- 2300 rpm
± 3032rpm.
Test
criteria based
on0hydraulic
oil ISO
per Parker HF-0 specifications.
pressure:
Maximum
14.5 psi
(1 bar)
OilCase
temperature:
50°C
± 2°C (120°F
±10°F).
NOTE: insure that the hydraulic
system does not overheat during this test procedure.
1. Mount
pump
on test
fixture.
Insure that shaft alignment is within specified
Operating
speed:
0 - 2300
rpm
± 30 rpm.
tolerances.
Case pressure:
Maximum 14.5 psi (1 bar)
1. 2.Mount
pumpwith
on test
fixture.
Insure that
shaftdrain
alignment
within specified
Fill case
clean
oil. Connect
upper
port toisreservoir
with no
Testtolerances.
criteria
based on hydraulic
oil ISO drain
32 per Parker
HF-0properly
specifications.
restrictions.
Insure other
ports are
plugged.
Oil temperature: 50°C ± 2°C (120°F ±10°F). NOTE: insure that the hydraulic
does not overheat during this test procedure.
2.system
case withinlet
clean oil.pressure
Connect upper drain port to reservoir with no
3.FillConnect
Operating
speed: 0 - 2300and
rpm ± 30 rpm. lines. Insure that lines are filled with oil. Refer to
restrictions.
Insure
other
are properly plugged.
circuit Maximum
below. For
“L” compensators,
connect a suitable pilot line
Case pressure:
14.5units
psidrain
(1 with
bar)ports
from port “X” to the pump discharge pressure line, down stream of the
Mount pump
on test
Insure
that shaft
alignment
is within
3.1. Connect
inlet
andfixture.
pressure
lines.
Insure
that lines
arespecified
filled with oil. Refer to
non-compensating
flow
valve.
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
case with clean
oil. Connect
upper drain
port to reservoir
withare
no correct.
direction
of rotation
for pump
and drive
non-compensating
flow
valve.
restrictions. Insure other
drain
ports are properly plugged.
Reduce
the main
compensator
setting
tofilled
minimum.
For units with “L”
Connect inlet
and pressure
lines. Insure
that lines
with
oil. Refer to
4.3. 5.Confirm
direction
of rotation
for pump
andare
drive
are
correct.
compensators,
the load sense
adjustment
circuit
below. For units advance
with “L” compensators,
connectcompensator
a suitable pilot line
from
port “X” toout,
the pump
discharge
pressure
line, down stream of the
bottoms
and
lock
into
position.
Reduce the main compensator setting to minimum. For units with “L”
non-compensating flow valve.
5.
until it
compensators, advance the load sense compensator adjustment until it
Set maximum
volume
stop
to full
out, and
lock
into
4. 6.bottoms
Confirm
direction
of rotation
for position.
pump (if
andincluded)
drive are correct.
displacement. If minimum
volume stop is included, back adjustment all of the way out.
Reduce
the main volume
compensator
to minimum.
Fordisplacement.
units with “L”
6.5. Set
maximum
stopsetting
(if included)
to full
If minimum
compensators,
advance
the load
sense compensator
until±it30 rpm with no load.
7.volume
If possible,
gradually
increase
pump speed
to way
1800
stop is
included,
back
adjustment
all adjustment
of the
out.
bottoms out, and lock into position.
7.6. 8.IfSetpossible,
increase
pump
to
1800
±
30 rpmout,
withwith
no load.
no pressure
Screw
ingradually
compensator
adjusting
screw
until
itIfbottoms
maximum
volume
stop
(if included)
to fullspeed
displacement.
minimum
volume
stop is included,
back adjustment
on system
load-relief
valve. all of the way out.
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.
system load-relief
9.on Break-in
pump at valve.
times and pressures listed below. Adjust the load-relief
8.
Screw
in compensator
adjusting
screwfor
untilthe
it bottoms
with no pressure
valve
to the pressure
listed
times out,
indicated.
After break-in,
8.
9.
reduce
Break-in
pump
at setting
times
pressures
listedpsi),
below.
load-relief
on system
load-relief
valve. and
compensator
to 280
bar (4060
andAdjust
adjustthe
system
load relief to
valve
to the
pressure
listed for the
timestimes
indicated.
After
break-in,
reduce
cause
pump
to
compensate
three
to
verify
that
pump
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
off pressure
stroke properly.
valve
to the
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
stroke
properly. three times to verify that pump compensates on
causeoff
pump
to compensate
Time
30properly.
seconds
and off stroke
Time
30 seconds
30 seconds
TESTCIRCUIT
CIRCUIT
TEST
TEST CIRCUIT
TEST CIRCUIT
1. Test pump
Test pump
2. Test
Test1.pump
stand
prime mover
1.
2. Test stand prime mover
3. Test
Pump
pressure
2.
stand
prime gauge
mover
3. Pump pressure gauge
3.
gaugeflow
4. Pump
Non-compensating
control
4. pressure
Non-compensating
flow
control
4.
flow
control
5. pressure
Load pressure
gauge
5. Non-compensating
Load
gauge
6.pressure
Load valve
relief
valve
5.
gauge
6. Load
Load
relief
7.relief
Safety
bypass relief valve
6.
valve
7. Load
Safety
bypass
relief
8. Main flow meter valve
7.
bypass
relief
valvegauge
8. Safety
Main
9. flow
Casemeter
drain
pressure
8.
meter
10.flow
Case
drain
flow meter
9. Main
Case
drain
pressure
gauge
9. Case
gauge
11. drain
Filterpressure
assembly
with
bypass
10.
Case
drain
flow meter
12. drain
Cooler
assembly
with bypass
10.
Case
flow
meter
11. Filter
assembly
with bypass
13.assembly
Reservoir with
11.
bypass
12. Filter
Cooler
assembly with
bypass
12. CoolerNOTE:
assembly
with
bypass
13. Reservoir Items 4 and 5 are required
13. Reservoir
for load sense pump test.
NOTE:Items
Items44and
and5 5are
arerequired
required
NOTE:
for
load
sense
pump
test.
for load sense pump test.
Pressure
30 seconds
30 seconds
Pressure30 seconds
Time
Time
3062-69
seconds
Pressure
Bar
Pressure
30 seconds
30 seconds
30 seconds
200-207 Bar
900-1000 psi
30 seconds
30 seconds269-276 Bar.
2900-3000 psi
3900-4000 psi
6
6
6
5
5
5
4
4
4
3
3
8
3
2
2
8
8
1
2
1
1
7
EM
“X”
EM
EM
7
7
11
11
“X”
“X”
12
13
9
10
Circuit 1
9
9
10 10
44
Circuit
1
Circuit
1
11
12
12
13
13
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
018, 028, 045 Pump Test Procedure
PERFORMANCE SPECIFICATIONS
PUMP WITH PRESSURE COMPENSATOR
STEP
REFERENCE
CONDITION
018
028
045
1
Rated Speed
1800
1800
1800
4
Output Flow at minimum pressure
32 lpm
minimum
49 lpm
minimum
80 lpm
minimum
5
Output Flow at rated pressure of 280 bar
30 lpm
minimum
47 lpm
minimum
77 lpm
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
11
Output Flow when pressure reduced to 273 bar
with compensator set at 280 bar
30 lpm
minimum
47 lpm
minimum
77 lpm
minimum
* When using the A series compensators increase compensated case leakage by 2.3 lpm
TEST PROCEDURE
PUMP WITH PRESSURE COMPENSATOR
STEP
REFERENCE
CONDITION
REQUIRED VALUE
1
Set the pump speed to 1800 RPM
1800 rpm
2
Increase pump pressure compensator adjustment to
maximum.
n/a
3
Record input oil temperature
43-54 ° C (110 – 130 °F)
4
Set output load pressure to minimum.
Record output flow
see performance chart
5
Set output load pressure to 280 ± 2 bar
(4060 ± 30 psi). Record output flow
see performance chart
6
Record case leakage
see performance chart
7
Set output pressure to 290 ± 2 bar (4200 ± 30 psi)
n/a
8
Set pressure compensator to
280 ± 2 bar (4060 ± 30 psi)
n/a
9
Record case leakage
see performance chart
10
Record input torque
see performance chart
11
Reduce output pressure to 273 ± 2 bar
(3960 ± 30 psi). Record output flow
see performance chart
12
Verify no external leaks
No leakage permitted
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
45
MEASURED VALUE
Medium Pressure Axial Piston Pumps
P1/PD Maintenance
Bulletin HY28-2665-02/SVC/EN
Conversions & Formulas
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
lbs/in2 (psi) x 6.895 = kPa
bar x 14.50 = lbs/in2 (psi)
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
cm2 x 0.1550 = in2
length
in x 25.4 = mm
2
2
mm x 0.03937 = in
temperature degree F-32 = °C
1.8
1.8 x C+32 = °F
viscosity
mm2/sec x 1.0 = cSt
20 cSt = 99 SSU
cSt x 1.0 = mm2/sec
SSU = cSt x 4.25 + 14
FLUID POWER FORMULAS
Pump input torque
lbs. in.
pressure(psi) x displacement (in3/rev)
2� x mech. eff.
Pump input power
hp
rpm x (in3/rev) x (psi)
395934 x overall eff.
Pump output flow
U.S. gpm
rpm x (in3/rev) x volumetric eff.
231
Fluid motor speed
rpm
231 x flow rate(U.S. gpm) x volumetric eff.
displacement (in3/rev)
Fluid motor torque
lbs. in.
pressure(psi) x displacement (in3/rev) x mech. eff.
2�
Fluid motor power
hp
rpm x (in3/rev) x (psi) x overall eff.
395934
(metric)
Pump input torque
Nm
pressure(bar) x displacement (cm3/rev)
20� x mech. eff.
Pump input power
kW
rpm x (cm3/rev) x (bar)
600000 x overall eff.
Pump output flow
Lpm
rpm x (cm3/rev) x volumetric eff.
1000
Fluid motor speed
rpm(min-1 ) (tr/mn)
1000 x flow rate (Lpm) x volumetric eff.
displacement (cm3/rev)
Fluid motor torque
Nm
pressure(bar) x displacement (cm3/rev) x mech. eff.
20�
Fluid motor power
kW
rpm x (cm3/rev) x (bar) x overall eff.
600000
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA
59
Check Valves
DC Series
DC Series Check Valves are Rugged,
Cost-competitive.
The DC Series offers basic, workhorse check valves – ruggedly
built, readily available and reasonably priced. They are in-line
valves, available in sizes 1Ú4” to 2”, with a pressure rating
range up to 5000 psi, and flow capacities to 300 GPM.
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.
3
2
4
4. Poppet has an oil retention groove that lubricates the bore
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
E Valves
DC Series- Part Numbers
Valve
Size
Dimensions (In.)
Part Number
Inlet Port Thread
Length
Wrench
Flats
Outlet Port Thread
** Std Crack
Pressure (psi)
Max Operating
Pressure (psi)
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
E-12
Parker Hannifin Corporation
Quick Coupling Division
Minneapolis, MN
www.parker.com/quickcouplings
Check Valves
Flow Data
DC Series
DC Series (3/8", 1/2" & 3/4")
Test Fluid: Oil - 200 SUS
DC Series (1/4")
Test Fluid: Oil - 200 SUS
120
80
70
50
Pressure Drop in PSID
Pressure Drop in PSID
60
1/4"
DC-250
40
30
3/4"
DC-750
1/2"
DC-500
3/8"
DC-370
100
80
60
40
20
20
10
0
0
0
2
4
6
8
10
0
10
20
Flow - USGPM
30
40
50
60
Flow in USGPM
DC Series (1", 1-1/4", 1-1/2" & 2")
Test Fluid: Oil - 200 SUS
120
110
90
1-1/4"
DC-1250
80
1-1/2"
DC-1500
1"
DC-1000
70
2"
DC-2000
60
50
40
E Valves
Pressure Drop in PSID
100
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-✱✱✱-✱✱✱✱-✱✱
Series
Size
250 = 1/4”
370 = 3/8”
500 = 1/2”
750 = 3/4”
1000 = 1”
1250 = 1-1/4”
1500 = 1-1/2”
2000 = 2”
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:
Blank = Female pipe inlet to Female pipe outlet
FOFO = Female O-ring Boss inlet to Female O-ring Boss outlet
E-13
Parker Hannifin Corporation
Quick Coupling Division
Minneapolis, MN
www.parker.com/quickcouplings
Inserta® Products, Inc.
CHECK VALVES
4-BOLT
FLANGE TYPE
INSERTA® ICFT Check Valves, Flange Type, provide an effective way to install a Check Valve or Fixed
Orifice Flow Control Valve in a piping system that
uses SAE 4-Bolt flange ports. These flange bodies
include the INSERTA® ICT Thread-In Type Check
Valves. The free flow direction is always from the
surface with the seal to the surface without the seal.
The nominal size INSERTA® ICT Thread-In Type
Check Valve, matches the nominal flange size to
meet most flow requirements for the given flange
size. The INSERTA® ICFT Check Valves, Flange
Type, 6132 and 6232 are also available with -24
size Check Valves for those applications that do
not require the flow capacity of the -32 size.
For those applications where one requires the free
flow from the plain surface to the surface with the
seal, the INSERTA® ICF Check Valve Body or
INSERTA® ICFS Check Valve Body with Support Member, Flange type, should be used with
the INSERTA® ICS Check Valve, Slip-In Type.
The INSERTA® ICS Check Valve, Slip-In Type,
can be inserted from either end to permit free flow
through the body in either direction. The ICF bodies
use a larger nominal size INSERTA® ICS Check
Valve, and is the check valve of choice in higher
flow applications.
PATENT 5,338,075
INSERTA® ICFT Check Valves, Flange Type, are
all steel construction.
ORDERING INFORMATION
ICFT – A – 61 32 (24) – N 015 – RØ
INSERTA®
CHECK VALVE
FLANGE TYPE
(w/ICT CHECK)
FLOW CONTROL OPTION
R = FIXED RESTRICTIVE ORIFICE
Ø = DIAMETER (INCH) OF THE FIXED
ORIFICE. CUSTOMER MUST SPECIFY
THE ORIFICE DIAMETER.
SEE “RØ” ON DATA SHEET FOR
DESIGN CODE
ORIFICE DATA.
MOUNTING PATTERN
CRACKING PRESSURE
61 = SAE CODE 61
62 = SAE CODE 62
NOMINAL SIZE
08
12
16
20
=
=
=
=
1/2
3/4
1
1 1/4
24
32
40
48
=
=
=
=
1-1/2
2
2 1/2
3
Inserta Products, Inc.
Blue Bell, Pa. 19422
003
007
015
030
(USED WHEN ICT
CHECK SIZE IS
SMALLER THAN THE
NOMINAL SIZE)
OMIT WHEN THE SAME
SEAL COMPOUND
N = BUNA–N (STANDARD)
V = VITON
CHECK VALVE
4-BOLT
FLANGE TYPE
© 2010 ADACONN® + INSERTA® All rights reserved.
= 3 PSI
= 7 PSI
= 15 PSI (STANDARD)
= 30 PSI
ø
1 ø
1
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.
**See Page 17 for Flow Control
Option Orifice data.
CAUTION - Care must be
exercised when installing check
valve to insure the free flow path is
correct for the system in which it is
installed.
L
1
Ø
* SEAL PROTECTOR
H
W
CODE 61
MOUNTING
PATTERN–
SIZE
6108
6112
6116
6120
6124
6132 (24)
6132
6140
6148
NOMINAL
SIZE
NOM. FLOW
RATE (GPM)
W
H
12
25
35
63
80
80
135
155
175
1.37
1.75
2.00
2.25
2.75
3.00
3.25
3.50
4.00
1.00
1.25
1.50
2.00
2.25
2.00
3.50
3.75
4.00
2.12
2.50
2.75
3.00
3.75
4.00
4.00
4.50
5.00
NOM. FLOW
RATE (GPM)
W
H
L
O-RING
SIZE NO.
THREAD-IN
CHECK VALVE
PART NO.
1.50
1.87
2.25
2.50
3.00
3.50
4.00
4.25
5.00
1.00
1.25
1.50
2.00
2.25
2.00
3.50
4.00
4.00
2.25
2.75
3.00
3.50
4.25
5.00
5.00
6.00
8.00
210
214
219
222
225
228
228
232
237
ICT–B–08–***
ICT–B–12–***
ICT–B–16–***
ICT–B–20–***
ICT–B–24–***
ICT–B–24–***
ICT–B–32–***
ICT–B–40–***
ICT–B–48–***
1/2
3/4
1
1 1/4
1 1/2
2
2
2 1/2
3
L
O-RING
SIZE NO.
THREAD-IN
CHECK VALVE
PART NO.
210
214
219
222
225
228
228
232
237
ICT–B–08–***
ICT–B–12–***
ICT–B–16–***
ICT–B–20–***
ICT–B–24–***
ICT–B–24–***
ICT–B–32–***
ICT–B–40–***
ICT–B–48–***
CODE 62
MOUNTING
PATTERN–
SIZE
NOMINAL
SIZE
6208
6212
6216
6220
6224
6232 (24)
6232
6240
6248
1/2
3/4
1
1 1/4
1 1/2
2
2
2 1/2
3
12
25
35
63
80
80
135
155
175
REFERENCE DATA
NOMINAL FLOW RATINGS ARE WITH A Δ P OF 30 TO 40 PSI. In applications where the valve is subject
to sudden shock opening or closing (e.g. Accumulator System), the nominal rated flow must not be exceeded and a minimum cracking pressure of 15 PSI is required. THE PRESSURE RATING OF THESE VALVE
ASSEMBLIES MAY BE LIMITED BY THE ICT CHECK INSERT. REFER TO THE ICT DATA SHEET.
Inserta Products, Inc.
Blue Bell, Pa. 19422
CHECK VALVE
4-BOLT
FLANGE TYPE
© 2010 ADACONN® + INSERTA® All rights reserved.
TEMPERATURE RANGE: -22 F (-30 C) TO 175 F (80 C)
OPERATING MEDIUM: HYDRAULIC FLUID
VISCOSITY RANGE: 50 SSU TO 2000 SSU
CRACKING PRESSURE: 3 PSI, 7 PSI, 15 PSI
(STANDARD) & 30 PSI.
ø
1 ø
1
www.adaconn.com / www.inserta.com
Catalog HY15-3502/US
Technical Tips
Pressure Control Valves
CV
INTRODUCTION
Check
Valves
SH
Shuttle
Valves
LM
Load/Motor
Controls
FC
This technical tips section is designed to help familiarize you with the Parker line of Pressure Controls. In this
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
give a brief synopsis of the operation and applications of the various product offered in this section.
NEW PRODUCTS
There are several new additions and product improvements to our Pressure
Controls product line.
Here are just some of the design features and advantages
to the “Winner’s Circle” product line.
Flow
Controls
Variety of Adjustments
Pressure controls are offered
in screw adjust, knob adjust,
fixed and tamper resistant
configurations.
PC
Pressure
Controls
LE
Logic
Elements
Yellow Zinc Coating
Steel adapters are
coated with yellow zinc
di-chromate for protection
from salt spray.
DC
Directional
Controls
MV
Manual
Valves
“D”-Ring
Standard 4301 Polyurethane Seal
eliminates the need for backup rings
providing easier manifold installation.
(For more information on “D”-Ring
see Technical Data Section)
High Pressure Design
Pilot operated valves are rated
to 350 Bar (5000 PSI) for use
at elevated pressure.
SV
Solenoid
Valves
PV
Proportional
Valves
Crimp Design
Fold over crimp provides
secure holding and
eliminates the need
for adhesive.
Guided Pilot
Pilot is fully guided providing
a more consistent reseat.
CE
Coils &
Electronics
Internal Screen
A small internal screen
protects the pilot orifice and
spring chamber from debris.
BC
Bodies &
Cavities
TD
Technical
Data
High Rate Bias Spring
Pilot operated reducing and sequence
valves are designed with a high rate
bias spring pressure, enhancing stability.
Low Profile Adapter
The low profile shape of the pilot
operated pressure controls reduces
the manifold clearance required.
PC1
Parker Hannifin Corporation
Hydraulic Cartridge Systems
Catalog HY15-3502/US
Technical Tips
Pressure Control Valves
CV
COMMON OPTIONS
Check
Valves
As you will see, Parker offers a variety of Pressure
Control products. As such, some of the options
mentioned below may not be available on all valves.
Consult the model coding and dimensions for each
valve for specifics. Here are some of the common
options available.
Shuttle
Valves
SH
Seals: The Winner’s Circle products feature a
standard 4301 Polyurethane “D”-Ring. The “D”-Ring
eliminates the need for backup rings. The majority of
the products are available in Nitrile or Fluorocarbon
Seals. You should match the seal compatibility to the
temperature and fluid being used in your application.
Flow
Controls
Pressure
Controls
PC
LE
DC
MV
Manual
Valves
Knob Adjustment - An aluminum
knob is added to the standard screw
adjustment. A lock knob is provided
to help maintain the desired setting
after adjustment. Parker offers knob
conversion kits for most pressure
control valves. For kit numbers consult
individual valve pages.
FC
Logic
Elements
Screw Adjustment - Valve can be
adjusted with an allen wrench. Lock
nut included to maintain desired
setting after adjustment. This is the
most common adjustment option
available on most Parker products.
Tamper Resistant - The tamper
resistant option is a screw adjustable
valve with a steel cap installed to
conceal the adjustment. The cap is
designed so that the internal edges
clamp into the groove of the valve
adapter. Once the cap is installed,
it cannot be removed without damaging
the cap and the valve. When a valve is ordered with
the tamper resistant option, it will be preset at the
factory, and the cap will be included in a separate
plastic bag to allow for fine tuning at the customer site.
Parker offers tamper resistant cap conversion kits for
most pressure control valves. For kit numbers consult
individual valve pages.
Directional
Controls
Adjustment Types: Parker offers four primary types
of adjustments for most of the pressure control products. Samples of these types are shown below. Please
note all options may not be available for all valves.
Consult the individual catalog pages for more details.
Load/Motor
Controls
LM
Solenoid
Valves
SV
Proportional
Valves
PV
Coils &
Electronics
CE
Bodies &
Cavities
BC
TD
Technical
Data
Fixed Style - In most cases, the
Fixed Style product is a screw
adjustable product with a steel collet
threaded over the screw adjustment.
These valves are preset at the
factory.
Pressure Range: Parker offers a range of spring
settings for the Pressure Control product line. You
want to choose the setting that best meets the
operating range. The model callout is equivalent to the
maximum setting (in psi) of the spring divided by 100
(i.e. 50 = 5000 psi).
PC2
Parker Hannifin Corporation
Hydraulic Cartridge Systems
Catalog HY15-3502/US
Technical Tips
Pressure Control Valves
CV
PRODUCT TYPES / APPLICATIONS
Check
Valves
SH
Shuttle
Valves
Direct Acting Relief Valves
Direct acting relief valves are designed
for fast response in intermittent duty
applications. They are often used as an
economical solution to clip pressure spikes.
The poppet design allows for low leakage.
Tank (2)
Pressure
(1)
LM
Load/Motor
Controls
FC
Flow
Controls
PC
Pressure
Controls
LE
Logic
Elements
DC
Directional
Controls
MV
OPERATION - The valve poppet is held against the seat by the
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
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.
Differential Area Relief Valves
Differential area relief valves also are
also best suited for intermittent appliTank
cations where fast response is critical.
(1)
These valves are often used as crossover relief valves to chop pressure spikes.
Due to their design, they generally can handle a larger flow
rate and have a lower pressure rise than the standard directing
acting relief. The poppet design allows for low leakage.
Pressure
(2)
OPERATION - Pressure on the inlet (port 2) of the valve acts on the differential area of the poppet (difference
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.
Note: Any backpressure on port 1 would be additive to the spring setting.
Manual
Valves
SV
Solenoid
Valves
PV
Proportional
Valves
CE
Pilot Operated Relief
Pilot operated relief valves are designed
for continuous duty applications. Due to
their stability and low pressure rise, the
pilot operated relief is the best option for
setting the pressure of a hydraulic system.
Tank (2)
Pressure
(1)
Coils &
Electronics
OPERATION - When inlet pressure at the nose (port 1) exceeds
the valve setting, the pilot ball unseats. The pilot flow creates a pressure
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.
BC
Bodies &
Cavities
TD
Technical
Data
PC3
Parker Hannifin Corporation
Hydraulic Cartridge Systems
Differential Area Relief Valve
Series RDH083
Catalog HY15-3502/US
Technical Information
CV
General Description
Check
Valves
Differential Area Relief Valve. For additional
information see Technical Tips on pages PC1-PC6.
SH
Shuttle
Valves
LM
Load/Motor
Controls
FC
Features
Flow
Controls
•
•
•
•
Hardened, precision ground parts for durability
•
All external parts have yellow zinc dichromate. This
coating is ideal for salt spray applications.
Spherical poppets for low leakage
High flow capacity
Internal mechanical stop limits poppet travel eliminating
spring solidification
(2)
(1)
(2)
PC
Pressure
Controls
(1)
Specifications
LE
Rated Flow
45 LPM (12 GPM)
Performance Curve
Logic
Elements
Maximum Inlet
Pressure
380 Bar (5500 PSI)
Flow vs. Inlet Pressure
(Pressure rise through cartridge only)
Maximum
Pressure Setting
350 Bar (5000 PSI)
Maximum Tank
Pressure
350 Bar (5000 PSI)
Reseat Pressure
75% of crack pressure
Leakage at
150 SSU (32 cSt)
10 drops/min. (.67 cc/min.)
@75% of crack pressure
Cartridge Material
All parts steel. All operating
parts hardened steel.
PSI Bar
6000 414
Hydraulic Oil 150 SSU @ 100°F (32 cSt)
Directional
Controls
5000 345
MV
Manual
Valves
Pressure, PSI
DC
4000 276
3000 207
2000 138
SV
Solenoid
Valves
PV
Proportional
Valves
CE
Coils &
Electronics
Operating Temp.
Range/Seals
-40°C to +93.3°C (Nitrile)
(-40°F to +200°F)
-31.7°C to +121.1°C (Fluorocarbon)
(-25°F to +250°F)
Fluid
Compatibility/
Viscosity
Mineral-based or synthetic with
lubricating properties at viscosities
of 45 to 2000 SSU (6 to 420 cSt)
Filtration
ISO Code 16/13,
SAE Class 4 or better
Approx. Weight
.19 kg (.43 lbs.)
Cavity
C08-2
(See BC Section for more details)
Form Tool
Rougher
Finisher
1000
69
0
LPM
0
GPM
8
15
23
30
38
45
53
2
4
6
8
10
12
14
Flow (Q)
BC
Bodies &
Cavities
TD
Technical
Data
None
NFT08-2F
PC27
Parker Hannifin Corporation
Hydraulic Cartridge Systems
Differential Area Relief Valve
Series RDH083
Catalog HY15-3502/US
Technical Information
CV
Millimeters (Inches)
Check
Valves
Dimensions
SH
Shuttle
Valves
25.4 (1.00)
Dia. Knob
74.6
(2.94)
LM
Load/Motor
Controls
75.3
(2.96)
72.8
(2.86)
71.7
(2.82)
Flow
Controls
FC
applications over 210 Bar
* For
(3000 PSI), Thread Lock
Compound is recommended.
(1)
THIRD-ANGLE
PROJECTION
27.7
(1.09)
Ø 12.7
(.50)
Screw/Knob Version
PC
Pressure
Controls
(2)
22.4 (.88) Hex.
31 N.m.
(276 In.-Lbs.)
Torque
LE
Fixed Cap/Tamper Resistant Version
Logic
Elements
* 3/4
16UNF-2A Thread
Directional
Controls
DC
Ordering Information
RDH083
Adjustment
Style
Pressure
Range
Seals
Optional
Pressure
Setting
Body
Material
Port
Size
Manual
Valves
08 Size
Differential Area
Relief Valve
MV
Tamper Resistant Cap (718083)
Code Pressure Range
15
6.9 - 103 Bar (100 - 1500 PSI)
Standard Setting:
51.7 Bar (750 PSI) @ crack pressure
approximately .95 LPM (.25 GPM)
30
69 - 207 Bar (1000 - 3000 PSI)
Standard Setting:
103 Bar (1500 PSI) @ crack pressure
approximately .95 LPM (.25 GPM)
138 - 345 Bar (2000 - 5000 PSI)
Standard Setting:
172.4 Bar (2500 PSI) @ crack pressure
approximately .95 LPM (.25 GPM)
50
PV
Optional Pressure Setting
Pressure ÷ 10
i.e. 235 = 2350 PSI
(Omit if standard setting is used)
Setting Range:
100 to 5000 PSI
All settings at crack pressure,
approximately .95 LPM (.25 GPM)
Code Port Size Body Part No.
Omit Cartridge Only
4P
6P
4T
6T
1/4″ NPTF
3/8″ NPTF
SAE-4
SAE-6
(B08-2-*4P)
(B08-2-*6P)
(B08-2-*4T)
(B08-2-*6T)
6B
3/8″ BSPG (B08-2-*6B)
* Add “A” for aluminum, omit for steel.
Proportional
Valves
Screw Adjust
T
Omit Steel
A Aluminum
CE
Coils &
Electronics
S
Omit Nitrile / (SK08-2N)
V Fluorocarbon / (SK08-2V)
BC
Bodies &
Cavities
Fixed style, preset at factory.
Knob Adjust (717784-10)
Code Body Material
TD
Technical
Data
F
K
Code Seals / Kit No.
Solenoid
Valves
SV
Code Adjustment Style / Kit No.
PC28
Parker Hannifin Corporation
Hydraulic Cartridge Systems
PT Series
Tank Top Filters
9
PT Series
Applications
Together we can…
the environment.
Preserve
Minimize waste and promote
energy efficiency.
worldwide filtration
Achieve
solutions.
Build global confidence.
ne new limits.
Redefi
Forge ahead with advanced
technology.
contamination under
Keep
control.
Reduce maintenance costs.
total system reliability.
Enhance
Focus on customer
satisfaction.
optimum potential.
Reach
Drill to greater depths.
…engineer your success.
The new PT series filter is available
in two diameters and three lengths
for flow ranges from 5-50 gpm.
The PT2 and PT4 filter cartridges
utilize Microglass media in 2, 5, 10
and 20 microns for the industry’s
best particle removal efficiency
and retention.
This unique design simply threads
into a ported weld ring or flange,
which can be bolted to a metal
reservoir.
The disposable filter cartridge is a
single-piece construction, which
incorporates the nylon cover
and integral 25 psi bypass valve.
The flow path is inside-out and
requires no special tools for
service.
This concept assures minimal
installation costs with the least
space requirements for return line
applications.
The PT Series filter combines high
efficiency Microglass filtration with
low cost installation featured in a
new patented element design.
10
Typical Applications
• Turf Maintenance
• Material Handling
• Aerial Lifts
• Fan Drive
1
PT Series
Features
2
3
1
Easy element assembly removal
2
Unique high flow top end cap
3
Lightweight cast aluminum head
4
Patented filter element assembly
5
Bowl-less, inside-out flow
6
Downstream element support with “no aeration” design
7
Solid bottom endcap with integrated bypass valve
8
Low profile tank top design
4
5
6
8
7
11
PT Series
Patented Filter Element
Premium original equipment
performance every time
Tank Top, Bowl-Less Design
Reduces weight
Significant cost savings over filters
with bowls
Bottom Endcap Integrated
Bypass Valve
New bypass valve with every
element change
Insures reliable performance
Inside-Out Element
Flow Path
Contamination contained
within the element
No system contamination during
element servicing
No Aeration Design
Oil cascades down the
perforated outer support core
High Flow, Low Pressure
Drop Top Endcap Design
Long element life
Premium Microglass
Media
Superior dirt holding
capacity and efficiency
No system aeration
Lower maintenance costs
Less maintenance and downtime
12
PT Series
PT4-3 Element Performance
Capacity
:[[^X^ZcXn
7ZiVGVi^c\
&%%%%
PSID
100
:[[^X^ZcXn
'F
BAR
6
*F
*F
80
2Q
5Q
10Q
20Q
..#.
&%%%
&%F
'%%
60
..#*
..#%
&%%
5
4
3
'%F
40
'%
.*#%
2
20
1
'
*%#%
0
%
)
-
&'
&+
'%
0
0
B^XgdcH^oZX
20
40
60
80
100
Capacity grams
Flow vs. Pressure Loss*
LPM
0
40
75
110
150
190
15
1.0
0.5
BAR
PSID
10
5
0
0
10
20
30
40
50
0.0
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.
*Note: Pressure drop calculations are based on SAE-16 porting.
17
120
PT Series
Specifications - PT4
Maximum Allowable Operating Pressure
(MAOP): 150 psi ( 10.3 bar)
Element Burst Rating: 150 psid
Operating Temperatures:
Buna: -40°F (-40°C) to 225°F (107°C)
Materials:
Tank Flange: aluminum
Endcaps: nylon
Drawings are for reference only.
Contact factory for current version.
1/8-27 PTF
2 PLC'S
REF.
Ø4.06
3.500-10 BUTTRESS
PORT OPTIONS SEE TABLE
2.70
15/16 (24MM) HEX
TORQUE 200-240 IN-LBS
941664
O-RING
Ø3.33
THRU. HOLE
A
2.045
2.41
1.11
6.20± .060 SINGLE
9.79± .060 DOUBLE
14.55 `.060 TRIPLE
A
.90 DIA FLAT
5 PLC'S
36°
n.345 ON A
Ø5.50 B.C.
5 PLC'S
EQ. SPACED
1/8-27 PTF
2 PLC'S
.400 MIN CLEARANCE
FROM TANK BOTTOM
Ø3.09
SECTION A-A
19
PT Series
PT4 Parts List
INDEX
PART DESCRIPTION
PART NUMBER
1
PT4-1-02Q-25 psid bypass
936742
PT4-1-05Q-25 psid bypass
936743
PT4-1-10Q-25 psid bypass
936744
PT4-1-20Q-25 psid bypass
936745
PT4-2-02Q-25 psid bypass
936746
PT4-2-05Q-25 psid bypass
936747
PT4-2-10Q-25 psid bypass
936748
PT4-2-20Q-25 psid bypass
936749
PT4-3-02Q-25 psid bypass
936876
PT4-3-05Q-25 psid bypass
936877
PT4-3-10Q-25 psid bypass
936878
PT4-3-20Q-25 psid bypass
936879
PT4 DIE CAST SAE-16 (1.312-12 UN-2B)
941417
PT4 DIE CAST SAE-20 (1.625-12 UN-2B)
941448
2
PT4 DIE CAST 1” NPT (1.000-11.5 NPTF-1)
941449
PT4 DIE CAST 1 1/4” NPT (1.250-11.5 NPTF-1)
941450
PT4 DIE CAST G1” BSPF
941905
PT4 DIE CAST G1 1/4” BSPF
941906
O-RING
941664
4
1/8-27 PIPE PLUG
900782
5
1/8-27 PRESSURE GAUGE
936912
3
1
2
4
1.51
38.4
.36
9.1
5
1/8 NPT
THREAD
1.58
40.1
Linear measure = inches
mm
Pressure Switch (926923)
21
3
PT 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
PT2
1
10Q
B
G
G
S16
1
BOX 1: Filter Series1
Symbol
Description
PT2
Tank top filter
PT4
Tank top filter
BOX 2: Element Length
Symbol
Description
BOX 4: Seals
Symbol
Description
B
V
Fluorocarbon (FKM)
1
Single
2
Double
P
Port plugged
3
Triple (Avail. on PT4 only)
G
Pressure Gauge, 25 psi
BOX 3: Media Code
Symbol
Description
S
PT2
Nitrile (NBR)
BOX 5: Indicator
Symbol
Description
Consult factory for additional element
lengths
BOX 7: Ports
Symbol
Description
Pressure Switch
G12
G¾” BSPP
G16
G1” BSPP
N12
¾” NPT
N16
1”NPT
S12
SAE-12
S16
SAE-16
PT4
G16
G1”BSPP
G20
G1¼” BSPP
N16
1”NPT
1¼”NPT
Microglass III, 2 micron
BOX 6: Bypass
Symbol
Pressure Setting
N20
02Q
S16
SAE-16
05Q
Microglass III, 5 micron
G
S20
SAE-20
10Q
Microglass III, 10 micron
20Q
Microglass III, 20 micron
25 PSI (1.7 bar)
BOX 8: Options
Symbol
Description
1
None
2
W
Steel weld ring
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”.
Please note the bolded options
reflect standard options with a
reduced lead-time. Consult factory
on all other lead-time options.
Global products as identified are offered
worldwide through all Parker locations and
utilize a common ordering code.
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
Steel bowl with standard drain port
Proprietary element end cap assembly includes bypass and reverse flow valves
Patented deformable tangs secure element in bowl
Coreless element assembly
Re-usable element support core
310
Corporate Office:
2725 Commerce Parkway
Auburn Hills, MI 48326
Toll Free: (800) 331-3118
Fax: (248) 377-3172
[email protected]
www.tfsi1.com
HYDRAULIC
World Pressure Filters - 7000 psi
WPF Series
Specifications
Maximum Allowable Operating
Pressure (MAOP):
7000 psi (483 bar)
T-Port
Rated Fatigue Pressure:
6000 psi (414 bar)
Design Safety Factor: 3:1
Operating Temperatures:15°F (-26°C) to 250°F (135°C)
Element Collapse Rating:
Standard: 300 psi (21 bar)
High Collapse: 2000 psi (138 bar)
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)
Drawings are for reference only.
Contact factory for current version.
T-PORT DIMENSIONS mm (inch)
Filter
Model
WPF1
WPF2
WPF3
WPF4
WPF5
A
70 (2.76)
79 (3.11)
88 (3.47)
100 (3.94)
100 (3.94)
B
C
180 (7.09) 69.5 (2.74)
293 (11.53) 75 (2.95)
345 (13.58) 93 (3.66)
445 (17.52) 128 (5.04)
561 (22.09) 128 (5.04)
D
E
F
G
23 (.91)
32 (1.26)
40 (1.57)
49 (1.93)
61 (2.40)
15 (.59)
26 (1.02)
29 (1.14)
39 (1.54)
51 (2.01)
27 (1.06)
30 (1.18)
35 (1.38)
48 (1.89)
48 (1.89)
60 (2.36)
80 (3.15)
90 (3.54)
120 (4.72)
140 (5.51)
Corporate Office:
2725 Commerce Parkway
Auburn Hills, MI 48326
H
I
J
K
30 (1.18) 90 (3.54) 92 (3.62) 46 (1.81)
40 (1.57) 98 (3.86) 110 (4.33) 55 (2.17)
55 (2.17) 120 (4.72) 126 (4.96) 63 (2.48)
50 (1.97) 160 (6.30) 163 (6.42) 81.5 (3.21)
80 (3.15) 160 (6.30) 183 (7.20) 91.5 (3.60)
Toll Free: (800) 331-3118
Fax: (248) 377-3172
L
M
30 (1.18) 15 (.59)
40 (1.57) 20 (.78)
45 (1.77) 27.5 (1.08)
60 (2.36) 25 (.98)
70 (2.76) 40 (1.57)
[email protected]
www.tfsi1.com
311
HYDRAULIC
World Pressure Filters - 7000 psi
WPF Series
Specifications
Maximum Allowable Operating
Pressure (MAOP):
7000 psi (483 bar)
Manifold
Rated Fatigue Pressure:
6000 psi (414 bar)
Design Safety Factor: 3:1
Operating Temperatures:15°F (-26°C) to 250°F (135°C)
Element Collapse Rating:
Standard: 300 psi (21 bar)
High Collapse: 2000 psi (138 bar)
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)
Drawings are for reference only.
Contact factory for current version.
MANIFOLD DIMENSIONS mm (inch)
Filter
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Model
WPF2 79 (3.11) 343 (13.50) 75 (2.95) 24 (.94) 39 (1.53) 95 (3.74) 116 (4.57)50 (1.97) 6 (.24) 110 (4.33) 80 (3.15) 40 (1.57) 110 (4.33) 121 (4.76) 17 (.67) 30 (1.18)
WPF4 100 (3.94) 532 (20.94) 128 (5.04) 38 (1.50) 57 (2.24) 140 (5.51) 150 (5.91)75 (2.95)13 (.51)142 (5.59) 100. (3.94)50 (1.97)166.5 (6.56) 161 (6.34) 21 (.83)31.7 (1.25)
WPF5 100 (3.94) 627 (24.69) 128 (5.04) 38 (1.50) 57 (2.24) 140 (5.51 150 (5.91)75 (2.95)13 (.51)142 (5.59) 100. (3.94)50 (1.97)166.5 (6.56) 161 (6.34) 21 (.83)31.7 (1.25)
312
Corporate Office:
2725 Commerce Parkway
Auburn Hills, MI 48326
Toll Free: (800) 331-3118
Fax: (248) 377-3172
[email protected]
www.tfsi1.com
HYDRAULIC
World Pressure Filters - 7000 psi
WPF Series
Service & Maintenance Instructions
1
Stop system power and vent captive pressure.
2
Drain filter assembly.
3
Remove bowl and element assembly.
Push down to squeeze tangs and lift element.
Twist to remove core.
Retain reusable core.
7
Discard used element.
Insert reusable core into new element until it snaps.
Push element assembly into bowl, snap tangs.
10 Inspect o-ring and anti-extrusion ring.
Install bowl with new element.
12 Torque bowl, vent and drain plugs.
13 Power up and inspect.
Corporate Office:
2725 Commerce Parkway
Auburn Hills, MI 48326
Toll Free: (800) 331-3118
Fax: (248) 377-3172
[email protected]
www.tfsi1.com
313
HYDRAULIC
World Pressure Filters - 7000 psi
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
BOX 1:
Symbol
WPF
Filter Series
Description
High Pressure Filter
BOX 2:
Symbol
1
2
3
4
5
Model
Description
1/2” Nomial ports
3/4” Nomial ports
1” Nomial ports
1 1/4” Nomial ports
1 1/2” Nomial ports
BOX 3:
Symbol
02QE
05QE
10QE
02QH
10QH
BOX 4:
Symbol
B
E
V
BOX 5:
Symbol
P
M2
E2
Indicator
Description
Plugged Indicator Port
Visual Automatic Reset
Electrical/ Visual
(DIN43650 style connection)
Note: When the “M2” or “E2” option is
selected, the indicator port is plugged
and the indicator is shipped as a loose
part.
Media Code
Description
Ecoglass III (bypass only)
Ecoglass III (bypass only)
Ecoglass III (bypass only)
High Collapse
Microglass III (no bypass
only)
Microglass III (no bypass
only)
Seals
Description
Nitrile (NBR)
Ethylene Propylene
Fluorocarbon (FKM)
BOX 7:
Symbol
S08
S12
Y12
X12
S16
Y16
BOX 6:
Symbol
K
Bypass
Description
50 PSID (3.5 bar)
No Bypass and No
X
Indicator (port plugged)
Note: When an indicator and no bypass
(“2” in Box 8) is selected, the
indicator setting is 50 psid
(3.5 bar).
S20
Y20
X20
Please note the bolded options reflect
standard options with a reduced lead-time.
Consult factory on all other lead-time
options.
S24
Y24
X24
BOX 8:
Symbol
1
2
Ports
Description
WPF1
SAE-8 Ports
WPF2
SAE-12 Ports
3/4” SAE Code 62 Flange
face
Manifold
WPF3
SAE-16 Pots
1” SAE Code 62 Flange
face
WPF4
SAE-20 Ports
1 1/4” SAE Code 62
Flange face
Manifold
WPF5
SAE-24 Ports
1 1/2” SAE Code 62
Flange face
Manifold
Options
Description
With Bypass
(for use with standard
element only)
No Bypass
(for use with high
collapse element only)
Replacement Elements:
Standard Collapse
300 psid/21 bar)
High Collapse
(2000 psid/138 bar)
Media
Ecoglass III, 02QE
Ecoglass III, 05QE
Ecoglass III, 10QE
Microglass III, 02QH
Microglass III, 10QH
WPF1
941029Q
941030Q
941031Q
941044Q
941045Q
WPF2
941032Q
941033Q
941034Q
941046Q
941047Q
WPF3
941035Q
941036Q
941037Q
941048Q
941049Q
WPF4
941038Q
941039Q
941040Q
941050Q
941051Q
WPF5
941041Q
941042Q
941043Q
941052Q
941053Q
Global products as identified are offered
worldwide through all Parker locations and
utilize a common ordering code.
314
Corporate Office:
2725 Commerce Parkway
Auburn Hills, MI 48326
Toll Free: (800) 331-3118
Fax: (248) 377-3172
[email protected]
www.tfsi1.com
Suction Strainers
Internally Mounted Tank Filters - your front-line defense against particle contamination
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.
Part Number
SS-003P006-1-01
SS-005P008-1-X1
SS-008P012-1-X1
SS-010P100-1-X1
SS-023P104-X-X
SS-032P108-X-X
SS-053P200-X-X
SS-075P208-X-X
SS-116P300-X-X
A
Outlet Port
3/8” NPT
1/2” NPT
3/4” NPT
1” NPT
1 1/4” NPT
1 1/2” NPT
2” NPT
2 1/2” NPT
3” NPT
B
Wrench Flat
1.20”
1.20”
1.50”
1.75”
2.25”
2.35”
3.00”
3.50”
4.00”
1 - Standard 100 Mesh, contact factory for other Mesh sizes.
How to Order:
C
Overall Length
3.00”
3.25”
3.25”
5.50”
6.60”
8.60”
7.20”
9.30”
12.50”
SS-003P006-1-0
Model Code
003P006
005P008
008P012
014P100
023P104
032P108
053P200
075P208
116P300
magnaloy coupling company
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
D
Outside Diameter
2.75”
2.75”
2.75”
2.75”
3.20”
3.20”
4.20”
4.20”
4.20”
Rated Flow
@ 5 ft/sec
3 GPM
5 GPM
8 GPM
10 GPM
23 GPM
32 GPM
53 GPM
75 GPM
116 GPM
Code
0
3
5
By-Pass Valve Setting
No By-Pass Valve
3 PSI
5 PSI
Code
1
2
3
6
Wire Cloth Mesh
100 Mesh (Std)
200 Mesh
30 Mesh
60 Mesh
989 356-2186
http://www.magnaloy.com
155
5
8
16
5
6
7
4
12
6
DESCRIPTION
1
1
PLATE 3/16", 304 SS
2
4
PLATE 3/16", 304 SS
3
2
P/N P100190, 1 1/4" NPT COUPLING, 3000 PSI, 304SS
4
1
P/N P100192, 1" NPT HALF COUPLING, 3000 PSI, 304SS
5
6
7
8
9
1
2
1
3
1
P/N P100196, 2" NPT HALF COUPLING, 3000 PSI, 304SS
P/N P100193, 3/4" NPT HALF COUPLING, 3000 PSI, 304SS
P/N P100195, 1 1/2" NPT HALF COUPLING, 3000 PSI, 304SS
P/N P100194, 1/2" NPT HALF COUPLING, 3000 PSI, 304SS
PLATE 2", 304 SS
12
9
1
6
10
17
2
2.48
9
6
13
7.50
VIEW SCALE 1 : 20
12
C
10
1
L1.5x1.5x0.25, 304 SS
6
11
1
ANGLE, 6" X 6" X 1/4"
6
12
1
PLATE 3/16", 304 SS
6
13
1
PLATE 3/16", 304 SS
14
1
PLATE, 1/4" AISI 304 SS
11
12
6
6
15
F
6
8
B
15
2
ANGLE, 1" X 1" X 1/8"
16
6
FLATBAR 1"x3/4", 304 SS
17
1
ANGLE 1 1/4"x 1 1/4"x 1/16"
18
2
ELBOW 90, 1 1/4" x 1 1/4"
D
C
D
8
7
1
QTY.
12
D
2
3
ITEM NO.
8
6
17
E
6
E
28.74
23.55
40.36
14
B
13
12
5
12
F
3
4
D
2
6
44.00
31.00
UNLESS OTHERWISE SPECIFIED:
A
06
05
04
07
REV.
UPDATED ACCORDING TO CURRENT REQUIREMENTS
CHANGED COOLER MOUNT PLATE TO FLAT BAR
MH
JP
3/3/14
8/20/13
ITEM 15 DETAIL CHANGE
JP
8/09/13
UPDATED PRINT TO AS BUILT SHOP REVISIONS
CZ
8/1/14
INITIAL
DATE
DESCRIPTION
8
7
6
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED.
5
NAME
DATE
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL 1/16
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
DRAWN
JA
7/17/2013
CHECKED
JP
2/5/13
ENG APPR.
XXX
XX/XX/XX
MFG APPR.
PN
XX/XX/XX
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
Q.A.
XXX
XX/XX/XX
MATERIAL
M104178-7
4
HPU TANK,
GDM 120 GAL
SIZE DWG. NO.
AISI 304
GDS PART No.-Revision
GDS International
TITLE:
B M104178
FINISH
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 1 OF 7
DO NOT SCALE DRAWING
3
A
2
1
8
5.50
4.82
5
6
7
4
3.83
1
NOTES:
1.
WELD ALL COUPLINGS, FLANGES, AND TANK ENDS FULLY SEAL WELDED INSIDE AND OUT.
2.
DRILL TANK FOR ITEM 12 AFTER WELDED TO TANK. THEN TAP TO 3/8-16 UNC.
3.
NOTE POSITION OF ITEM 12 TO TANK EDGES.
4.
DRILL HOLES IN FEET AFTER WELDING TO TANK FOR PROPER ALIGNMENT.
5.
BAFFLE INSIDE TANK STITCH WELD TO BOTTOM AND SIDES.
8.82
3.38
2
3
D
D
12.00
16.00
3x, .75
TOP VIEW
12
3.00
6.00
30.36
C
C
42.50
18
23.36
10.00
2x, .56
A
21.25
R.38 INSIDE
TYP
6.00
B
4.18
4.00
B
18
6x,
4x, 12.50
2x, 25.00
2x,
2.28
3.00
BOTTOM VIEW OF ASSEMBLY
2.45
1.22
.56
40.00
1.78
GDS International
TITLE:
A
5.82
4.18
BOTTOM VIEW
8
7
SIZE DWG. NO.
DETAIL A
SCALE 1 : 4
30.36
HPU TANK,
GDM, 120 GAL
B M104178
A
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 2 OF 7
6
5
4
3
2
1
8
5
6
7
7.00
D
B
5x, 90°
4
.13
3.38
THRU
2.00
D
1/8 x 45 CHAMFER
C
.31
6X
.31 THRU ALL
3/8-16 UNC - 2B THRU ALL
45°
DETAIL C
SCALE 1 : 2
.75
4.5
2.50
54°
2.00
B
.18
ITEM 16 DETAIL
C
ITEM 9 DETAIL
10
1.00
4.23
SECTION B-B
SCALE 1 : 4
C
1
5.50
BOLT CIRCLE
5X
90°
2
3
ITEM 2 DETAIL
17.50
2x, .75
3.00
.315
2.30
.50
1.25
B
TYP
B
1.25
8x, 2.625
EQ SPACE
10.500
15.000
.125
.09
20x,
ITEM 17 DETAIL
12.50
13.50
12.00
.344
16.00
GDS International
TITLE:
A
3/8-16 Tapped Hole
4x, 2.25
4x, 2.250
1.25
2x, .75
8x, 3.625
EQ SPACE
1.50
SIZE DWG. NO.
B M104178
ITEM 10 DETAIL
14.500
19.000
8
7
HPU TANK,
GDM, 120 GAL
A
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 3 OF 7
6
5
4
3
2
1
8
5
6
7
4
2
3
5X
.31
1.06
3/8-16 UNC - 2B
.75
10
1
NOTE CLOCKING POSITION OF BOLT HOLES
BEVEL SIDE TO TANK.
D
D
9.00
2X
3/16
8.12
2.88
11.00
2X
G
4.15
C
2.75
3X
4.5
3X
9
9
8.00
3X
3/8-16 Tapped Hole
TYP
SECTION E-E
SCALE 1 : 12
9
1.50
3/16
16
C
1.06
14.91
INSIDE
7
1
2.00
3/16
6
TYP
2.45
FLUSH INSIDE
1.24
8
6
1/8
.98
3/16
3/16
3/16
3
SECTION F-F
SCALE 1 : 8
4
1-4
3/16
GDS International
TITLE:
5
HPU TANK,
GDM, 120 GAL
SIZE DWG. NO.
B M104178
SECTION D-D
SCALE 1 : 8
8
7
B
18
3/16
6
TYP
3/16
.63
7
8
3/16
A
4.11
10
DETAIL G
SCALE 1 : 6
3.26
3/16
8
B
14.60
5.00
5.50
A
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 4 OF 7
6
5
4
3
2
1
8
5
6
7
TYP
1/8"
D
4
1.00
1
12.00
16
7.62
5.63 INSIDE
2
3
H
D
9
12.00
15
.25
7
TYP
16.56
C
1/8
4.75
.13
1.25
.438
1.00
4x,
5.00
5
6.00
2x,
.31
.25
1.00
6.00
2
.59
1.00
DETAIL ITEM 15
2x, 2.188
B
1.00
C
11
6.00
R.75
17
PRESSURE FILTER
MOUNT
3.33
45°
4.13
6"X6" J-BOX
MOUNT
DESC: ANGLE, 1" X 1" X 1/8"
REQD: 2
REFERENCE HOLE
DIMENSIONS
2x, 1.00
2.05
B
DETAIL ITEM 11
2x, 1.23
40.00
DESC: ANGLE, 6" X 6" X 1/4"
REQD: 1
2x, 3.54
15
4x,
2x, 1.25
2x, R.25
.31
15.00
.25
.63
1.71
2x, 6.81
45.00°
28.00
5.25
GDS International
DETAIL ITEM 1
TITLE:
DESC: PLATE 3/16"
REQD: 1
A
3.00
DETAIL ITEM 14
2.00
DESC: PLATE, 1/4"
MATL: ASTM A 572
REQD: 1
8
HPU TANK,
GDM, 120 GAL
SIZE DWG. NO.
2x, 4.00
7
6
5
4
DETAIL H
SCALE 1 : 6
3
2
B M104178
A
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 5 OF 7
1
3.00
2x
3.82
10.00
30.00
23.18
.56
2x
2.28
13
40.00
1.78
ITEM 13 DETAIL
GDS International
TITLE:
HPU TANK,
GDM, 120 GAL
30.22
SIZE DWG. NO.
A M104178
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 6 OF 7
5
4
3
2
1
B1 B3 C1
D1
B2
C2
28.55
A1
2x3.50
Y
3.50
.95
2xR1.50
X
6x
.56
X LOC
5.00
Y LOC
9.82
SIZE
3.00 THRU
B1
5.75
25.37
1.13 THRU
B2
7.56
21.37
1.13 THRU
B3
9.38
25.37
1.13 THRU
C1
13.63
25.37
1.41 THRU
C2
27.25
16.99
1.41 THRU
D1
22.38
20.74
2.56 THRU
2x3.00
2x12.50
12.50
3.38
TAG
A1
ITEM 12 DETAIL
4.05
16.50
GDS International
TITLE:
9.13
5.38
5.82
SIZE DWG. NO.
1.45
31.00
HPU TANK,
GDM, 120 GAL
A
M104178
REV
7
SCALE: 1:16 WEIGHT: 394.72 SHEET 7 OF 7
5
4
3
2
1
McDANIEL
M
C
Liquid Filled, Stainless Steel Case
Utility Gauges
“For the price-conscious buyer . . .
McDaniel utility gauges are designed for the priceconscious buyer and user who have an emphasis on
maintaining quality and accuracy in a general
purpose gauge.
Our utility line offers trusted McDaniel quality in an
economical package. Special consideration given to
rigorous McDaniel standards for durability, accuracy,
and quality of construction.
Our Series 6: Glycerin filled, stainless steel case
utility gauges with brass internals. Designed for
applications with a corrosive atmosphere and where
pulsation and/or vibration are present.
Standard features include a restrictor screw
(removable) in the inlet port for pulsation dampening.
. . . and quality user.”
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.
Case:
304 Stainless steel.
Pressure Utilization:
Static:
75% maximum scale.
Dynamic: 66% maximum scale.
Stem and Socket:
Pointer:
Brass. Restrictor screw standard.
J6 = 1/4” NPT (1/8” special order available)
T6 = 1/4” or 1/8” NPT available
Black enameled aluminum.
Lens:
Polycarbonate.
Dial Sizes / Ranges Available
Precision Movement
2”
- (T6) / Vac, Comp, Rec 3-15, up to 5,000 psi
2 1/2”- (J6) / Vac, Comp, Rec 3-15, up to 15,000 psi
Brass.
Configurations Available:
Bourdon Tube:
Copper alloy
(C Form 600 PSI & below).
Phosphorous bronze (Spiral 800 PSI & above).
Bottom connected standard
(L) = Center-back connected
(U) = U-Clamp mounted, Center-back connected
(P) = Front flange, Center-back connected
McDaniel Controls, Inc.
P. O. Box 187, Luling, LA 70070 • 14148 Highway 90, Boutte, LA 70039 U.S.A.
(985) 758-2782 • New Orleans (504) 467-1333 • Fax (985) 758-1688
www.mcdanielcontrols.com
WARNING
Read before 1nstalling or using gauge. Misuse ot trlis product may cause explOSIOn and
personal injut¥
I CAN BE
DAMAGED BY ...
Pressure gauges must be correctly selected
and installed to avoid possible inJury or
damage caused by misuse. Please note:
OXYGEN SERVICE Gauges must be
spec1ally cleaned tor oxygen service QY. the
manutacturer and labeled tor oxygen service.
~ use any gauge on oxygen service that
has been used on any other service.
PRESSURE Gauge dial range should be
IWice the Intended operating pressure range..
Do not apply pressure beyond top of scale.
VIBRAnON Isolate gauge from sources of
vibration to avo1d wear to movement which
results in decreased accu~·
TEMPERATURE Gauge temperature
should not exceed 150°F (65°C).
CORROSION Materials of pressure-<antaming parts must be res1stant to process
ftuid used.
PULSAnoN Excess1ve pressure pulsation
may cause pressure element !allure or substantial movement wear"
LIQUID·F1LLED GAUCiES Never use
for applications involvmg strong ox1c!1Zin<J
agents including !but not lim1ted to) oxygen.
chlonne. nitnc ac1d, and hydrogen perox1de.
These substances can comb1ne explosively
With liQuid filling.
Always wear safety gl~ses when workmg
w1tt1 pressuriZed eQuipment
For additional application data. refer to AN()E:
B40.1 or consult manufacturet
'LiQUid-filled gauges or pulsat1on-dampemng
dev1ces may be necessary tor some applica!lonS.
I CAN EXPLODE!
... and can injure you
and those around you.
WARNING
~~~0~~8i7e·IL~~~!~~~~~A17~0~;
(504] 758-2782 • FAX (504) 758-1688
•
Model Gauge Selecta·on Guide
www.mcdanielcontrols.com
Hlllllllll.llll
1~"
(40mm)
s
1/s"
* 1/4 11
304
316
STAINLESS
STEEL
STAINLESS
STEEL
Fillable
12)
R7
RB
lfs"
1
* /4"
STAINLESS
STEEL
Q3
lfs"
T6
2" T7
TB
304
lfs"
* lf4"
J
u
2~" K9
(63 mm)
J6
J7
JB
<(
BLACK
ENAMELED
STEEL
m
316
STAINLESS
STEEL
Fillable
(2)
1/s"
%"
STAINLESS
STEEL
Grade A
Up to
10,000 psi
'- Polycarbonate Lens
3-2-3o/o
Grade B
Up to
5,000 psi
304
1/s"
%"
'- Economical McDaniel Duality
Restrictor screw for pulsation dampening
MOUNTING STYLES:
Bottom, Center-back, U-Ciamp, Panel mount
1o/a
Grade 1A
Up to
15,000 psi
304
Filled**
'- Full blow-out protection
" Repairable
Lexan Lens
" Weather Tight Case
Compensating diaphragm
M_!IUNTING STYLES:
Bottom, Center-back 111, U-Ciamp, Panel mount
'- Util1ty Gauge
13)
304
STAINLESS
STEEL
., Laminated Safety Glass Lens " Repairable
_, Blow-out disc
:- Weather Tight Case
MOUNTING STYLES:
Bottom, Center-back , U-Ciamp, Panel mount
,_ Utility Gauge
en
en
<(
a:
Non-Fillable
m
BLACK
ENAMELED
STEEL
(3)
' Polycarbonate Lens
3-2-3%
Grade B
Up to
5,000 psi
·• Economical McDaniel Quality
,, Restrictor screw for pulsation dampening
MOUNTING STYLES:
Bottom, Center-back, U-Ciamp (except T71,
Panel mount
Non·Fillable
* lfs"
1(4"
* lfs"
%"
a:
STAINLESS
STEEL
1/s"
lf4"
(SO mm)
K
Non-Fillable
Non-Fillable
1/4 11
en
en
1.5°/o
OTHER FEATURES
304
316
STAINLESS
STEEL
STAINLESS
STEEL
Fillable
12)
Up to
20,000 psi
304
.
* lfs"
%"
* Ifs"
%"
* 1/s"
1/4"
* 1/s"
1/4 11
* 1/s"
1/4 11
SPECIAL
NON-STOCK
STAINLESS
STEEL
en
en
Fillable
<(
CAST
BRASS
m
Fillable
1o/o
Grade 1A
a:
131
304
316
STAINLESS
STEEL
STAINLESS
STEEL
Fillable
121
2-1-2%
Grade A
Up to
6,000 psi
-- Laminated Safety Glass Lens
_,_ Repairable
-:- Weather Tight Case
Restrictor screw for pulsation dampening
_,_ Solid Front Blow out Back Case Available
MOUNTING STYLES:
Bottom, Lower-back, U-Ciamp, Panel mount, Rear Flange,
CElllter-Back available by spec1al order,
Up to
10,000 psi
Laminated Safety Glass Lens " Repairable
_, Heavy-duty
One-piece case and stem
MOUNTING STYLES:
Bottom, Center-back , U-Ciamp
Up to
10,000 psi
'- Polycarbonate Lens
_, Restrictor Screw
,_ Rolled Threads
" Welded Case and Stem
MOUNTING STYLES:
Bottom, Lower-back, U-Ciamp, Front Flange, Rear Flange
304
Filled**
304
STAINLESS
STEEL
en
en
<(
a:
Non-Fillable
m
BLACK
ENAMELED
STEEL
131
3-2-3%
Grade B
Non-Fillable
FILLED
GLYCERIN
Ut1l1ty Gauge
Up to
15,000 psi
STAINLESS
STEEL
ACCURACY
ASME
840.1
Inches of
Water
&
Up to
15,000 psi
Polycarbonate Lens
_,_ Economical McDaniel Quality
_, Restrlctor screw for pulsation dampening
MOUNTING STYLES:
Bottom, Center-back, U-Clamp, Panel mount
RANGE
l11
Includes, Vacuum, ("I
Compound, and
l21
Receiver 3-15
Model S 1/4 NPT only 1n Back connect1on
316 SS Tube, Tip and Socket
Brass Socket, Copper Alloy I Phosphorous Bronze Tube and Tip
McDaniel Controls, Inc.
P. 0. BOX 187 • LULING, LOUISIANA 70070
(504) 758-2782 • FAX (504) 758-1688
www.mcdanielcontrols.com
(' 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.
How To ORDER BY CoDE
Adder Codes Special Configuration
l.
2.
3.
4.
5.
Select the model.
Select the pressure range
Specify mounting code if other than standard bottom connection.
Add special configurations if needed- either by code or written description.
Add choice of filling, if appropriate.
(GF = Glycerin Filled, SF = Silicone Filled, or FF = Flourolube Filled)
EXAMPLE:
Range
Special
Configuration
Code
n
p
Type of
Filling
GF
Order: A 2'h'' sealed gauge with a scale of 0 to 100 psi, panel-mounted I front flange, 1f4' NPT
lower-back connection, filled at factory with glycerin (KDP-GF).
B
K
M
N
0
s
psi/bar (dual scale)
psi/kPa (dual scale)
Monel® Internals
Non-standard internals (316 SS tube/tip/socket)
Models: L, M, N, P, Y, Z
02 (cleaned for oxygen service).
Solid Front I Blow-out Back case
Mounting Codes
c
L
p
u
R
Center-back Connected (use for models Q3, E9, G9)
Lower-back or Center-back
Panel mount. Front Flange
U-clamp, Panel Mount
Rear Flange
INSTRUCTIONS
Orange Research Inc.
Series 1201
140 Cascade Boulevard, Milford, Connecticut 06460
203 877-5657 800 989-5657 Fax: 203 783-9546
www.orangeresearch.com
DIFFERENTIAL PRESSURE INSTRUMENTS
Your new Orange Research Differential Pressure Instrument is a
rugged instrument featuring simplicity of design to provide
dependable and efficient service. Because it is an instrument it
should be handled with care. Read all instructions carefully
before attempting to install the instrument.
this instrument may need attention. Erratic pointer or switch
action may indicate that cleaning is required. For cleaning:
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
magnet to provide gauge readings proportional to differential
pressure variations. There are no mechanical seals between the
pressure side of the instrument and the gauge mechanism side.
This is accomplished by coupling the forces between two adjacent
magnets through a solid wall.
SWITCH UNITS: On switch and indicating switch models, reed
switches are located adjacent to the pressure chamber and are
actuated when the piston magnet field interacts at a preset point
with the reed switch armature. Reed switch set points are
adjustable.
INSTALLATION
Check instrument and identify the HI and LO markings. HI
identifies the high pressure port; LO the low pressure port. If
instrument is installed backwards, it will neither operate nor be
damaged. Reverse connections if installed backwards. The
instrument can be line mounted, bracket mounted or panel
mounted depending upon the model purchased.
Under normal conditions Series 1201 Instruments are designed
for line pressure to 3000 psig and can sustain a continuous 3000
psig forward or reverse overpressure.
1.
2.
3.
4.
5.
Remove the unit from service.
Remove both end caps with a 1” spanner wrench.
Remove the range spring and the piston/magnet assembly.
BE CAREFUL NOT TO LOSE STACKING SPACERS.
Clean parts in a solvent solution after removing O-Ring seals
from the end caps since some solvents will attack the seal
material.
It is good to practice to replace the O-Ring seals while the
instrument is dismantled. DO NOT ATTEMPT TO MOVE
THE TEFLON PISTON SEAL FROM THE PISTON. If piston
seal is damaged order a new piston/magnet assembly.
To reassemble:
1. Lubricate the piston bore lightly with petroleum jelly, light oil
or silicone grease.
2. Install the HI end cap first and tighten.
3. Install the piston/magnet assembly (magnet facing HI
pressure port).
4. Insert stacking spacers in bottom of piston spring pocket and
insert range spring.
5. Reassemble LO end cap making certain that spring is seated
in the end cap spring pocket.
6. Tighten LO end cap and the instrument is now ready for
service.
IMPORTANT: Magnet end of piston/magnet assembly
It is recommended that the instrument be located above the
pressure source to allow drainage of the unit.
MUST be facing the HI pressure port of the instrument;
otherwise, the instrument will not operate.
IMPORTANT: Because of the magnetic movement, this
LENS REPLACEMENT: To replace a broken lens, check to see if
the lens is held on by a bezel or a snap-ring. To remove a bezel,
twist off by hand (watch out for the broken glass).To remove a
snap-ring, pry out the ring with a small screwdriver. Remove all
glass chips, insert new lens and re-insert the bezel or snap. With
snap-rings, locate the ring joint at the bottom of the gauge.
instrument should never be mounted in direct contact with a steel
surface; otherwise, a calibration shift will occur. Mount the
instrument so that the pressure body is at least 1” away from
metal surfaces with non-magnetic spacers or an aluminummounting bracket. Flush panel mounted instruments will not be
affected by contact with aluminum panels. However, 2” and 2½”
gauges flush mounted in a steel panel may require resetting of
the pointer at zero. This should be done at time of manufacture
but can be reset in the field with a small loss of accuracy.
MAINTENANCE
POINTER REPLACEMENT: (Probably damaged when lens was
broken). Remove bezel or snap-ring as previously described and
clean out glass chips. Remove old pointer with pointer puller or
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.
Other than replacing broken lens there is only one area where
GN128-1201 Rev. E
Orange Research Inc.
Page 1 of 2
SWITCH ADJUSTMENT
Reed switch set points are field adjustable. On indicating switches, the reed
switches can be adjusted over the top 80% of the gauge range. On switch
models the reed switches can be adjusted over the range shown on the
nameplates.
To change the reed switch setting, a source of pressure will be needed with the
instrument. Loosen the screw holding the reed switch. To increase the set
point, slide the switch tube toward the LO port. To decrease the set point, slide
the switch tube toward the HI port. Repeat as required until new setting is
reached. Tighten the screw holding the switch tube in place and recheck the
new actuation point. CAUTION: Do not over tighten the switch holding screwthis is a cone point set screw and digs into the tube with light pressure. (in
some cases, it might be necessary to reverse the switch tube end for end to
locate the new actuation point-this is normal procedure.
SWITCH WIRE COLOR
-A SPST white and white
-B SPST green(N/C); blue(common)
-C SPDT green(N/C); red(N/O); blue(common)
HI PRESS
PORT
LO PRESS
PORT
REPLACEMENT PARTS
GAUGE
DIA.
2”
2 ½”
3 ½”
4 ½”
6”
GLASS
LENS
GG1-1
GG1-2
GG1-3
GG1-4
GG1-5
PLASTIC
LENS
GG2-1
GG2-2
GG2-3
GG2-4
GG2-5
POINTER
AF15-1
AF15-2
AF15-3
AF15-4
AF15-5
SST BEZEL
(press-fit)
M1-5
M2-5
M4-5
M5-5
---
END CAP “O”-RING
Buna N
BB1-1A
Viton
BB1-1B
Fluorosilicone
BB1-1C
Teflon
BB1-1F
EPDM
BB1-1E
PISTON/MAGNET ASSEMBLY
Aluminum
SD12-1
316 SST
SD12-3
PVC
SD12-4
Naval Brass
SD12-5
RECALIBRATION
Recalibration of this instrument is not required. However, if the range spring is damaged or a new dial is required, the instrument must
be returned to the factory for the parts and recalibration.
NOTE: When ordering replacement parts, identify instrument SO# or WO# from the nameplate. Identify parts required and quantity.
GN128-1201 Rev. E
Orange Research Inc.
Page 2 of 2
MODEL 1201PG (1/4" NPT)
DIAL CASE STYLES
*.78 FOR "F"-STYLE GA. CASE
[19.8]
2.5" "B" & 2.5" "F" STYLE
DIAL CASE
2.5" "F"
STYLE ONLY
.50
[12.7]
PANEL CUTOUT:
2.98
2 MTG. HOLES
.187 EQUALLY
SPACED ON VERTICAL
CL OF DIAL
3.38
3.19
[85.9]
[81.0]
"B"-STYLE
DIAL CASE
"E"
"D"
2.92
[74.2]
.04
[1.0]
1.00
[25.4]
.50
[12.7]
CL
GA.
"C"
"B"
"A"
1.00
[25.4]
*.69
[17.5]
2.00
[50.8]
CL
PORT
CL
GA.
.75
[19.1]
CL
PORT
2.00
[50.8]
DIAL CASE SIZES & DIMENSIONS
3.5"
A
B
C
D
E
4.25[108.0]
3.94[100.1]
.25[6.4]
.13[3.3]
.72[18.3]
4.5"
6.0"
5.25[133.4]
4.94[125.5]
.62[15.7]
.13[3.3]
.72[18.3]
6.68[169.7]
6.44[163.6]
1.35[34.3]
.13[3.3]
.75[19.1]
.75
[19.1]
"E"
"F"-STYLE
DIAL CASE
"D"
CL
GA
"C"
CL
PORT
.75
[19.1]
"F"
-1 IN-LINE
HI PRESS
PORT
3.60
[91.4]
CL GA.
A
B
C
D
E
.77
[19.6]
.50
[12.7]
.88
[22.4]
1.75
[44.5]
-5 BOTTOM PORTS
6.0"
4.5"
6.00[152.4]
5.00[127.0]
4.94[125.5]
3.94[100.1]
.62[15.7]
.25[6.4]
.13[3.3]
.13[3.3]
.72[18.3]
.72[18.3]
2.00
PANEL CUTOUT: PANEL CUTOUT:
[50.8]
4.00
5.00
F 3 MTG. HOLES
3 MTG. HOLES
.187 EQUALLY
.218 EQUALLY
SPACED ON A
SPACED ON A
4.56 B.C.
5.38 B.C.
PORTING LOCATIONS
-1 IN-LINE
LO PRESS
PORT
3.5"
.50
[12.7]
"B"
"A"
DIAL CASE SIZES & DIMENSIONS
1.00
[25.4]
2.13
[54.1]
#8-32 UNC-2B
x .38 DEEP
MTG. HLS.
(2) PL.
.63
[16.0]
CL
GA.
CL PORT
PANEL CUTOUT:
6.50
3 MTG. HOLES
.218 EQUALLY
SPACED ON A
7.00 B.C.
1.63
[41.4]
1.06
[26.9]
-4 BACK PORTS
7.62[193.5]
6.44[163.6]
1.35[34.3]
.13[3.3]
.75[19.1]
CL GA.
SHT. 1 of 2 REV. A
MODEL 1201PGS-1 (1/4" NPT) 1 SWITCH CONFIGURATION
LOCATION OF 2ND SWITCH
IF APPLICABLE
CL
GA.
.63
[16.0]
#8-32 UNC-2B
MNTG. HOLES
(2) PL.
CL PORT
1.63
[41.4]
2.00
[50.8]
STD. FINISHED
WIRE LENGTH
IS 12 in.
1.00
[25.4]
1.13
[28.7]
1.43
[36.3]
STD. MTG. HOLES
1/4-20 UNC-2B x .375
FULL THD. DEPTH
(2) PLCS.
2.25
[57.2]
1 SWITCH SHOWN
MODEL 1201PS (1/4" NPT) 1 SWITCH CONFIGURATION
STD. FINISHED
WIRE LENGTH
IS 12 in.
1.00
[25.4]
.50
[12.7]
1.00
[25.4]
1.43
[36.3]
.50
[12.7]
3.00
[76.2]
3.62
[91.9]
SHT. 2 of 2 REV. A
Product specifications for model 1201
Product Specifications, (gauge, switch)
Sensor type
Functions
Calibration medium
Dial sizes
Dial Starting Mark
Lens
Range
Accuracy
Piston
Gauge, Gauge/Switch, Switch
Units with EPDM Seals: Water Brass or PVC: Water Alum or SS: Hydraulic Oil
PVC: 2.5”,3.5” style “M” only All Others: 2.5”,3.5”,4.5”,6” style “B” and “F”
Approximately 10% of full scale
PVC: Plastic All Others: Glass, Plastic
Min: 0-5 psid Max: PVC: 0-60 psid, All other 0-150 psid
±2% of full scale ascending after rap at room temperature
Repeatability
Max. line\min. burst pressure
Direction of Pressure
Porting size & orientation
±2% of full scale
PVC: 200\750 psig All Others: 3000\10500 psig
PVC: Left to Right All Others: Left to Right, Right to Left available (reverse porting)
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
200°F, 150°F plastic lens
PVC: 120°F All Others: Gauge
Gauge/switch
176°F, 150°F plastic lens
Switch
176°F
PVC: N/A All Others: 450°F (SST only, not available in aluminum or brass)
PVC: 32°F All Others: Consult factory
External hermetically sealed reed switch
Upper 80% of full scale ascending, 70% for B & C form switches in SS
5-20% full scale
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)
(120VAC,0.25A,5VA;175VDC,0.25A,5W)
-C SPDT
Top of range ascending or other set points within adjustability ascending or descending
PVC: Viton
All Others: Buna-N (Viton,Teflon,Neoprene,EPDM,Flourosilicone optional)
PVC: PVC
All Others: aluminum, 316 SS, naval brass (in-line only)
All: SS range spring, SS spacers, ceramic magnet, Teflon piston seal
Teflon coated spring, spacers & magnet available
CSA (File 043810) ∗Consult factory for CE equivalent.
Standard max. temperature
High Temperature
Minimum temperature
Switch Type
Switch Adjustability
Switch Dead Band
Switch Options
Switch Setting
Static & Piston Seals
Primary Wetted Parts
Secondary Wetted Parts
Certification
GN108-1, Rev. M
∗
Calibration accuracy is affected by temperature, liquid filling and follower-pointer applications.
Page 1 of 1
Oil Coolers For Temperature
Optimization In Hydraulic Systems
Catalog HY10-1700/Americas
If you have questions about
the products contained in this
catalog, or their applications,
please contact:
Accumulator & Cooler
Division - Americas
phone 815 636 4100
fax 815 636 4111
parker.com/accumulator
Extra care is taken in the
preparation of this literature, but
Parker is not responsible for any
inadvertent typographical errors
or omissions. Information in this
catalog is only accurate as of
the date of publication. For a
more current information base,
please consult the Parker
Accumulator Division web site at
parker.com/accumulator.
Offer of Sale
The items described in this document are hereby offered for sale
by Parker Hannifin Corporation, its subsidiaries or its authorized
distributors. This offer and its acceptance are governed by the
provisions in the “Offer of Sale.”
!
NOTE: Failure or improper selection or
improper use of coolers or related items
can cause death, personal injury and
property damage. Parker Hannifin shall
not be liable for any incidental,
consequential or special damages that
result from use of the information
contained in this publication.
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.
© Copyright 2012, Parker Hannifin Corporation. All rights reserved.
Parker is a global player specializing in innovative, efficient system solutions for temperature optimization and
energy storage. All over the world, our products are working in the most diverse environments and applications.
Oil Coolers
Choosing the right cooler requires
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
experienced, skilled engineers,
gives you the opportunity for more
cooling per $ invested.
Cooling capacity
Lifetime
Overheating – an expensive
problem
An underestimated cooling
capacity produces a temperature
that is too high. The consequences
are poor lubricating properties,
higher internal leakage, a higher
risk of cavitation, damaged
components, etc. Overheating
leads to a significant drop
in efficiency which can be
detrimental to our environment.
Temperature optimization –
a basic prerequisite for
cost-efficient operation
Temperature balance in a hydraulic
system occurs when the cooler can
cool down the energy input that
the system does not consume –
the system’s lost energy
(Ploss = Pcool = Pin – Pused).
Temperature optimization occurs
at the temperature at which the
oil viscosity is maintained at
4
recommended values. The correct
working temperature produces
a number of economic and
environmental benefits:
• The hydraulic system’s
useful life is extended.
• The oil’s useful life is
extended.
• The hydraulic system’s
availability increases –
more operating time and
fewer shutdowns.
• Service and repair costs
are reduced.
• High efficiency level
maintained in continuous
operation – the system’s
efficiency falls if the
temperature exceeds the
ideal working temperature.
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.
ULOC Cooling System
For industrial use – maximum cooling capacity 60 HP
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.
ULDC with DC Motor
For mobile use – maximum cooling capacity 40 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.
DC motor 12V/24V
Quiet fan and fan motor.
ULHC with Hydraulic Motor
For mobile and industrial use – maximum cooling capacity 215 HP
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.
*At 250 gpm and 70 °F ITD
5
Calculate the cooling capacity requirement
Cooling
capacity
requirement?
Installed
horse power
Flow?
Pressure?
Pump efficiency?
Measure in
your existing
unit
Theoretical
horse power
losses
Choose the right kind of cooler
Enter your values ....
... get suggested solution
7
Contact
Olaer USA
representative
ULAC
Catalog HY10-1700/Americas
ULAC with AC Motor
For industrial use – cooling capacity up to 400 HP
• Easy to maintain and easy to retrofit
into many applications.
The ULAC oil cooler with AC motor is optimized
for use in the industrial sector. Together with a wide
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
of materials and components ensures
a reliable and long lasting cooler with
low service and maintenance costs.
• 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.
• Compact design resulting in lighter
weight unit yet with higher cooling
capacity and lower pressure drop.
9
ULAC
Catalog HY10-1700/Americas
TYPE
ULAC 007B
ULAC 011B
ULAC 016B
ULAC 023D
ULAC 033D
ULAC 033F
ULAC 044D
ULAC 044F
ULAC 058G
ULAC 078G
ULAC 112H
ULAC 200K
Acoustic Pressure
Level
LpA dB(A) 3 Ft.*
69
71
74
81
82
86
83
87
90
92
96
93
No. Of Poles/
Capacity
hP
4/0.5
4/0.5
4/0.5
4/1
4/1
4/3
4/1
4/3
4/5
4/5
4/7.5
6/15
Weight
Lbs. (Approx.)
P
SAE O-Ring
Q
SAE O-Ring Boss
33
44
53
79
115
170
143
197
264
434
542
1,030
½" (#8)
½" (#8)
½" (#8)
½" (#8)
½" (#8)
½" (#8)
½" (#8)
½" (#8)
¾" (#12)
¾" (#12)
¾" (#12)
NA
1" (#16)
1" (#16)
1" (#16)
1" (#16)
1¼" (#20)
1¼" (#20)
1¼" (#20)
1¼" (#20)
1½" (#24)
1½" (#24)
1½" (#24)
CODE 61 SAE 2" FLANGE
* Noise level tolerance ± 3 dB(A).
12
ULAC
Catalog HY10-1700/Americas
TYPE
ULAC 007B
ULAC 011B
ULAC 016B
ULAC 023D
ULAC 033D
ULAC 033F
ULAC 044D
ULAC 044F
ULAC 058G
ULAC 078G
ULAC 112H
ULAC 200K
A
B
C
D
E
F
G
H
I
J
K
L
M
Nø
5.2
5.4
5.2
5.2
5.2
5.2
4.6
4.6
5.2
5.2
5.1
7.2
6.3
9.0
11.7
14.9
19.1
19.1
26.1
26.1
26.1
32.3
38.8
50.9
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.9
3.9
5.0
8.0
8.0
8.0
14.0
14.0
14.0
14.0
14.0
20.0
26.8
31.1
49.6
0.24
0.12
0.28
0.20
NA
NA
NA
NA
NA
NA
0.14
1.2
11.7
14.3
17.0
20.2
24.5
24.5
31.5
31.5
31.5
38.9
45.4
61.0
15.6
18.5
20.7
24.0
28.4
28.4
34.1
34.1
35.4
41.4
47.8
64.2
8.0
8.0
8.0
14.0
14.0
14.0
14.0
14.0
20.0
20.4
23.6
55.9
14.4
17.3
19.5
22.8
27.2
27.2
27.2
27.2
34.2
40.2
46.7
59.4
20.1
20.1
20.1
20.1
20.1
24.0
20.1
24.0
24.0
35.4
35.4
35.4
8.4
9.8
10.9
12.6
14.8
14.8
17.6
18.3
18.3
21.1
24.4
32.7
19.8
20.8
21.6
22.2
23.1
25.6
24.1
26.6
29.9
30.9
31.9
41.5
8.8
9.8
10.7
11.3
12.5
12.5
13.3
13.5
15.2
16.2
17.2
18.7
0.35
0.35
0.35
0.35
0.35
0.55
0.35
0.55
0.55
0.55
0.55
0.71
All dimensions listed above are in inches.
13
ULAC
Catalog HY10-1700/Americas
Order Key for ULAC Oil Coolers
Technical Specifications
All positions must be filled in when ordering.
EXAMPLE:
ULAC -
007B
-M
- 100
Series
Model
Motor Type
Thermoswitch
Core Bypass
1
2
3
4
5
FLUID COMBINATIONS
Mineral oil
Oil/water emulsion
Water glycol
Phosphate ester
- SA
MATERIAL
Cooler core
Fan blades/hub
1. OIL COOLER SERIES WITH AC MOTOR; ULAC
2. COOLER SIZE/MODEL
007B, 011B, 016B, 023D, 033F, 033D, 044F, 044D,
058G, 078G, 112H and 200K.
3. MOTOR TYPE
No motor
Three-phase 190/380V 50 Hz, 208-230/460V 60 Hz
Three-phase 208-230/460V 60 Hz
Three-phase 230/460V 60 Hz
Three-phase 575V 60 Hz
Single-phase 115/230V 60 Hz
Single-phase 230 V 60 Hz
Explosion proof, Division 1, Class 1 Group D,
Class II Group F & G, T3C
Not listed, consult Olaer USA
Fan housing
Fan guard
Other parts
Surface treatment
=W
= M*
=N
=P
=Q
=R
=S
COOLER CORE
Maximum static working pressure
Dynamic working pressure
Heat transfer tolerance
Maximum oil inlet temperature
COOLING CAPACITY CURvES
Cooling capacity curves are based on testing in accordance with
EN1048 with ISO VG 46.
* The M-motor is our standard motor sizes 1 hP and lower. The performance at
50 hZ will be reduced by approximately 10%
= 000
= 100
= 120
= 140
= 160
= 175
= 195
= ZZZ
5. CORE BYPASS*
No Bypass
20 psi External Hose Bypass (standard option)
65 psi External Hose Bypass (standard option)
30 psi External Tube Bypass
75 psi External Tube Bypass
120 psi External Tube Bypass
120 °F External Thermo-Bypass
140 °F External Thermo-Bypass
160 °F External Thermo-Bypass
195 °F External Thermo-Bypass
Full Flow External Bypass
= SW
= SA
= SB
= SG
= SH
= SJ
= SM
= SN
= SP
= SQ
= SF
300 psi
200 psi*
±6%
250 °F
* Tested in accordance with ISO/DIS 10771-1
=X
=Z
4. THERMOSWITCH
No thermoswitch
100 °F
120 °F
140 °F
160 °F
175 °F
195 °F
Not listed, consult Accumulator and Cooler Division
Aluminum
Glass fiber reinforced polypropylene/
Aluminum
Steel
Steel
Steel
Electrostatically powder-coated
CONTACT PARKER FOR ADvICE ON
Oil temperatures > 250 °F
Oil viscosity > 100 cSt / 500 SSU
Aggressive environments
Environments with heavy airborne particulates
High-altitude locations
* The standard cores are single pass. Two pass cores and other options
available upon request, please consult Accumulator and Cooler Division.
The information in this brochure is subject to change without prior notice.
14
Magnaloy Flexible Drive Couplings
SECTION 1
1
MAGNALOY FLEXIBLE DRIVE COUPLINGS
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
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
1
Magnaloy Coupling Design Features
Load-Lock Design... is simple and effective. The drive lug
1
1
configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-lock
design protects bearings and equipment by eliminating end
thrust in both directions.... and it requires only one set-screw in
each hub.
Radial Lug Design... is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking and 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.
Conventional Design A...
Under loaded conditions this jaw design results in the applied forces
exerting components in the compressive and radial directions. These forces
change direction and magnitude along the jaw arc which greatly increase
the internal movement of the element which causes heat generation.
Conventional Design B...
A note about Set-Screws ...
This more conventional straight sided jaw design also exerts component
forces in the compressive and radial directions when under load. The
radial component is outward (acting to extrude the element) and changes
in magnitude only, as does the compressive component, along the jaw
surface. The component forces resulting from this design also causes
increased internal movement in the element.
The Premium Line of Magnaloy Couplings comes standard with a single set-screw over the keyway. Optional
Double Set-Screws are available at either 45o or 90o to the keyway. Double set-screws help improve shaft
gripping forces by increasing the hoop-stresses generated from tightening a single set-screw. Double set-screws
at 45o will produce greater forces than double set-screws at 90o. Either are available upon request by
specifying ‘DSS45’ or ‘DSS90’ following the hub part number. M30011210DSS45
Magnaloy’s Clamp feature is also availble with bored and keyed hubs, specify ‘C’ following the hub part
number. M30011210C
2
magnaloy coupling company
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
Premium Flexible Drive Couplings
Magnaloy is the original lightweight, heavy-duty
flexible drive coupling. Light weight magnesium
construction makes Magnaloy couplings 76% lighter than
cast iron and 36% lighter than aluminum units... and
they’re stronger than either!
The benefits are many... Reduced loads on bearings,
shafts and pumps, for longer component life. Easier
handling and installation. Rust proof and corrosion
resistant.
Magnaloy’s close machining tolerances (TIR of .002”)
assures vibration-free operation and easy, accurate
alignment without need for special tools. Solid
magnesium alloy permanent mold castings are heat
treated and offer the highest strength-to-weight ratio
available.
Coupling Performance Specifications
Coupling Maximum
Model
Bore
Wr2
lb-ft2
100
1 1/8
0.0046
200
1 3/8
0.0068
300
1 5/8
0.022
400
1 7/8
0.031
500
2 3/8
0.071
600
2 5/8
0.16
700
2 7/8
0.34
800
3 7/8
0.95
900
4 3/4
4.20
magnaloy coupling company
A Division of Douville Johnston Corporation
Insert
Number
170N
170U
170H
270N
270U
270H
370N
370U
370H
470N
470U
470H
570N
570U
570H
670N
670U
670H
770N
770U
770H
870N
870U
870H
970N
970U
Rated
Torque
lb-in
340.7
511.0
1,022.1
398.3
597.4
1,194.9
701.4
1,052.1
2,104.2
1,056.3
1,584.5
3,168.9
2,194.8
3,292.2
6,584.4
4,946.7
7,420.1
14,840.1
11,639.8
17,459.7
29,099.5
21,889.4
32,834.1
47,062.2
47,842.3
71,763.5
Torsional
Rigidity
lb-in/Deg
42
53
182
55
68
234
81
148
336
138
310
488
314
695
1,571
676
1,510
2,960
1,805
2,104
5,960
3,680
11,950
8,428
-
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
Horse Power Rating @
100
1200
1800
rpm
rpm
rpm
0.55
0.82
1.65
0.64
0.96
1.92
1.12
1.68
3.36
1.69
2.50
5.10
3.50
5.30
10.50
7.90
11.90
23.70
18.60
27.90
46.50
35.00
52.50
75.20
76.50
114.80
6.5
9.8
19.8
7.6
11.5
23.0
13.5
20.2
40.4
20.3
30.4
60.8
42.1
63.2
146.4
94.9
142.5
284.9
223.5
335.2
558.8
420.3
630.4
903.0
918.6
1,377.9
989 356-2186
http://www.magnaloy.com
9.8
14.7
29.7
11.5
17.2
34.5
20.2
30.3
60.6
30.4
45.6
91.3
63.2
94.8
189.6
142.5
213.7
427.4
335.2
502.8
838.0
630.4
945.6
1,354.5
1,377.9
2,066.8
3
1
Dimensional Specifications
Magnaloy Coupling Dimensional Specifications
Models 100, 200, 300, 400
1
1
A
B
C
D
E
F
G
W
X
T
100
2.54
2.600
2.00
0.56
0.68
0.42
0.31
1/16
0.90
1/4-20
200
3.10
2.900
2.25
0.68
0.84
0.42
0.43
1/16
0.90
5/16-18
300
3.58
3.450
2.90
0.78
0.96
0.44
0.56
1/16
0.98
5/16-18
400
4.24
3.980
3.05
1.00
1.06
0.54
0.73
1/16
1.20
3/8-16
TOLERANCES: 2 Place Decimals ± .01
3 Place Decimals ± .001
Model 500
A
B
C
D
E
F
G
W
X
T
500
4.67
4.800
4.00
1.04
1.23
.064
.070
1/16
1.41
3/8-16
X*: Maximum Space between
shaft ends to allow full
shaft engagement in
Hub Bore.
W*: Minimum Space between
shaft ends.
* Given for reference only.
TOLERANCES: 2 Place Decimals ± .01
3 Place Decimals ± .001
Models 600, 600, 800, 900
A
B
C
D
E
F
G
W
X
T
4
600
5.98
5.975
4.50
1.60
1.33
0.62
1.13
1/16
1.36
3/8-16
700
6.99
6.900
5.19
2.08
1.32
0.89
1.13
1/16
1.97
1/2-13
800
7.99
8.600
7.00
2.25
1.62
1.00
1.58
1/16
2.25
1/2-13
900
10.15
11.400
8.30
2.75
2.20
1.32
1.88
1/16
2.89
3/4-10
magnaloy coupling company
A Division of Douville Johnston Corporation
TOLERANCES: 2 Place Decimals ± .01
3 Place Decimals ± .001
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
Bore & Keyway Combinations
Standard Bore and Keyway Combinations
Magnaloy “Standard” Bore Key Combinations
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
* *
* *
* *
*
*
*
*
* * *
* * *
* * *
* * *
* * *
* * *
*
* * *
* * * * *
* * * * *
*
*
* *
* *
*
*
*
*
*
*
Model
Bore
Key
1 3/4 x 7/16
1 7/8 x 1/2
15/16 x 1/2
2 x 1/2
2 1/8 x 1/2
2 1/4 x 1/2
2 3/8 x 5/8
2 1/2 x 5/8
2 5/8 x 5/8
2 3/4 x 5/8
2 7/8 x 3/4
3 x 3/4
3 1/4 x 3/4
3 3/8 x 7/8
3 1/2 x 7/8
3 5/8 x 7/8
3 3/4 x 7/8
3 7/8 x 1
4 x 1
4 1/8 x 1
4 1/4 x 1
4 3/8 x 1
4 1/2 x 1
4 1/2 x 1 1/4
4 5/8 x 1 1/4
4 3/4 x 1 1/4
*
* * *
* * *
* * *
Shaded Area: AGMA semi-standard bore key combinations.
Over Include
-1
2
3
4
Example: Model 500 Hub with a 1 /38 bore and 5/16 keyway would be
specified as: M50011210 - No bore hubs are designated as “R” code, ie.
M500R.
Model Number
100
Maximum Bore
1 1/8
Complete Coupling Approx. Weight
3/4
(Solid Hub)
Number of Drive Lugs
Hub Movement for Insert Removal
Basic Insert Number
magnaloy coupling company
A Division of Douville Johnston Corporation
3
.74
170
* * *
* * *
* *
* *
* *
* *
* *
*
*
1
2
3
4
5
400
1 7/8
500
2 3/8
600
2 5/8
700
2 7/8
800
3 7/8
900
4 3/4
3
.74
270
3
.75
370
3
.98
470
4
1.12
570
6
1.02
670
6
1.50
770
6
1.63
870
6
2.27
970
3
4
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
+.0008/+.0003
+.0013/+.0005
+.0018/+.0008
+.0020/+.0010
+.0023/+.0010
300
1 5/8
2
*
*
*
*
*
*
*
*
Tolerance
200
1 3/8
1
* *
* * *
Bore Tolerances
Part Number Usage: Magnaloy Coupling Hub part numbers may be specified
using the following format: Start with letter “M” designating Magnaloy,
followed by 3 digit Model Code (100, 200, etc.), then the specific 5 digit
Bore/Key Code.
Additional Coupling Specifications
900
800
700
600
500
400
300
200
100
Key
3/32
3/32
1/8
1/8
1/8
5/32
3/16
3/16
1/8
3/16
3/16
1/4
1/4
3/16
1/4
1/4
1/4
1/4
5/16
5/16
3/8
3/8
5/16
3/8
3/8
3/8
Magnaloy “Standard” Bore Key Combinations
Model Bore/Key
Code
Code
M _ _ _ 12414
M _ _ _ 12816
M _ _ _ 13016
M _ _ _ 20016
M _ _ _ 20416
M _ _ _ 20816
M _ _ _ 21220
M _ _ _ 21620
M _ _ _ 22020
M _ _ _ 22420
M _ _ _ 22824
M _ _ _ 30024
M _ _ _ 30824
M _ _ _ 31228
M _ _ _ 31628
M _ _ _ 32028
M _ _ _ 32428
M _ _ _ 32832
M _ _ _ 40032
M _ _ _ 40432
M _ _ _ 40832
M _ _ _ 41232
M _ _ _ 41632
M _ _ _ 41640
M _ _ _ 42040
M _ _ _ 42440
900
800
700
600
500
400
300
200
100
Model
Model Bore/Key
Code
Code
Bore
M _ _ _ 01203
3/8 x
M _ _ _ 01403
7/16 x
M _ _ _ 01404
7/16 x
M _ _ _ 01604
1/2 x
M _ _ _ 01804
9/16 x
M _ _ _ 02005
5/8 x
M _ _ _ 02006
5/8 x
M _ _ _ 02206
11/16 x
M _ _ _ 02404
3/4 x
M _ _ _ 02406
3/4 x
M _ _ _ 02806
7/8 x
M _ _ _ 02808
7/8 x
M _ _ _ 03008
15/16 x
M _ _ _ 10006
1 x
M _ _ _ 10008
1 x
M _ _ _ 10408
1 1/8 x
M _ _ _ 10608 1 3/16 x
M _ _ _ 10808
1 1/4 x
M _ _ _ 10810
1 1/4 x
M _ _ _ 11210
1 3/8 x
M _ _ _ 11212
1 3/8 x
M _ _ _ 11412 1 7/16 x
M _ _ _ 11610
1 1/2 x
M _ _ _ 11612
1 1/2 x
M _ _ _ 12012
1 5/8 x
M _ _ _ 12412
1 3/4 x
7
12
989 356-2186
http://www.magnaloy.com
18
38
5
1
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
Part Number Usage: Magnaloy Coupling Insert part
numbers may be specified using the following format:
Start with the letter “M” for Magnaloy, followed by the 3
digit Basic Insert Number Code (170, 270, etc.), then the
specific single letter Insert Material Code. If an optional
durometer is being specified, after the Material Code
supply the durometer number divided by 10.
Examples: Urethane insert for Model 300: M370U. 80
Durometer Neoprene for Model 200: M270N8.
Insert Selection Guide
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
to +660C).
Viton (Fluorocarbon)(Code V) - Red material.
Excellent fluid compatibility and high temperature
characteristics. Good compression set and
resiliency. Temp range -200F to +3500F (-290C to
+1770C).
Hytrel (Code H) - Blue material. Superior physical
and mechanical properties and excellent fluid
compatibility and high temperature characteristics.
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
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
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*
Heavy (H)
2.0*
2.5*
2.5*
3.0*
Moderate (M)
1.5
2.0
2.0
2.5*
1
Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts, infrequent reversals,
peak torque may exceed average 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
Agitators
Blowers
Compressors - Centrifugal
- Rotary
- Reciprocating
Conveyors - Reciprocating
- Screw
- Shaker
Cranes & Hoists
Crushers
Elevators
- Freight & Pass.
Fans
- Centrifugal
- Propeller
- Cooling Tower
Generators
- Welding
Mills
Machine Tools
Mixers
Paper Mill Machinery
Pumps
- Centrifugal
- Rotary
- Reciprocating
- On Injection
Molding Equip.
Screens
- Air & Water
Washing
- Freight & Pass.
Stokers
Textile Machinery
Woodworking Machinery
Winches
Load Sym.
U
U
U
M
H*
U
M
M
H
M
H*
M
H*
U
M
H
U
H
H*
M
M
M
U
M
H*
H*
U
H
U
M
M
H*
1. Several specifics must be considered to make the best
choice of couplings:
A. Type of prime mover and load characteristics (see table
above)
B. Shaft diameter and key size or spline configuration (No. of
teeth, pitch ratio, pressure angle)
C. Horsepower rating of loads to be transmitted.
D. Maximum operating speed (rpm)
E. Maximum operating misalignment
F. Clearance limitations
2. Calculate effective hp/100 rpm by use of table above and
select the minimum size coupling recommended
3. VERIFY YOUR SELECTION:
A. Check for maximum bore size
B. Check dimensions for adequate clearance
C. Indicate any special insert specification and/or coupling
coating for environmental protection, if required
Equation: Effective HP per 100 RPM = rated HP x Service
Factor x 100 / RPM
Example: 150 HP, 4 cyl. Diesel Engine Driving a Reciprocating
Irrigation Pump operating at 3250 RPM
Service Factor - 3.0 (Hytrel Insert Recommended)
Eff. HP per 100 RPM = 150 HP x 3.0 x 100 /
3250 RPM = 13.85 HP/100 RPM. Model 600
rating with Hytrel Insert is 23.7 HP/100 RPM.
Note: Above service factors are intended for use as a general guide only.
*Recommend use of Steel Bushing and Clamp with Splined Bores.
magnaloy coupling company
A Division of Douville Johnston Corporation
Selection Method
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
98
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
condition - maximum shaft engagement should be
utilized in any case.
1
1
Alignment - Place a straight edge (scale) at top and
side of coupling. Use a .005 inch feeler gauge under
scale for final inspection. This will indicate accurate
parallel and angular alignment.
Magnaloy’s precision machined outside surfaces
permit this simple, but accurate alignment method.
190
Secure equipment mounts and recheck alignment for
movement.
Install the insert in the coupling positioning hubs in
contact with lip around outside of insert.
Before tightening set screws, run the coupling and
check for separation of hubs or “creep”. Recheck
alignment and tighten set screws.
With the Steel Bushed/Clamp type couplings, to
facilitate installation on the shaft, it may be
necessary to slightly loosen the set-screw over the
keystock. When securing the coupling on the shaft,
first tighten the clamp bolt, then tighten the set-screw
against the keystock.
magnaloy coupling company
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
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.
Model
100
200
300
400
500
600
700
800
900
Recommended Torques
for Fasteners
Set Screw
60 - 70 in lbs
75 - 85 in lbs
75 - 85 in lbs
190 - 200 in lbs
190 - 200 in lbs
190 - 200 in lbs
300 - 310 in lbs
300 - 310 in lbs
100 - 110 ft lbs
1
Clamp Screw
130 - 140 in lbs
130 - 140 in lbs
210 - 220 in lbs
210 - 220 in lbs
300 - 310 in lbs
35 - 36 ft lbs
35 - 36 ft lbs
49 - 50 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
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
1110
Keystock Interference with Drive Lug
1
1
Technical Bulletin & Notes
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
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.
Interference Potential exists when
shaft diameters are greater than
shown in this chart.
Model Size Shaft Diameter Key Size
100
7/8
1/4
200
1 3/16
1/4
300
1 5/16
5/16
400
1 1/2
3/8
500
1 15/16
1/2
600
2 1/2
5/8
700
2 3/4
5/8
800
3 1/2
7/8
900
4 1/2
1 1/4
Failure to correct this condition will result in assembly difficulty and could cause damage to the drive
or driven equipment. Check our web site at www.magnaloy.com for other bulletins.
Notes
1112
magnaloy coupling company
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
Magnaloy Pump/Motor Mounts
SECTION 2
2
MAGNALOY PUMP/MOTOR MOUNTS
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
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
17
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).
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
Illustration A
Selection Program.
Magnaloy Cast Aluminum Mounts
MAGNALOY CAST ALUMINUM MOUNTS are permanent mold cast of lightweight, high strength aluminum alloy
and incorporate many unique design features. Custom molded OSHA orange coupling access covers are
included for mounts larger than motor group size 056. These covers are quickly and securely retained via a liptab on one end and a single self-tapping screw on the other. Magnaloy’s horizontal mounts are supplied with a
pre-cast drain hole for residual fluids. This unique feature assists in quick detection of leaky seals and other
trouble areas.
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.
Magnaloy Horizontal Pump/Motor Mounts
MAGNALOY’S HORIZONTAL PUMP/MOTOR MOUNTS are available for mounting NEMA C’Face motors in
frame sizes 56C through 449TSC to most SAE and Metric 2 and 4 bolt pump flanges.
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
A Division of Douville Johnston Corporation
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
989 356-2186
http://www.magnaloy.com
19
2
Horizontal Pump/Motor Mounts - NEMA Frame Motors
TABLE 8A - NEMA Frames 182TC - 256TC, 213UC - 256UC
Horizontal Mounting (or Vertical Mounting - Option A)
MOTOR END DATA
AJ BF BD AK
7.
25
17
/3
2
9.
00
8.
50
1
182-A Casting
7.
25
17
/3
2
9.
00
8.
50
1
XAK
XAJ2
XBF2
XAJ4
XBF4
MOUNT NO. CL M MOUNT NO. CL M
USA4F17 4 Bolt
1.782
2.84 5/16-18 M182474F 4.00 4.75 M182504F 4.31 5.00
SAE AA
2 Bolt
2.001
3.25 3/8-16
M182472AA 4.00 4.75 M182502AA 4.31 5.00
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
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
63 S4
4 Bolt 63.01mm
80mm 11/32 M1824763MS 4.00 4.75 M1825063MS 4.31 5.00
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
80 S4
4 Bolt 80.01mm
100mm 5/16-18 M1824780MS 4.00 4.75 M1825080MS 4.31 5.00
PUMP FLANGE
PUMP END DATA
4.75 LENGTH
5.0 LENGTH
MOTOR END DATA
RADIAL CLEARANCE “Z” = 5.00
AJ BF BD AK
XAK
XAJ2
USA4F17 4 Bolt
1.782
SAE AA
2 Bolt
2.001
3.25
SAE A 2(4) Bolt 3.251
4.19
63 2A/B4 2(4) Bolt 63.01mm 100mm
63 S4
4 Bolt 63.01mm
80 2A/B4 2(4) Bolt 80.01mm 109mm
80 S4
4 Bolt 80.01mm
PUMP FLANGE
XBF2
3/8-16
3/8-16
5/16-16
3/8-16
XAJ4
XBF4
MOUNT NO.
2.84 5/16-18 M182584F
M182582AA
4.12 3/8-16 M182582A
85mm 5/16-18 M1825863M
80mm 11/32 M1825863MS
103mm 5/16-18 M1825880M
100mm 5/16-18 M1825880MS
PUMP END DATA
CL M
5.06 5.81
5.06 5.81
5.06 5.81
5.06 5.81
5.06 5.81
5.06 5.81
5.06 5.81
5.81 LENGTH
TABLE 8B - NEMA Frames 182TC - 256TC, 213UC - 256UC
Horizontal Mounting
7.
25
17
/3
2
9.
00
8.
50
1
MOTOR END DATA
AJ BF BD AK
SAE B
SAE C
2(4) Bolt
2(4) Bolt
2
RADIAL CLEARANCE “Z” = 5.00
XAK
4.001
5.001
MOUNT NO.
M182684F
M182682AA
M182682A
M1826863M
M1826863MS
M1826880M
M1826880MS
MOUNT NO. CL M
M182524F 4.31 5.25
M182522AA 4.31 5.25
M182522A 4.31 5.25
M1825263M 4.31 5.25
M1825263MS 4.31 5.25
M1825280M 4.31 5.25
M1825280MS 4.31 5.25
5.25 LENGTH
CL M
6.06 6.81
6.06 6.81
6.06 6.81
6.06 6.81
6.06 6.81
6.06 6.81
6.06 6.81
6.81 LENGTH
RADIAL CLEARANCE “Z” = 5.00
XAJ2 XBF2 XAJ4
5.75 1/2-13 5.00
7.12
5/8-11
6.38
XBF4
1/2-13
1/2-13
182-B Casting
MOUNT NO. CL M MOUNT NO. CL M MOUNT NO. CL M
M182522B 4.50 5.25 M182582B 5.06 5.81 M182602B 5.25 6.00
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
magnaloy coupling company
A Division of Douville Johnston Corporation
5.25 LENGTH
501 Commerce Drive Alpena, MI 49707
Fax: 989 354-4190
5.81 LENGTH
989 356-2186
http://www.magnaloy.com
6.00 LENGTH
21
Bulletin E-73
Series L4
Float Switch
Specifications - Installation and Operating Instructions
Rugged and reliable the Flotect® L4 Level switch operates automatically
to indicate tank level. Perfect for starting or stopping pumps, opening or
closing valves, or actuate level alarm signals. A unique magnetically
actuated switching design gives superior performance. There are no
bellows, springs, or seals to fail. Instead, the free-swinging float attracts
a magnet within the solid metal switch body, actuating a snap switch by
means of a simple lever arm. Float arm hinge design limits the arm angle
to prevent vertical hangup.
FEATURES
• Leak proof body machined from bar stock
• Choice of floats dependent on maximum pressure and specific gravity
• Weatherproof, designed to meet NEMA 4
• Explosion-proof (listings included in specifications)
• Installs directly and easily into tank with a thredolet or flange
(see application drawings on page 4)
• Electrical assembly can be easily replaced without removing the unit
from the installation so that the process does not have to be shut down
• Horizontal installation or optional top mount vertical installation
APPLICATIONS
• Direct pump control for maintaining level
• Automatic tank dump operations
• Control levels or provide alarms in sumps, scrubber systems, hydropneumatic tanks, low pressure boilers, and various waste
water/sewage treatment processes
W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC.
P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A.
SPECIFICATIONS
Service: Liquids compatible with wetted materials.
Wetted Materials:
Float and Rod: 316 SS;
Body: Brass or 316 SS standard;
Magnet Keeper: 430 SS standard, 316 SS or nickel optional.
Temperature Limits: 4 to 275°F (-20 to 135°C) standard, MT high
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).
Pressure Limit: Brass body 1000 psig (69 bar), 316 SS body 2000 psig
(138 bar). Standard float rated 100 psig (6.9 bar). For other floats see
model chart on next page.
Enclosure Rating: Weatherproof and Explosion-proof. Listed with UL
and CSA for Class I, Groups C and D; Class II, Groups E, F, and G.
ATEX
0518
II 2 G Ex d IIB T6 Gb -20°C≤Tamb≤73°C.
-20°C≤Process Temp≤73°C.
EC-Type Certificate No.: KEMA 03 ATEX 2383.
ATEX Standards: EN60079-0: 2009; EN60079-1: 2007.
IECEx Certified: For Ex d IIB T6 Gb -20°C≤Tamb≤73°C. -20°C≤Process
Temp≤73°C.
IECEx Certificate of Conformity: IECEx DEK 11.0071.
IECEx Standards: IEC 60079-0: 2007; IEC 60079-1: 2007.
Switch Type: SPDT snap switch standard, DPDT snap switch optional.
Electrical Rating: UL, FM, ATEX or IECEx models: 10A @ 125/250 VAC
(V~). CSA models: 5A @ 125/250 VAC (V~); 5A res., 3A ind. @ 30 VDC
(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.
Phone: 219/879-8000
Fax: 219/872-9057
www.dwyer-inst.com
e-mail: [email protected]
Example
Construction
L4
SS D
C
F
L4
L4-TOP
Wetted Material
SS
Options
316
NI
Switch Options
D
Float Options
50
150
300
Other Options
AT
IEC
EPOXY
MT
MV
NB
NH
TBC
TRD
TRI
Flange*
F
Flange Size
2
C
1
L4-SS-D-C-F2C1
Side Mount, Brass Body, SPDT Switch
Top Mount, Brass Body, SPDT Switch (Specify rod length)
316 SS Body with 430 SS Magnet Keeper
316 SS Body and Magnet Keeper (Order with SS option)
Nickel 20 Magnet Keeper
DPDT Switch
2-1/2˝ Spherical, 304 SS rated 50 psi (3.5 bar), > 0.5 s.g.
2-1/2˝ Spherical, 316 SS rated 150 psi (10.3 bar), > 0.7 s.g.
2-1/2˝ Spherical, 304 SS rated 300 psi (20.7 bar), > 0.7 s.g.
ATEX
IECEx
Epoxy Coated Housing
High Temperature* (See specifications for rating)
Gold Contact Snap Switch* (See specifications for rating)
Neoprene Boot*
No Electrical Housing*
Terminal Block Wire Connections*
Time Delay Relay* (On flow decrease)
Time Delay Relay* (On flow increase)
Flange Process Connection
2˝
3˝
4˝
Carbon Steel
316 SS
1 150 #
3 300 #
6 600 #
9 900 #
Bushing Process Connection
2˝
2-1/2˝
4˝
Hex
Flush
B Brass
C Carbon Steel
S 316 SS
4 304 SS
2
3
4
Flange Material
C
S
Flange Rating
Bushing*
Bushing Size
B
1
2
4
Bushing Type
H
F
Bushing
Material
* Options that do not have ATEX or IECEx
Attention: Units without the “AT” suffix are not Directive 94/9/EC (ATEX) compliant. These units are not intended for use in potentially hazardous atmospheres in the EU.
These units may be CE marked for other Directives of the EU.
FLOAT
316 STNLS. STL
(STANDARD)
1-1/2 MALE NPT
FLOAT ARM & BLOCK SWITCH BODY
BRASS OR MOUNTING CONNECTION
316 STNLS. STL.
316
STNLS.
STL.
16 GA. LEADS
OR BRASS
6 [152.40] LONG
Ø2-1/2
[63.50] 3-11/32
[84.93]
Ø1-5/8
[41.28]
5
[127.00]
6
[152.40]
MAGNET
KEEPER
430 STNLS.
STL.
1. Cover lock. (ATEX/IECEx unit only).
3
[76.20]
5
[127.00]
8-7/32
[208.76]
3/4 FEMALE NPT
CONDUIT
CONNECTION
19-7/32
[488.16]
3 2
5
1
3. Enclosure housing and cover.
5. Internal ground.
*6. Magnet arm and switch assembly.
1-1/2 NPT
2-1/2
[63.50] 3-11/32
[84.93]
1-5/8
[41.28]
5
[127.00]
2. External ground. (ATEX/IECEx unit only).
4. Terminal block. (ATEX/IECEx unit only,
UL/CSA unit has 6˝ leads).
UL/CSA unit
6
PARTS LIST
6
[152.40]
3
[76.20]
8-7/32
[208.76]
19-7/32
[488.16]
ATEX/IECEx unit
5
[127.00]
7. Switch body.
*8. Float, arm and block assembly.
*Approved replacement parts
3/4 NPT
Bulletin E-73
INSTALLATION
NOTES:
• Check all ratings given in the instructions and on the product to make
sure that the product is suitable for your application. Do not exceed
electrical ratings, pressure ratings, or temperature ratings of the product.
• Disconnect power supply before beginning installation to prevent
possible equipment damage or electrical shock.
1. Remove packing material from switch body-cap and remove tape from
magnet keeper. Install standard switch in thredolet previously welded to
tank. Install optional switch mountings per application drawings. Make
sure locknuts on float are tight.
NOTE: ATEX and IECEx units only: The temperature class is
determined by the maximum ambient and/or process temperature. Units
are intended to be used in ambient of -20°C ≤Tamb≤73°C. Units may be
used in process temperatures up to 133°C providing the enclosure and
switch body temperature do not exceed 73°C. The standard
Temperature Class is T6 Process Temp ≤73°C.
5. For units supplied with both internal ground and external bonding
terminals, the ground screw inside the housing must be used to ground
the control. The external bonding screw is for supplementary bonding
when allowed or required by local code. When external bonding
conductor is required, conductor must be wrapped a minimum of 180°
about the external bonding screw. See below.
2. When mounting switch in the side of a tank, the arrow on the side of
the switch must point up.
LOCKWASHER
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.
ATEX and IECEx Installation Instructions:
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.
NOTE: The switch is deactivated and contacts are in normal condition
when the liquid is below the float.
4. Make sure conduit or cable are properly sealed. Electrical
components must be kept free of moisture, including condensation, at all
times.
CAUTION: To prevent ignition of hazardous atmosphere, disconnect the
device from the supply circuit before opening. Keep assembly tightly
closed when in operation.
CONDUCTOR
CLAMP
FRONT VIEW DETAIL
SIDE VIEW DETAIL
SPDT
DPDT
TERMINAL CONNECTIONS
MAINTENANCE
Inspect and clean wetted parts at regular intervals. The cover should be
in place at all times to protect the internal components from dirt, dust,
and weather, and to maintain hazardous location ratings. Disconnect
device from the supply circuit before opening to prevent ignition of
hazardous atmosphere. Repairs to be conducted by Dwyer Instruments,
Inc. Units in need of repair should be returned to the factory prepaid.
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
3/4 NPT
ANSI RF
THREADED
REDUCING
FLANGE
ANSI RF THREADED
REDUCING FLANGE
3/4 NPT
*FLANGE FACE TO CENTERLINE OF FLOAT
SPECIFIED BY CUSTOMER NORMALLY
SHOULD NOT EXCEED 20' [508 MM].
VERTICAL, FLANGE INSTALLATION
11-3/4
[298.5]
HORIZONTAL, FLANGE INSTALLATION
2-1/2
THREDOLET
CUT HOLE
2-7/8 [73] DIA.
2-1/2 X 1-1/2
FACE BUSHING
HORIZONTAL, 2-1/2 THREDOLET INSTALLATION
WITH OPTIONAL 2-1/2 [64] SPHERICAL FLOAT
© Copyright 2014 Dwyer Instruments, Inc.
Printed in U.S.A. 9/14
W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC.
P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A.
Phone: 219/879-8000
Fax: 219/872-9057
FR# 82-440631-00 Rev. 5
www.dwyer-inst.com
e-mail: [email protected]
Fluid Level / Temperature Indicators
Dimensions / Technical Data / Order Codes
Level Gauge § Type SNA
Design of Scale Plates Thermometer Options
Capillary Tube Thermometer
with a dual Celsius / Fahrenheit
scale up to +80 °C / +180 °F
A
D
C
40
20
0
Dial Thermometer with
Probe T1/T2 (optional)
E
Dimensions
Characteristics
Visual fluid level indication in hydraulic reservoirs with
maximum tank pressures not exceeding 2 bar / 29 PSI
Nominal Size
SNA 076
Nominal Sizes and Designs
6 nominal sizes from 76 mm / 2.99 in to 305 mm / 12.00 in
Display either undivided (SNA 076 ... 176) or subdivided
by strut(s) into 2 (SNA 254) or 3 sections (SNA 305)
SNA 127
SNA 150
SNA 176
Please see page E5 for alternative nominal sizes and designs.
Media Compatibility
Suitable for use with Mineral and Petroleum based
hydraulic fluids (HL and HLP)
SNA 254
SNA 305
Please see page E5 for alternative housing materials.
Technical Data
IP 65 protection rating: Dust tight and protected
against water jets (IP 67 on request)
Operating temperature range:
-30 °C ... +80 °C / -22 °F ... +176 °F
Recommended tightening torque: 8 N·m / 5.9 ft·lb
Accessories / Options
Red / blue capillary tube thermometers with a dual
Celsius / Fahrenheit scale and a temperature display
range of up to +80 °C / +180 °F
Dial thermometers with probe and a Celsius or a dual Celsius /
Fahrenheit scale with a temperature display range of up to
+100 °C / +200 °F
Thermo Switches
Temperature Sensors
HZB-27-03-2012-EN.indd 4
www.stauff.com
N
160
140
50
120
40
100
30
20
10
0
-10
C
X
180
60
80
60
40
20
F
S-T
100
Clearance Hole:
Ø13 (Ø.51) for M12 / Ø10,5 (Ø.41) for M10 /
Ø13,5 (Ø.53) for UNC, UNF and UNEF
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.
Dimensions (mm/in)
A
B
C (Max.)
D
E
F (with T1)
F (with T2)
L1
L2
L3
45
1.77
45
1.77
45
1.77
45
1.77
45
1.77
45
1.77
8
.32
8
.32
8
.32
8
.32
8
.32
8
.32
27
1.06
27
1.06
27
1.06
27
1.06
27
1.06
27
1.06
43,5
1.71
43,5
1.71
43,5
1.71
43,5
1.71
43,5
1.71
43,5
1.71
165,5
6.52
165,5
6.52
165,5
6.52
165,5
6.52
165,5
6.52
165,5
6.52
265,5
10.45
265,5
10.45
265,5
10.45
265,5
10.45
265,5
10.45
265,5
10.45
108
4.25
159
6.26
182
7.17
208
8.19
285
11.22
336
13.23
76
2.99
127
5.00
150
5.91
176
6.93
254
10.00
305
12.00
31
1.22
76
2.99
99
3.90
124
4.88
192
7.56
244
9.61
34,5
1.36
34,5
1.36
34,5
1.36
34,5
1.36
34,5
1.36
34,5
1.36
SNA 127 B - S - O - 12 - O - 60
a Type
Level Gauge with visual fluid level indication
f Banjo Bolt Size
SNA
b Nominal Size
SNA 076 (nominal size of 76 mm / 2.99 in)
SNA 127 (nominal size of 127 mm / 5.00 in)
SNA 150 (nominal size of 150 mm / 5.91 in)
SNA 176 (nominal size of 176 mm / 6.93 in)
SNA 254 (nominal size of 254 mm / 10.00 in)
SNA 305 (nominal size of 305 mm / 12.00 in)
076
127
150
176
254
305
Please see page E5 for alternative nominal sizes.
c Sealing Material
NBR (Buna-N®) (standard option)
FPM (Viton®)
B
V
d Design of Scale Plate
With STAUFF logo (standard option)
Neutral design without any logo
Custom-designed scale plate (please specify)
S
N
X
e Thermometer Option
Supplied without thermometer
O
Red Capillary Tube thermometer on scale plate
T
Blue Capillary Tube thermometer on scale plate
TB
Dial thermometer with probe (200 mm / 7.87 in)
T1C
and a Celsius scale up to 100 °C
Dial thermometer with probe (300 mm / 11.81 in)
T2C
and a Celsius scale up to 100 °C
Dial thermometer with probe (200 mm / 7.87 in)
T1CF
and a dual scale up to 100 °C / 200 °F
Dial thermometer with probe (300 mm / 11.81 in)
T2CF
and a dual scale up to 100 °C / 200 °F
Please see pages E8 and E9 for details.
E4
S
60
80
80
70
Order Codes
Materials
Housing made of Steel St 12, black epoxy-coated
Sight tube and plugs made of Polyamide (PA)
Sealings made of NBR (Buna-N®)
Scale plate made of PVC
Special sight tube materials for improved UV or chemical
resistance and use with special media (such as bio-degradable
fluids, diesel oils, gasolines, etc.) as well as special sealing
materials, e.g. FPM (Viton®), and scale plate materials,
e.g. Aluminium, are available on request.
F
YOUR LOGO
L1
L3
L2
B
12
10
U1
U2
U3
Metric ISO thread M12 (standard option)
Metric ISO thread M10
Unified coarse thread 1/2–13 UNC
Unified fine thread 1/2–20 UNF
Unified extra-fine thread 1/2–28 UNEF
g Thermo Switch / Temperature Sensor Option
Supplied without Thermo Switch / Temperature Sensor Thermo Switch TS-SNA/SNK; Break contact
O
(normally closed); Equipped with standard connector
Thermo Switch TS-SNA/SNK; Break contact
OD
(normally closed); Equipped with connector M12
Thermo Switch TS-SNA/SNK; Make contact
C
(normally open); Equipped with standard connector
Thermo Switch TS-SNA/SNK; Make contact
CD
(normally open); Equipped with connector M12
Temperature Sensor TS-SNA/SNK-PT100;
PT100
Equipped with connector M12
Thermo Switches / Temperature Sensors only available for
banjo bolt size M12. Please see pages E8 and E9 for details.
h Switching Temperature
60
70
80
90
Contact switches at +60 °C / +140 °F
Contact switches at +70 °C / +158 °F
Contact switches at +80 °C / +176 °F
Contact switches at +90 °C / +194 °F
Only to be indicated when using a Thermo Switch.
Options T1C/CF and T2C/CF are not available for
banjo bolt size M10 and not be used in conjunction with
Thermo Switches or Temperature Sensors.
Please see page E8 for details.
Dimensional drawings: All dimensions in mm (in).
29.03.2012 10:23:13
Special Options: Characteristics / Inquiry Checklist
Fluid Level / Temperature Indicators
Level Gauge (Special Options) § Type SNA
Characteristics
Visual fluid level indication in hydraulic reservoirs with
maximum tank pressures not exceeding 2 bar / 29 PSI;
ideal for custom applications in terms of reservoir
capacities and dimensions
Nominal Sizes
Special sizes beyond the normal of 305 mm / 12 in
up to a maximum nominal size of 950 mm / 37.4 in –
even for small and medium quantities
High-precision manufacturing within 1 mm
tolerance to customer requirements
Materials
Housing made of Steel, Aluminium or Stainless Steel
Sight tube and plugs made of Polyamide (PA)
Sealings made of NBR (Buna-N®)
Scale plate made of PVC
Floating element made of Polyamide (PA)
Special sight tube materials for improved UV or chemical
resistance and use with special media (such as bio-degradable
fluids, diesel oils, gasolines, etc.) as well as special sealing
materials, e.g. FPM (Viton®), and scale plate materials,
e.g. Aluminium, are available on request.
Design
Robust design thanks to one or more struts that
subdivide the display into 2 or more sections
Positioning of the strut(s) based on engineering
considerations and/or according to particular
customer requirements
Precise visual indication of the fluid level by use
of scale plates (only available for nominal sizes
smaller than 670 mm / 26.4 in) or by use of a
coloured floating element (recommended option
for nominal sizes larger than 670 mm / 26.4 in)
Plastic dampening clips to reduce vibration
of the sight tube are used for nominal sizes larger
than 450 mm / 17.7 in
Please also ask for our special low-temperature versions,
suitable for extreme temperatures up to -40 °C / -40 °F.
Accessories / Options
Capillary tube thermometers with a dual
Celsius / Fahrenheit scale and a temperature display
range of up to +80 °C / +180 °F
Dial thermometers with probe and a Celsius or a dual Celsius /
Fahrenheit scale with a temperature display range of up to
+100 °C / +200 °F
Thermo switches
Temperature sensors
Please see pages E8 and E9 for details.
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.
Nominal Size
Bolt centre distance (in mm)
Housing Material
Aluminium
Housing Design
Regular housing design with positioning of strut(s) based on engineering considerations
Steel
Stainless Steel
M12
M10
1/2–20 UNF
1/2–28 UNEF
Banjo Bolt Material
Steel
Stainless Steel
Sealing Material
NBR (Buna-N®)
FPM (Viton®)
1/2–13 UNC
E
Banjo Bolt Size
Hydraulic
Accessories
Please provide additional details / drawing for custom housing designs.
EPDM
Alternative sealing materials to be defined separately.
Level Indication
Scale plate (only for nominal sizes smaller than 670 mm / 26.4 in)
Scale plate made of PVC
Scale plate made of Aluminium
With STAUFF logo
Neutral design without any logo
Custom-design (please specify)
Without thermometer on scale plate
Capillary tube thermometer with dual Celsius / Fahrenheit scale up to +80 °C / +180 °F
Floating element (recommended option for nominal sizes larger than 670 mm / 26.4 in)
Other types of level indication (magnetic floats, etc.) to be defined separately.
Options
Dial thermometer with probe
Celsius scale up to +100 °C
Dual scale up to +100 °C / +200 °F
Length of probe: 200 mm / 7.87 in
Length of probe: 300 mm / 11.81 in
Thermo Switch TS-SNA/SNK
Break contact; Standard connector
Break contact; Connector M12
Make contact; Standard connector
Make contact; Connector M12
Contact switches at +60 °C / +140 °F
Contact switches at +70 °C / +158 °F
Contact switches at +80 °C / +176 °F
Contact switches at +90 °C / +194 °F
Temperature Sensor TS-SNA/SNK-PT100
www.stauff.com
HZB-27-03-2012-EN.indd 5
E5
29.03.2012 10:23:16
Maintenance
Manual for
Standard
Hydraulic
Power Units
Maintenance Manual
Standard Hydraulic Power Units
Table of Contents
Introduction
Description ..
Preparation for Use . . . . . . . . . . . . . . . .
Unpacking and Checking
Storage
Removing from Shipping Skids
Installation . . . . . .
Locating Power Unit
Service Connections
Supply and Return Connections
Reservoir Inspection
Reservoir Filling
Coupling Alignment
Start Up Procedure ........ .
Special Tools ..
General Maintenance ........ .
Recommended Spare Parts ..... .
Reference Data
Filter Service
Maintaining Oil Temperature ............................ .
Troubleshooting ....
Page
.... 1
. ... 1
...... 2
. ..... 2
. ... 5
. ... 6
. ..... 6
. ... 6
... 6
... 6
... 7
. .. 9
Maintenance Manual
Standard Hydraulic Power Units
Introduction
This manual provides descriptive information, operation and maintenance instructions 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.
Preparation For Use
Unpacking and Checking
The Power Unit is mounted on skids and carefully packed for shipment. Do not
remove it from skid until it has been carefully checked for damage that may have
occurred in transit. Report all damage immediately to the carrier and send a copy
-1-
Maintenance Manual
Standard Hydraulic Power Units
to the vendor. All open ports on the Power Unit were plugged at the factory to prevent 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 indoors, 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.
Removing from Shipping Skids
Small JIC style Power Units should be moved with a fork-lift truck, with 2X4 boards
under the reservoir belly, to distribute and steady the load. Larger JIC style Power
Units have lifting holes in the reservoir end plates. Extra heavy 1 1/2 pipes can be
inserted into the lifting holes for allowing movement with a fork-lift truck. L-shaped
reservoirs are provided with clearance and cross braces under the base plate for
movement with a fork-lift truck.
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 provided, 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 exchangers 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
Water
Outlet .---a------.....L.....,
Temperature
Control
Valve
Strainer
Shut-off
Heat Exchanger
Oil Sen sing Bulb
-2-
Water
Inlet
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.
If Solenoid valves, pressure/temperature switches, or oil immersion heaters have
been provided on the power unit, refer to the component nametag or other service
information in this manual for operating voltage and ratings.
Supply and Return Connections
Complete all necessary interconnecting piping between the power unit and
hydraulic actuators. The line sizes should be determined based on oil
flow, operating pressure and allowable pressure drop between the power unit
and actuator.
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.
Refer to the component manufacturer's catalog for fluid requirements.
The cleanliness of the fluid going into the reservoir is very important, and in some
cases, even new oil out of the drum is not adequate. We recommend that any
fluid being transferred into the reservoir be done with a transfer pump with a 10
micron filter installed. A Parker filter cart is available for this purpose.
Coupling Alignment
It is possible for pump/motor shaft alignment to be incorrect because of shock incurred 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 adjustment 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 momentarily 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 incorrect, 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 flowing. 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.
Recommended Spare Parts
Spare filter elements should be purchased with the power unit, and be available
during the start-up operation. Other spare parts may be required, and are a
function of the duty cycle of the hydraulic system, operation environment, and the
acceptable down time of the equipment.
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 positioned 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 installation 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 manufacturers 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.
Maintaining Proper Oil Temperature
Hot oil in your equipment's hydraulic system is one of the primary causes of poor
operation, component failure and downtime. Here are some pointers on maintaining proper oil temperature.
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
How Hot is "Too Hot"?
"Hot oil" is a relative term. In most cases, 120°F. at the reservoir is considered an
ideal operating temperature. Always take an oil temperature reading at the
reservoir, not at a component or any of the piping.
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.
Measuring Oil Temperature
There are several ways to check the temperature of the oil. The best, most
accurate method is by means of a thermometer. On some machines, this is
mounted on the reservoir. Make it a habit to check the thermometer periodically,
after the equipment has been running for more than an hour.
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.
Look, Smell and Feel
Checking oil temperature periodically is good preventive maintenance. So too is
the practice of periodically siphoning an oil sample from the reservoir, and comparing it with a sample of clean, new oil.
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.
Fire resistant fluids
1) Incorrect seals cause binding spools.
2) Paint, varnish or enamel in contact with fluids can cause sludge deposits
on filters and around seal areas.
-9-
Maintenance Manual
Standard Hydraulic Power Units
3) Electrolytic action is possible with some metals. Usually zinc or cadmium.
4) Improper mixtures can cause heavy sludge formations.
5) High temperatures adversely affect some of the fluids, particularly the
water base fluids.
6) Adequate indentificaiton of tanks containing these fluids should be provided so that they will be refilled with the proper media.
7) As with mineral base oils, nuisance leaks should be remedied at once.
8) Make certain replacement parts are compatible with fluid media.
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
5) Reservoir assembled without baffling or sufficient baffling.
6) Case drain line from pressure compensated pump returning oil too close
to suction line.
a. Repipe case drain line to opposite side of reservoir baffling.
7) Pipe, tube or hose I.D. too small causing high velocity.
8) Valving too small, causing high velocity.
9) Improper air circulation around reservoir.
10) System relief valve set too high.
11) Power unit operating in direct sunlight or ambient temperature is too
high.
Foreign matter sources in the circuit
1) Pipe scale not properly removed.
2) Sealing compound (pipe dope, teflon tape allowed to get inside fittings.
3) Improperly screened fill pipes and air breathers.
4) Burrs inside piping.
5) Tag ends of packing coming loose.
6) Seal extrusions from pressure higher than compatible with the seal or
gasket.
7) Human element... not protecting components while being repaired and
open lines left unprotected.
8) Wipers or boots not provided on cylinders or rams where necessary.
9) Repair parts and replacement components not properly protected while
stored in repair depot. (Rust and other contaminants.)
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
5) Check compatibility of fluid being pumped against manufacturers
recommendations.
6) Relief or unloading valve set too high. Use reliable gauge to check
operating pressure. Relief valve may have been set too high with a
damaged pressure gauge. Check various unloading devices to see that
they are properly controlling the pump delivery.
7) Aeration of fluid in reservoir (return lines above fluid level).
8) Worn or sticking vanes (vane type pump).
9) Worn cam ring (vane type pump).
10) Worn or damaged gears and housing (gear pump).
11) Worn or faulty bearing.
12) Reversed rotation.
13) Cartridge installed backwards or improperly.
14) Plugged or restricted suction line or suction strainer.
15) Plugged reservoir filter breather.
16) Oil viscosity too high or operating temperature too low.
17) Oil pour point too high.
18) Air leak in suction line or fittings also causing irregular movement of
control circuit.
19) Loose or worn pump parts.
20)
Pump being driven in excess of rated speed.
21) Air leak at pump shaft seal.
22) Oil level too low and drawing air in through inlet pipe opening.
23) Air bubbles in intake oil.
24) Suction filter too small or too dirty.
25) Suction line too small or too long.
26)
Pump housing bolts loose or not properly torqued.
Pump failure to deliver fluid
1) Low fluid level in reservoir.
2) Oil intake pipe suction strainer plugged.
3) Air leak in suction line and preventing priming.
4) Pump shaft turning too slowly.
5) Oil viscosity too high.
-12-
Maintenance Manual
Standard Hydraulic Power Units
6) Oil lift too high.
7) Wrong shaft rotation.
8) Pump shaft or parts broken.
9) Dirt in pump.
10) Variable delivery pumps. (Improper stroke.)
Oil leakage around pump.
1) Shaft seal worn.
2) Head of oil on suction pipe connection-connection leaking.
3) Pump housing bolts loose or improperly torqued.
4) Case drain line too small or restricted. (Shaft seal leaking.)
Excessive pump wear
1) Abrasive dirt in the hydraulic oil being circulated through the system.
2) Oi I viscosity too low.
3) System pressure exceeds pump rating.
4) Pump misalignment or belt drive too tight.
5) Air being drawn in through inlet of pump.
Pump parts inside housing broken
1) Seizure due to lack of oil.
2) Excessive system pressure above maximum pump rating.
3) Excessive torquing of housing bolts.
4) Solid matter being drawn in from reservoir and wedged in pump.
Troubleshooting Solenoid Valves
Solenoid failures
1) Voltage too low. If voltage will not complete the stroke of alternating current (AC) solenoid it will burn out the coil.
2) Signal to both solenoids of a double solenoid valve simultaneously. One
or both of the solenoids will be unable to complete their stroke and will
burn out. (Make certain the electrical signal is interlocked so that this
condition cannot exist.)
3) Mechanical damage to leads. (Short circuit, open connections, etc.)
-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 inadequate 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.
Solenoid valve fails to operate
1) Is there an electrical signal to the solenoid or operating device? Is the
voltage too low? (Check with voltmeter ... test light in emergency.)
2) If the supply to the pilot body is orificed, is the orifice restricted? (Remove
orifice and check for foreign matter. Flushing is sometimes necessary
because of floating impediment.)
3) Has foreign matter jammed the main spool? (Remove end caps and see
that main spool is free in its movement ... remember that there will be a
quantity of fluid escaping when the cap is removed and provide a
container to catch it.)
4) Is pilot pressure available? Is the pilot pressure adequate? (Check with
gauge on main pressure input port for internally piloted types and in the
supply line to the externally piloted type.)
5) Is pilot drain restricted? (Remove pilot drain and let the fluid pour into an
open container while the machine is again tried for normal operation.
Small lines are often crushed by machine parts banging against them
causing a subsequent restriction to fluid flow.)
6) Is pilot tank port connected to main tank port where pressures are high
enough to neutralize pilot input pressure? (Combine pilot drain and pilot
tand port and check for operation with the combined flow draining into an
open container ... block line to main tank form pilot valve ... if this corrects
the situation, reroute pilot drain and tank line.)
7) Are solenoids improperly interlocked so that a signal is provided to both
units simultaneously? (Put test light on each solenoid lead in parallel and
watch for simultaneous lighting ... check electrical interlock. This condition
probably burns out more solenoids than any other factor.)
-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 compatible 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
Three-Phase
General Purpose
Motors
W22 - Cast Iron
TEFC - Cast Iron
Standard Features:
• 50/60 Hz rated (380V on
nameplate - 400/415 available)
• Rated 50HZ at same horsepower
up to 250HP 1.0 Service Factor
for 2,4 & 6 pole motors
• Rated 50Hz at same horsepower
up to 125HP 1.0 Service Factor for
8 pole motors
• Class F insulation (impregnation
resin and magnet wire are class
H)
• F1 mounted (cast iron frames are
F2 convertible). Frames 447T and
up can easily be F2 converted by
simply rotating the terminal box
adapter
• Cast iron frames: regreasable ball
bearings (frames 254T and up)
• Gasketed conduit box
New Cooling System
Fan Cover
Aerodynamic design
g Noise level reduction
g Better air flow distribution over frame
g Increased mechanical strength
Features that make a difference:
Terminal Box
Fan
Reinforced fan hub structure
g Noise level reduction
g Increased air flow
g Fan with higher stiffness
g
Better connection quality
Easier cable handling
during installation
g
More space available for
accessory installation
gEasier Maintenance
g Mounting F1/F2/F3
g
Rotation on 90° stages
g
g
g
• All NEMA Premium ratings have a 1.25 service factor (up
to 100 HP) resulting in cooler operation and extended life
of the motor
• All Cast Iron Construction, including Terminal Box and
Fan Cover (*)
• Solid feet for reduced vibration levels and impact
absorption
Bearing Caps
External
g
Finned surface for
improved bearing
heat dissipation
Internal
g
Change of grease
path for positive
lubrication
gBearing lubrication
quality improvement
gReduced bearing
temperature
• Optimized ventilation system for cooler operation and
extended life
• High Grade FC200 cast iron provides superior mechanical
strength and heat dissipation
• All WEG W22 motors are Totally Enclosed Fan Cooled
with a true IP55 rating against dust and moisture. (IPW56,
IPW65 and IPW66 available as optional)
• Exclusive W-Seal 364T and larger provides superior
bearing protection
• Taconite Labyrinth seal 586 Frame and larger
Seal Subsystem
• Exclusive WEG painting system exceed 200hrs ASTM 117
corrosion test (Exceeds IEEE841 standard)
Inverter Rated
1000:1 for Variable Torque
NEMA Premium
20:1 Constant Torque up to 250HP
6:1 Constant Torque 300HP and up
High Efficiency (EPAct)
12:1 Constant Torque up to 250HP
4:1 Constant Torque 300HP and up
• Balanced to 0.08 inches per second vibration limits
(Meets IEEE841 standard)
• Four Bolt Conduit Cover with glued Neoprene Gasket
• Impregnation Resin and magnet wire are insulation class H
• Stainless Steel Nameplate - Laser etched with high
contrast background
• Corrosion Proof Drains
• Inverter Duty per NEMA MG1, Part 31
Increased dust and
moisture protection
gIncreased protection
to high-pressure
cleaning
g
Frame
Reduced temperature on windings
and bearings
Noise level reduction
g
Terminal box position outlet on top
g
g
Pad for vibration sensor
gDisplaced 90 0 from each other
Enhanced Lifting Provisions
Easier handling - horizontal & vertical
g
Higher mechanical strength and
handling safety
g
Solid feet
g
More impact resistance
g
Ideal for high vibration level
applications
Endshields Subsystem
DE (Drive Endshield)
New fin design
Bearing moved outwards for better load support
Improved bearing heat dissipation for reduced bearing
temperature
g
Reinforced endshield structure
g
g
g
NDE (Non-Drive Endshield)
New design with smooth exterior surface
Improved air flow
Noise level reduction
g
Improved structural rigidity for low vibration
g
g
ADDITIONAL TECHNICAL DATA
ELECTRICAL DATA:
p. B-6
MECHANICAL DATA: p. C-2
A-18
www.weg.net/us
Three-Phase
General Purpose
Motors
W22
• Certified Class I Div 2, Groups A, B, C & D; Class II, Div 2,
Groups F & G
g
• Suitable for IEEE45 and USCG 259 – Marine Duty
*Cast iron fan cover available as an option on 143-215T frames
Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934)
A-19
Three-Phase
General Purpose
Motors
TEFC – Foot Mount continued
HP
kW
RPM
3600
1800
450
500
600
650
330
370
450
480
700
515
750
550
NEMA
Frame
Catalog Number
L447/9TS 45036ET3G449TS-W22
586/7
45018EP3G586/7-W22
TEFC – C-Flange – Foot Mount
List
Price
Approx.
FL
Mult. Shipping Service
Amps
Symbol Weight
Factor
@ High
(lbs)
FL. Eff
(%)
"C"
Dimension
(in)
Voltage (V)
Notes
HP
kW
RPM
NEMA
Frame
Catalog Number
List
Price
Approx.
Mult. Shipping Service
Symbol Weight
Factor
(lbs)
FL
Amps
@
High
FL. Eff
(%)
"C"
Dimension
(in)
Voltage (V)
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
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
1800
143/5TC
00118ET3E143TC-W22
555
N1
49
1.25
1.41
85.5
13.346
208-230/460
1800
143/5TC
00118ET3ERS143TC
484
RSP
41
1.15
1.55
85.5
14.095
208-230/460
1800
L447/9T 45018ET3G449T-W22
48,010
N1
3524
1.15
501
96.2
57.181
460
1800
L447/9T 45018ET3GRB449T-W22
48,010
N1
3542
1.15
501
96.2
57.181
460
14
1
0.75
Notes
9
9
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
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
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
143/5TC
00156ET3ERS143TC
497
RSP
40
1.15
1.95
84.0
14.095
208-230/460
3600
143/5TC
00156ET3H143TC-W22
571
N1
45
1.25
1.53
84.0
13.346
575
1800
143/5TC
00158ET3E145TC-S
504
RSP
43
1.15
2.02
86.5
13.583
208-230/460
1800
143/5TC
00158ET3E145TC-W22
579
N1
55
1.25
2.02
86.5
13.346
208-230/460
3600
586/7S 50036ET3G586/7S-W22
56,305
N1
4571
1.15
530
96.2
55.027
460
1800
L447/9T 50018ET3G449T-W22
50,594
N1
3652
1.00
561
96.2
57.181
460
1;19
1800
L447/9T 50018ET3GRB449T-W22
50,594
N1
5424
1.00
561
96.2
57.181
460
1;14
62,962
N1
4896
1.00
603
96.2
61.902
460
1
50012ET3G586/7-W22
1.5
1.1
9
9
9
1200
586/7
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
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
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
1800
588/9
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
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
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
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
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
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
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
65018ET3G588/9-W22
2
1.5
9
9
9
9
9
9
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”
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.
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
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
Three-Phase General Purpose Motors
Three-Phase
General Purpose
Motors
TEFC – C-Flange – Foot Mount continued
HP
3
5
7.5
kW
2.2
3.7
5.5
RPM
NEMA
Frame
Catalog Number
List
Price
TEFC – C-Flange – Foot Mount continued
Approx.
Mult. Shipping Service
Symbol Weight
Factor
(lbs)
FL
Amps
@
High
FL. Eff
(%)
"C"
Dimension
(in)
Voltage (V)
Notes
9
3600
182/4TC
00336ET3E182TC-S
698
RSP
71
1.15
3.67
86.5
16.339
208-230/460
3600
182/4TC
00336ET3E182TC-W22
802
N1
103
1.25
3.63
86.5
15.860
208-230/460
3600
182/4TC
00336ET3ERS182TC
698
RSP
91
1.15
3.68
87.5
16.404
208-230/460
3600
182/4TC
00336ET3H182TC-W22
802
N1
103
1.25
2.90
86.5
15.860
575
1800
182/4TC
00318ET3E182TC-S
610
RSP
87
1.15
3.81
89.5
17.894
208-230/460
1800
182/4TC
00318ET3E182TC-W22
700
N1
100
1.25
3.88
89.5
15.860
208-230/460
1800
182/4TC
00318ET3ERS182TC
610
RSP
72
1.15
3.91
89.5
16.404
208-230/460
1800
182/4TC
00318ET3H182TC-W22
700
N1
100
1.25
3.10
89.5
15.860
575
1200
213/5TC
00312ET3E213TC-S
1,028
RSP
142
1.15
4.17
89.5
19.291
208-230/460
1200
213/5TC
00312ET3E213TC-W22
1,180
N1
154
1.25
4.41
89.5
19.517
208-230/460
1200
213/5TC
00312ET3ERS213TC
1,028
RSP
142
1.15
4.41
89.5
20.257
208-230/460
900
213/5TC
00309ET3E215TC-W22
2,166
N1
192
1.25
4.56
85.5
19.517
208-230/460
HP
kW
9
9
10
7.5
9
9
9
3600
3600
Approx.
Mult. Shipping Service
Symbol Weight
Factor
(lbs)
FL
Amps
@
High
FL. Eff
(%)
"C"
Dimension
(in)
Voltage (V)
Notes
9
Catalog Number
List
Price
213/5TC
01036ET3E215TC-S
1,205
RSP
173
1.15
11.5
90.2
21.654
208-230/460
213/5TC
01036ET3E215TC-W22
1,383
N1
187
1.25
11.6
90.2
19.517
208-230/460
3600
213/5TC
01036ET3ERS215TC
1,205
RSP
170
1.15
11.5
91.7
20.257
208-230/460
3600
213/5TC
01036ET3H215TC-W22
1,383
N1
185
1.25
9.28
90.2
19.517
575
1800
213/5TC
01018ET3E215TC-S
1,154
RSP
142
1.15
12.2
91.7
19.291
208-230/460
1800
213/5TC
01018ET3E215TC-W22
1,325
N1
196
1.25
12.4
91.7
19.517
208-230/460
1800
213/5TC
01018ET3ERS215TC
1,154
RSP
166
1.15
12.7
91.7
20.257
208-230/460
1800
213/5TC
01018ET3H215TC-W22
1,325
N1
197
1.25
9.92
91.7
19.517
575
1200
254/6TC
01012ET3E256TC-S
2,148
RSP
277
1.15
13.8
91
23.346
208-230/460
1200
254/6TC
01012ET3E256TC-W22
2,465
N1
324
1.25
12.9
91.0
24.945
208-230/460
1200
254/6TC
01012ET3ERS256TC
2,148
RSP
282
1.15
13.3
91.0
24.925
208-230/460
3600
213/5TC
01536ET3E215TC-W22
1,748
N1
199
1.25
17.0
91.0
19.517
208-230/460
3600
254/6TC
01536ET3E254TC-S
1,649
RSP
220
1.15
17.4
91
22.559
208-230/460
3600
254/6TC
01536ET3E254TC-W22
1,893
N1
283
1.25
17.2
91.0
24.945
208-230/460
3600
254/6TC
01536ET3ERS254TC
1,649
RSP
235
1.15
16.9
91.7
24.925
208-230/460
3600
254/6TC
01536ET3H254TC-W22
1,893
N1
282
1.25
13.8
91.0
24.945
575
1800
254/6TC
01518ET3E254TC-S
1,670
RSP
242
1.15
18.2
92.4
22.559
208-230/460
1800
254/6TC
01518ET3E254TC-W22
1,917
N1
336
1.25
18.0
92.4
24.945
208-230/460
1800
254/6TC
01518ET3ERS254TC
1,670
RSP
259
1.15
18.0
92.4
24.925
208-230/460
1800
254/6TC
01518ET3H254TC-W22
1,917
N1
330
1.25
14.4
92.4
24.945
575
1200
284/6TC
01512ET3E284TC-W22
3,388
N1
409
1.25
17.9
91.7
27.929
208-230/460
1200
284/6TC
01512ET3H284TC-W22
3,388
N1
408
1.25
14.3
91.7
27.929
575
3600
182/4TC
00536ET3E184TC-S
793
RSP
86
1.15
5.90
88.5
17.894
208-230/460
3600
182/4TC
00536ET3E184TC-W22
911
N1
110
1.25
5.90
88.5
15.860
208-230/460
3600
182/4TC
00536ET3ERS184TC
793
RSP
101
1.15
5.96
89.5
16.404
208-230/460
3600
182/4TC
00536ET3H184TC-W22
911
N1
112
1.25
4.72
88.5
15.860
575
1800
182/4TC
00518ET3E184TC-S
706
RSP
79
1.15
6.49
89.5
17.894
208-230/460
1800
182/4TC
00518ET3E184TC-W22
810
N1
109
1.25
6.45
89.5
15.860
208-230/460
1800
182/4TC
00518ET3ERS184TC
706
RSP
97
1.15
6.40
89.5
16.404
208-230/460
1800
182/4TC
00518ET3H184TC-W22
810
N1
108
1.25
5.16
89.5
15.860
575
1200
213/5TC
00512ET3E215TC-S
1,206
RSP
156
1.15
6.74
89.5
20.079
208-230/460
1200
213/5TC
00512ET3E215TC-W22
1,384
N1
177
1.25
6.83
89.5
19.517
208-230/460
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
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
3600
213/5TC
00736ET3ERS213TC
1,025
RSP
147
1.15
8.63
91.0
20.257
208-230/460
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
1800
254/6TC
02018ET3E256TC-S
1,978
RSP
271
1.15
24.5
92.4
23.346
208-230/460
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
1800
254/6TC
02018ET3ERS256TC
1,978
RSP
286
1.15
24.4
93.0
24.925
208-230/460
1800
213/5TC
00718ET3E213TC-W22
1800
254/6TC
02018ET3H256TC-W22
2,270
N1
366
1.25
19.3
93.0
24.945
575
1800
213/5TC
00718ET3ERS213TC
02012ET3E286TC-W22
1800
213/5TC
00718ET3H213TC-W22
1200
254/6TC
00712ET3E254TC-S
1,859
RSP
1200
254/6TC
00712ET3E254TC-W22
2,134
N1
994
RSP
131
1.15
9.07
91.7
18.898
208-230/460
1,141
N1
174
1.25
9.00
91.7
19.517
208-230/460
994
RSP
154
1.15
9.29
91.7
20.257
208-230/460
1,141
N1
167
1.25
7.20
91.7
19.517
575
248
1.15
9.98
91
22.559
208-230/460
295
1.25
9.48
91.0
24.945
208-230/460
1200
254/6TC
00712ET3ERS254TC
1,859
RSP
262
1.15
9.73
91.0
24.925
208-230/460
900
254/6TC
00709ET3E256TC-W22
3,726
N1
324
1.25
11.1
87.5
24.945
208-230/460
9
RPM
NEMA
Frame
9
9
15
11
9
9
9
20
15
9
9
9
9
25
18.5
1200
284/6TC
4,060
N1
456
1.25
24.2
91.7
27.929
208-230/460
3600
284/6TSC 02536ET3E284TSC-W22
3,096
N1
407
1.25
28.5
91.7
26.557
208-230/460
3600
284/6TSC 02536ET3H284TSC-W22
3,096
N1
406
1.25
22.8
91.7
26.557
575
1800
284/6TC
02518ET3E284TC-W22
2,840
N1
439
1.25
29.5
93.6
27.929
208-230/460
1800
284/6TC
02518ET3H284TC-W22
2,840
N1
432
1.25
23.6
93.6
27.929
9
9
9
9
9
9
9
9
9
9
9
9
9
575
Continued on next page
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”
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.
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”
For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com
Data subject to change without notice.
Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934)
A-35
Three-Phase
General Purpose
Motors
Three-Phase General Purpose Motors
Three-Phase General Purpose Motors
Part Number Configuration
Ordering
WEG model numbers contains up to 20 characters, distributed as follows:
XXX
(HP)
XX
(rpm)
XXX
(Model)
X
XXXXX
(Volts)
(Application + Frame)
HP1 - .12 - .16 - .25 - .33 - .50 - .75 - 001 - 0015 - 002 - 003 - 004 - 00451 - 005 - 007 - 010 - 015 020 - 025 - 030 - 040 - 050 - 075 - 100 - 125 - 150 - 200 - 250 - 300 - 400 - 450 - 500 - 600 - 650 ...
RPM -
36: 3600rpm
30: 3000rpm
18: 1800rpm
15: 1500rpm
12: 1200rpm
10: 1000rpm
09: 900rpm
07: 750rpm
Model - Three Characters:
X
X
X
ENCLOSUREEFFICIENCYPHASE
E - Totally Enclosed
S - Standard Efficiency
S - Severe Duty IEEE 841
P - High Efficiency
O - Open drip proof
T - NEMA Premium
X - eXplosion proof
G - Super Premium
A - Totally Enclosed Air Over
N - Totall Enclosed Non Ventilated
1 - 1 Phase
3 - 3 Phase
Application + Frame -
Volts For
Definite Purpose lines, two pre-selected
A - 115V
L - 415V
letters
must be used after voltage code:
B - 115 / 208 - 230V
M - 220 / 380 - 415V
AD
Auger Drive
C - 208 - 230V
N - 220 / 380V
D - 230V
O - 380 - 415V
ALuminum Frame
AL
E - 208 - 230 / 460V*
P - 200V
ATEX Motor
AX
F - 230 / 460V
Q - 460V
Brake Motor
BM
G - 460V PWS
R - 115 / 230V
Compressor Duty
CD
H - 575V
V - 200 / 400V
Cooling Tower
CT
I - 220V
W - 460/220-240/380-415V
Double Pole (2 Speed)
DP
J - 380V
X - Other Voltage
Evaporative Cooler
EC
K - 190 / 380V
Y - 460/380-415/660-690V
Farm Duty
FD
Fire Pump
FP
Hydraulic Pump
HP
Hollow Shaft
HS
Inverter Duty (TEBC)
IB
* Suitable for PWS on 254T and larger on low voltage connection.
IEEE 841 (Severe Duty IEEE 841)
IE
Irrigation Pumping
IP
1)
Jet Pump
JP
• For IEC Metric motors, the output will be given in kW:
.12 - .18 - .25 - .37 - .55 - .75 - 001 - 0015 - 002 - 003 - 004 - 0045 - 005 Crusher-Duty
KD
007 - 009 - 011 - 015 - 018 - 022 - 030 - 037 - 045 - 055 - 075 - 090 - 110 Manual OverLoad Protection
OL
130 - 150 - 185 - 200 - 220 - 250 - 300 - 315 ...
Oil Well Pumping - Triple Rated
OT
• 0015 (1.5HP) is the rating that will have four digits for output
Oil Well Pumping
OW
Identification and only one for RPM.
Poultry Fan
PF
• 0045 (4.5kW) is the rating that will have four digits for output
Pad Mount
PM
identification and only one for RPM.
(Before the frame size): Round Body
R
Roller Bearings (Integrals)2
RB
Resilient Base (Fractionals)
RB
Frame
Rolled Steel Frame
RS
The frame number must be included as long as the
Saw Arbor
SA
number of remaining characters allow.
Split Phase
SP
Example: 143T, 143TC, 405T, 405TS, 184JP.
Stainless Steel
SS
Vector Duty (TEBC or TENV)
VD
-W22
Suffix
-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.
Roller bearings are recommended for all belt driven applications
100HP and above.
2)
- W22
When Applicable
8
650/850 T O N T O P D R I V E MANUAL REV 0
Section
WAGO
381
System 750
Overview
Modular Fieldbus Independent I/O System
1
© WAGO Corporation, Germantown WI
Topics of Discussion
• WAGO-I/O-SYSTEM 750 Components
• General Features
• Assembly, Mounting, and Connections
• Power Supply Groups and Isolation
• Input and Output Process Image
2
© WAGO Corporation, Germantown WI
Networks
I/O
16+ Networks
IPC, HMI/PLC
Extended Temp
IPCs
IP20 PFCs
Digital
Analog
Managed &
Unmanaged
Switches
Controllers
Specialty
Modules
IP67 PFCs
Wireless
Bluetooth
Interface
Boards
PFC200
IP67
© WAGO Corporation, Germantown WI
HMI/PLC
3
382
WAGO-I/O-SYSTEM 750 Components
The WAGO-I/O SYSTEM 750 is a modular, fieldbus
independent, I/O system. A node is comprised of three major
components:
1) Coupler/Controller
2) I/O Modules
3) End Module
4
© WAGO Corporation, Germantown WI
Coupler vs. Controller
Coupler - Remote I/O head - the I/O is
controlled by an external scanner or
master
750-3xx
Controller – Combines the functionality of
a Coupler with a PLC. Application
programs are written WAGO-I/O-PRO
(IEC61131-3 Programming Tool)
750-8xx & 758-8xx
5
© WAGO Corporation, Germantown WI
Fieldbus Independent
•
•
•
•
•
DeviceNet
PROFIBUS
INTERBUS
MODBUS
LonWorks
•
•
•
•
•
ModbusTCP
EtherNet/IP
Firewire
CANopen
And More…
Simply “snap in”
a Coupler or
Controller
© WAGO Corporation, Germantown WI
6
383
Programmable Fieldbus Controllers
Fieldbus Couplers
CONTROLLERS (IEC61131-3 Programmable)
750-804
INTERBUS
FIELDBUS COUPLERS
750-806
DeviceNet
750-812, 750-814,
750-815, 750-816
MODBUS
750-301, 750-303, 750-333,
750-343, 750-331
750-819
LONWORKS
PROFIBUS
750-304, 750-344, 750-345,
750-334
INTERBUS
750-342,750-352
ETHERNET TCP/IP 10Mbit
750-306, 750-346
DeviceNet
750-833
PROFIBUS DP/V1
750-837, 750-838
CANopen
750-873
ETHERNET w/RS232
750-307, 750-337, 750-338,
750-347, 750-348
CANopen
750-842
ETHERNET TCP/IP 10Mbit
750-305
CAL
750-860
Linux
Ethernet w/2-port switch
750-312, 750-314, 750-315,
& 750-316
MODBUS
750-871
758-870
Industrial Compact PC
750-310
CC-Link
750-830
BACnet/IP
750-339
Firewire
750-831
BACnet w/2 port swich & SD Card
750-319
LONWORKS
750-880
Ethernet w/2 port swich & SD Card
750-300
750-881
Ethernet w/2-port swtich
750-354
EtherCAT
750-882
Ethernet w/Dual independent ports
750-375, 750-377
ProfiNet w/ 2-port switch
750-885
Ethernet w/Dual independent ports
w/SD Card
750-351
SERCOS III
750-880/025-001
Telecontrol
II/O-LIGHTBUS
7
© WAGO Corporation, Germantown WI
750-880
ETHERNET 2.0 - Triad of Control
Efficiency Expert – SD
card for memory expansion
up to 32G, or used for
backup and restore of
application programs.
750-881
1MB Program Memory
1MB Data Memory
32kB Retain Memory
Pacesetter – Highperformance controller
Web Based Management,
Built in switch supports
MODBUS TCP and
EtherNet I/P.
750-882
1MB Program Memory
512kB Data Memory
32kB Retain Memory
Dynamic Duo – Media
Redundancy controller with dual
independent Ethernet ports for
network redundancy or separation
of networks
1MB Program Memory
512kB Data Memory
32kB Retain Memory
8
© WAGO Corporation, Germantown WI
750-880 Ethernet Controller
© WAGO Corporation, Germantown WI
•
High-speed processor(1000 instructions in 230µS)
•
•
Program memory: 1 Mbyte
Data memory: 1 MByte
•
•
Retained memory: 32 kByte
Large and fast file system (2 MB)
Web pages,data logging
•
•
2 Ethernet-interfaces + integrated Switch
Supports both EtherNet I/P and MODBUS TCP
•
•
IP-Address over DIP-switch option
Shipped with pre-configured IP Address
– 192.168.1.xxx
•
Protocols supported : HTTP, BootP, DHCP, DNS,
SNTP, SNMP, FTP
•
SD Card Interface(up to 32 GB) Backup, restore,
data logging
9
384
750-881 Ethernet Controller
•
High-speed processor(1000 instructions in
230µS)
•
•
Program memory: 1 Mbyte
Data memory: 512 kByte
•
Retained memory: 32 kByte
•
Large and fast file system (2 MB)
Web pages,data logging
•
•
•
2 Ethernet-interfaces + integrated Switch
Supports both EtherNet I/P and MODBUS TCP
IP-Address over DIP-switch option
•
Shipped with pre-configured IP Address
•
– 192.168.1.xxx
Protocols supported : HTTP, BootP, DHCP,
DNS, SNTP, SNMP, FTP
10
© WAGO Corporation, Germantown WI
750-882 Ethernet Controller
•
High-speed processor(1000 instructions in 230µS)
•
Program memory: 1 Mbyte
Data memory: 1 MByte
•
•
•
Retained memory: 32 kByte
Large and fast file system (2 MB)
Web pages, data logging
•
2 Independent Ethernet
•
IP-Address over DIP-switch option
•
Shipped with pre-configured IP Address
– 192.168.1.xxx
– 192.168.2.xxx
•
Protocols supported : HTTP, BootP, DHCP, DNS,
SNTP, SNMP, FTP
•
Media redundancy- Network redundancy &
network separation.
11
© WAGO Corporation, Germantown WI
750-885 Ethernet Controller
•
© WAGO Corporation, Germantown WI
High-speed processor(1000 instructions in 230µS)
•
Program memory: 1 Mbyte
•
Data memory: 1 MByte
•
•
Retained memory: 32 kByte
Large and fast file system (2 MB)
Web pages, data logging
•
•
2 Independent Ethernet
IP-Address over DIP-switch option
•
Shipped with pre-configured IP Address
– 192.168.1.xxx
– 192.168.2.xxx
•
Protocols supported : HTTP, BootP, DHCP, DNS,
SNTP, SNMP, FTP
•
Media redundancy- Network redundancy &
network separation.
•
SD Card Interface(up to 32 GB) Backup, restore,
data logging
12
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
•
Considerations
• Performs like a 750-88X
• No Web server
• No real time Clock
• Lower memory
•
Benefits
• Cost savings
© WAGO Kontakttechnik GmbH & Co. KG 04.04.2013
13
13
© WAGO Corporation, Germantown WI
The New Controller Family
Introducing PFC200
Programmable Fieldbus Controller
Introduction of
4 different types of Controllers with
different interfaces
14
© WAGO Corporation, Germantown WI
Ethernet-Based Automation Portfolio
762-3xxx PERSPECTO
758-8xx IPC’s
750-82XX PFC200
750-88X PFC’s
© WAGO Corporation, Germantown WI
Starting List $1,000
Starting List $2,100
Starting List $1,100
Starting List $475.00 (750-852)
15
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
16
© WAGO Corporation, Germantown WI
Controller PFC200
• PFC200 Controller Ethernet & Serial
• Cortex A8, 600 MHz
• CODESYS v2.3 accessible memory
• Program Memory: 256 MB
• Data Memory:
256 MB
• Retain Memory:
128 kB
• Interfaces
•
•
•
•
Part Number: 750-8202
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)
17
© WAGO Corporation, Germantown WI
Controller PFC200
• PFC200 Controller Ethernet & CAN
• Cortex A8, 600 MHz
• CODESYS v2.3 accessible memory
• Program Memory: 256 MB
• Data Memory:
256 MB
• Retain Memory:
128 kB
• Interfaces
•
•
•
•
Part Number: 750-8203
© WAGO Corporation, Germantown WI
Ethernet (switch)
CAN; CANopen (D-SUB 9 male)
SD/SDHC Card Slot up to 32 GB
Operation Mode Switch (RUN, STOP,
RESET)
• LED (System, Fieldbus, USER)
18
387
Controller PFC200
• PFC200 Controller Ethernet & Serial & CAN
• Cortex A8, 600 MHz
• CODESYS v2.3 accessible memory
• Program Memory: 256 MB
• Data Memory:
256 MB
• Retain Memory:
128 kB
• Interfaces
•
•
•
•
•
Part Number: 750-8204
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)
• LED (System, Fieldbus, USER)
19
© WAGO Corporation, Germantown WI
Controller PFC200
• PFC200 Controller
Eth&Serial&CAN&PROFIB
• Cortex A8, 600 MHz
• CODESYS v2.3 accessible memory
• Program Memory: 256 MB
• Data Memory:
256 MB
• Retain Memory:
128 kB
• Interfaces
•
•
•
•
•
•
Part Number: 750-8206
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,
RESET)
• LED (System, Fieldbus, USER)
20
© WAGO Corporation, Germantown WI
Next Generation IPCs- Product Features
Universal and flexible
• Stable PLC functionality combined with classic PC
interfaces
• Control, monitor and visualization directly from the
fieldbus node
• PLC + IT functions all in one device
• Full integration of I/O-IPC in Series 750 and 753
Scalable
• Various CPU performance outputs from Geode to
Pentium® M
• Operating system Linux as WAGO Distribution
• Optional PLC functionality with CoDeSys 2.3 and
integrated visualization via Web browser or direct monitor
connection
Industrial strength
• Minimal space requirement
• Non-volatile memory
• Real-time clock
Stability
• Hot-Plug USB Sticks
– Automatic mounting and dismounting
• Application: Data logging on USB stick
© WAGO Corporation, Germantown WI
21
388
Next Generation CoDeSys IPCs
I/O-IPC-C6
I/O-IPC-C10E
I/O-IPC-P14
Processor
Celeron
Celeron
Pentium M
CPU Speed
600 MHz
1 GHz
1.4 GHz
Main Memory (RAM)
256 MB
256 MB
256 MB
Internal Memory (flash)
512 MB
512 MB
512 MB
Retain Memory
1024 kB
1024 kB
1024 kB
CF card interface
Socket type I+II
Socket type I+II
Status LEDs
8 (tri-color)
8 (tri-color)
8 (tri-color)
USB
2.0
2.0
2.0
On-board digital I/O
Socket type I+II
2in/2out
2in/2out
2in/2out
RS-232
1
1
1
DVI (VGA via adapter)
DVI-I
DVI-I
DVI-I
Graphics Res. (max)
1280 x 1024
1280 x 1024
1280 x 1024
Operating Temperature
0C – 55C
-20C to 60C
0C to 55C
Housing Material
Aluminum
Aluminum
Aluminum
22
© WAGO Corporation, Germantown WI
Example Architectures
Industrial PC
Programmable
Fieldbus Controllers
Fieldbus Couplers
3rd Party Controllers
IP67 Programmable
Fieldbus Controllers
& Couplers
Fieldbus Couplers
23
© WAGO Corporation, Germantown WI
Modular
A node can consist of a combination of analog, digital, and specialty I/O
modules, with different potentials and signals (up to 230VAC). Up to 64 I/O
modules* can be inserted in a node.
• Over 500 different I/O modules
• Digital Inputs & Outputs
5-240 VDC & 24 - 230 VAC
(1, 2, 4, 8 & 16 Channel Devices)
• Analog Inputs & Outputs
0-10 V, +/-10 V, 4-20 ma, thermocouple, RTD;
3 PH power measure. (differ. & single ended)
• Specialty Modules
Counters, encoders, serial interface (RS232 &
RS485), AS Interface, Vibration, DC Drive
* System can support up to 250 I/O modules with Bus Extension modules.
© WAGO Corporation, Germantown WI
24
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
750-438
2 Channel, NAMUR, Proximity switch
750-402
4 Channel, DC 24 V, 3.0 ms, high-side switching
750-403
4 Channel, DC 24 V, 0.2 ms, high-side switching
750-422
4 Channel, DC 24 V, 10 ms pulse extension
750-408
4 Channel, DC 24 V, 3.0 ms, low-side switching
750-409
4 Channel, DC 24 V, 0.2 ms, low-side switching
750-430
8 Channel, DC 24 V, 3.0 ms, high-side switching
750-431
8 Channel, DC 24 V, 0.2 ms, high-side switching
DI 24 VDC
750-435
1 Channel, NAMUR EEx i, Proximity switch
750-400
2 Channel, DC 24 V, 3.0 ms, high-side switching
750-401
2 Channel, DC 24 V, 0.2 ms, high-side switching
750-410
2 Channel, DC 24 V, 3.0 ms, proximity switch
750-411
2 Channel, DC 24 V, 0.2 ms, proximity switch
750-418
2 Channel, DC 24 V, 3.0 ms, diagnostic, ack
750-424
2 Channel, DC 24 V, Intruder Detection
750-419
2 Channel, DC 24 V, 0.2 ms, diagnostic
750-415
4 Channel, AC/DC 24 V
750-432
4 Channel, DC 24 V, 3.0 ms, low-side switching, w/(+) terminal
750-423
4 Channel, AC/DC 24 V, with power jumper contacts
750-428
Channel, AC/DC 42 V, 2-conductor connection
750-412
2 Channel, DC 48 V, 3.0ms, high-side switching
DI 24 VAC/VDC
DI 42 VAC/VDC
750-433
4 Channel, DC 24 V, 0.2 ms, low-side switching , w/(+) terminal
750-1400
16 Channel DC 24V 3.0 ms, ribbon cable
750-1402
16 Channel DC 24V 0.2 ms, ribbon cable, LSS
750-1405
16 Channel DC 24V 0.2 ms, CAGE CLAMP® S
750-1406
16 Channel DC 24V 0.2 ms,
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
750-1415
8 Channel DC 24V 3.0 ms, 2 conductor connection
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
DI 48 VDC
DI 110 VDC
DI 120/230 VAC
25
© WAGO Corporation, Germantown WI
Digital Output Modules
750-507
2 Channel, DC 24 V, 2.0 A, short-circuit-protected;
high-side switching; with diagnostics
750-534
8 Channel, DC 5 V, 1A, short-circuit-protected; high-side
switching
750-535
2 Channel, DC 24 V, EEx i, short-circuit-protected;
PNP-positive switching
750-519
4 Channel, DC 5 V, 20mA, short-circuit-protected; high-side
switching
750-504
4 Channel, DC 24 V, 0.5 A, short-circuit-protected; highside switching
750-516
750-501
2 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-side
switching
4 Channel, DC 24 V, 0.5 A, short-circuit-protected; lowside switching
750-530
750-502
2 Channel, DC 24 V, 2.0 A, short-circuit-protected; high-side
switching
8 Channel, DC 24 V, 0.5 A, short-circuit-protected; highside switching
750-531
4 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-side
switching w/4 (-) terminals
750-509
2 Channel Solid State Relay, AC/DC 230 V, 300 mA
750-532
4 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-side
switching, w/4 (-) terminals, w/diagnostics
753-540
4 Channel Solid State Relay, AC 120/230 V, 250 mA
750-522
750-506
2 Channel, DC 24 V, 0.5 A, short-circuit-protected;
high-side switching; with diagnostics
2 Channel Solid State Relay, AC/DC 230 V, 500 mA, 3 A
(< 30 s)
750-1500
16 Channel DC 24V 0.5 A, ribbon cable
750-1501
16 Channel DC 24V 0.5 A, ribbon cable, LSS
DO DC 5/12 V
DO DC 24 V
750-1502
8DI 8DO 24V DC 0.5 A, ribbon cable
750-1504
16 Channel DC 24V 0.5 A, CAGE CLAMP® S
750-1505
16 Channel DC 24V 0.5 A, CAGE CLAMP® S , LSS
750-1506
8DI 8DO 24V DC 0.5 A, CAGE CLAMP® S
750-1515
8 Channel DC 24V 0.5 A, 2 conductor connection
750-1516
8 Channel DC 24V 0.5 A, 2 conductor connection, LSS
DO AC/DC 120/230 V
DO Relay
750-514
2 Channel, AC 125 V, AC 0.5 A, DC 30 V, DC 1 A,
isolated outputs, 2 changeover contacts
750-517
2 Channel, AC 230 V, 1 A, isolated outputs, 2 changeover
contacts
750-512
2 Channel, AC 230 V, DC 30 V, AC/DC 2 A, non-floating,
2 make contacts
750-513
2 Channel, AC 230 V, DC 30 V, AC/DC 2 A, isolated
outputs, 2 make contacts
750-523
1 Channel, AC 230 V, AC 16 A, isolated output, 1 make
contact, bistable, manual operation
26
© WAGO Corporation, Germantown WI
Analog Input Modules
AI 0 - 20 mA
AI 0 - 10 V
750-452
2 Channel, 0 - 20 mA, Differential Inputs
750-459
4 Channel, DC 0 - 10 V, single-ended (S.E.)
750-453
4 Channel, 0 - 20 mA, single-ended (S.E.)
750-467
2 Channel, DC 0 - 10 V, single-ended (S.E.)
750-465
2 Channel, 0 - 20 mA, single-ended (S.E.)
750-468
4 Channel, DC 0 - 10 V, single-ended (S.E.)
750-472
2-channel, 0 - 20 mA, 16 Bit, single-ended (S.E.)
750-477
2 Channel, AC/DC 0 - 10 V,Differential Inputs
750-480
2-channel, 0 - 20 mA, Differential Inputs
750-478
2 Channel, DC 0 - 10 V, single-ended (S.E.)
AI 4 - 20 mA
AI ...
750-454
2 Channel, 4 - 20 mA,Differential Inputs
750-483
2 Channel, DC 0 -30 V, Differential Measurement Input
750-455
4 Channel, 4 - 20 mA, single ended (S.E.)
750-461
2 Channel, Resistance Sensors, PT100 / RTD
750-474
2 Channel, 4 - 20 mA, 16 Bit, single-ended (S.E.)
750-460
4 Channel, Resistance Sensors, PT100 / RTD
750-466
2 Channel, 4 - 20 mA, single ended (S.E.)
750-469
2 Channel, thermocouples (J, K, B, E, N, R, S, T, U, L)
750-485
2 Channel, 4 - 20 mA, EEx i, single ended (S.E.)
750-491
1 Channel for Resistor Bridges (Strain Gauge)
750-492
2 Channel, 4 - 20 mA, Isolated Differential Inputs
750-493
3-Phase Power Measurement
750-494
3-Phase Power Measurement
750-495
3-Phase Power Measurement
750-464
2/4 Analog Input RTD Configurable
750-450
4 Analog Input RTD(2,3,4-wire) Configurable or
Potentiometer
750-451
8 Analog Input RTD(2-wire) Configurable or Potentiometer
AI 0 - 1 A
750-475
2-channel, 0 - 1 A AC/DC ,Differential Inputs
AI 0 - 5 A
750-475/020-000
2-Channel, 0 - 5 A AC/DC ,Differential Inputs
AI DC ± 10 V
750-456
2 Channel, DC ± 10 V, Differential Inputs
750-457
4 Channel, DC ± 10 V, single-ended (S.E.)
750-479
2 Channel, DC ± 10 V, Differential Input
750-476
2 Channel, DC ± 10 V, single-ended (S.E.)
© WAGO Corporation, Germantown WI
27
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
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
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
750-556
2 Channel, DC ± 10 V
750-557
4 Channel, DC ± 10 V
AO 4 - 20 mA
AO DC 0 - 10 V
AO DC ± 10 V
28
© WAGO Corporation, Germantown WI
Specialty Modules
Serial Interfaces
Counter Modules
750-404
Up / Down Counter, DC 24 V, 100 kHz
750-638
2 Channel, Up / Down Counter, DC 24 V/ 16Bit / 500 Hz
Frequency Measuring
750-404/
000-003
750-645
2 Channel Vibration Monitoring
750-511
2-channel Pulse Width Module, DC 24 V,
short-circuit-protected, high-side switching
750-652
Serial Interface RS 232/RS 485 Configurable
750-651
TTY-Serial Interface, 20 mA Current Loop
750-654
Data Exchange Module
750-641
DALI/DSI Master Module
750-642
enocean Radio Radio Receiver
Networking
Pulse Width Module
DC Drive Controller
DC-Drive Controller 24V/5A
Proportional Valve Module
750-632
Serial Interface RS 232 C
Serial Interface RS 485
Frequency Measuring 0.1Hz – 100kHz
Vibration Monitoring
750-636
750-650
750-653
Proportional Valve Module supports Pneumatic or Hydraulic
Valves
Angle and Distance
750-630
SSI Transmitter Interface
750-637
Incremental Encoder Interface RS 422, cam outputs
750-634
Incremental Encoder Interface, DC 24 V
750-635
Digital Pulse Interface
750-643
MP-Bus Master Module
750-655
AS-Interface
750-482
2 AI 4M20mA HART Module
750-658
CAN Gateway(CANopen/J1939)
750-644
Bluetooth® RF-Transceiver Module
750-657
IO Link Master
750-670
Stepper Controller, RS422
750-671
Stepper Controller, 24V/1.5A
750-672
Stepper Controller, 50V/7.5A
750-673
Stepper Servo, 50V/7.5A
Stepper Controllers
29
© WAGO Corporation, Germantown WI
Supply Modules
AC 230 V Power Supply Modules
750-612
AC/DC 230 V without diagnostics, passive
750-609
AC 230 V, max. 6.3 A without diagnostics, w/ fuse-holder
750-611
AC 230 V, max. 6.3 A with diagnostics, with fuse-holder
750-624
Filter Module for field side power supply
750-626
Filter Module for system and field side power supply
Filter Modules
Field Side Connection Module
Module Bus Extension
750-603
Field Side Connection Module, 8 (+)
750-627
Module Bus Extension, End Module
750-604
Field Side Connection Module, 8 (-)
750-628
Module Bus Extension, Coupler Module
750-614
Field Side Connection Module, AC/DC 0 ... 230 V
750-1605
Field Side Connection Module 16 (+)
750-602
DC 24 V, passive
750-1606
Field Side Connection Module 16 (-)
750-601
DC 24 V, max. 6.3 A, without diagnostics, with fuse-holder
750-1607
Field Side Connection Module 8(+) / 8(-)
750-610
DC 24 V, max. 6.3 A, with diagnostics, with fuse-holder
750-625
DC 24 V, EEx i, diagnostics, with fuse-holder
750-616
Separation Module / DC 24 V / AC 230 V
750-623
DC Input 24V/Output 5V, 8V, 10V, 12V, 15VDC/.5A
750-621
Separation Module with Power Contacts
750-613
Bus power supply, 24 V DC
750-622
Binary Spacer Module
750-600
End Module, to loop the internal bus
DC Power Supply Modules
Separation Modules
Internal Supply Module
Binary Spacer Module
AC 120 V Power Supply Modules
750-615
AC 120 V, max. 6.3 A without diagnostics, w/ fuse-holder
© WAGO Corporation, Germantown WI
End Module
30
391
I/O Modules: Color Code and Markers
I/O Modules are color coded for easy identification
Yellow
Red
Green
Blue
Clear
–
–
–
–
–
Digital Inputs
Digital Outputs
Analog Inputs
Analog Outputs
Specialty or Supply
Group Marking Carriers allow clear
labeling of I/O modules. They can be
withdrawn and replaced.
31
© WAGO Corporation, Germantown WI
I/O Module Components
Status LED
(module specific)
Internal Bus Contacts
(KBUS)
WSB Markers
Power Jumper Contact
(feed blade contact)
Power Jumper Contact
(feed spring contact)
CAGE CLAMP
Connections
32
© WAGO Corporation, Germantown WI
WAGO-I/O-SYSTEM 750 Ex i
13 Intrinsically Safe Modules
750-606
24V DC 1.0A Power Supply Ex i [ia]
*
750-625/000-001 24V DC 1.0A Power Supply Ex i [ia]
750-435
1DI NAMUR Ex i [ia] *
750-438
2DI NAMUR Ex i [ia]
750-535
2DO 24V DC Ex i [ib]
750-485
2AI 4-20mA Ex i [ib] *
750-484
2AI 4-20mA S.E. HART Ex i [ia] *
750-481/003-000 2AI RTD Ex i [ia] *
750-487/003-000 2AI TC Ex i [ia] *
750-585
2AO 0-20mA Ex i [ia]
750-586
2AO 4-20mA Ex i [ia]
750-633
Up/ Down Counter Ex i [ia] *
750-663/000-003 4F-Ex i DI 24V PROFIsafe V2 iPar
Differentiate WAGO Automation with Blue Modules!
© WAGO Corporation, Germantown WI
33
392
Series 750 For Harsh Temperature Environments
• Part Numbers: 750-xxx/025-000
• Will withstand Operating
Temperatures of –20ºC to +60ºC
Compared to standard Series 750
0ºC to +55ºC
• How did we do it?
Special components and materials
Enhanced design
Coated PCBs
34
© WAGO Corporation, Germantown WI
Series 753 Pluggable Wiring System
Tool-less assembly of
connector and module
Coding feature
For added safety
Built-in eyelet
for wire-tie
strain relief
35
© WAGO Corporation, Germantown WI
Bus Extension Modules
Bus Extension Modules make panel layout flexible.
• Max. no. of I/O
modules: 250
• Max. no. of bus
extensions: 10
• Cable length:
5m
• Cable: STPcable with RJ45
(straight through
cable)
© WAGO Corporation, Germantown WI
36
393
Assembly Features
Controller
Locking Disc
Secure
Tongue and
Groove
Connections
Module
Release Lug
(without tool)
DIN Rail
Mounting
37
© WAGO Corporation, Germantown WI
Cage Clamp
All modules use WAGO CAGE
CLAMP connections. This
connection is appropriate for solid,
stranded, and fine stranded
conductors. Each clamping unit
accommodates one conductor.
1) Insert a screwdriver or operating tool in
the opening above the connection point.
2) The screwdriver blade holds the clamping
spring open. Insert the conductor into the
connection point.
The WAGO CAGE CLAMP connections
provide fast and easy wiring with high
reliability. The connections are vibrationproof and maintenance-free.
3) Withdraw the screwdriver – the conductor is
securely clamped.
38
© WAGO Corporation, Germantown WI
Isolated Power Groups
There are three electrically isolated power groups in a node. Isolation is
achieved by DC to DC converters.
INTERNAL SYSTEM SUPPLY POWER
FIELDBUS
POWER
© WAGO Corporation, Germantown WI
FIELD WIRING POWER
39
394
Internal System Supply
The Coupler/Controller requires 24VDC (-15% to +20%) for the
Internal System Supply.
+24 VDC
0 VDC
The 24VDC for the System Supply is
converted to 5 VDC, and then is used
to power the controller electronics,
fieldbus interface, and the I/O
modules via the internal bus (K-Bus).
The I/O current draw of the 5VDC
bus must not exceed the specified
value for the selected controller (e.g.,
750-881 Total Current for I/O
Modules is 1700 mA).
40
© WAGO Corporation, Germantown WI
Internal Supply Module
If the I/O current consumption of the 5VDC Internal Supply
exceeds the specified value for the selected controller, an
Internal Supply Module (750-613) is required.
An Internal System Supply Module increases the
current capacity for the internal 5V bus by 2
amps. It’s placed before the module where the
current capacity is exceeded.
Very large nodes may require one or more
Internal System Supply Modules.
41
© WAGO Corporation, Germantown WI
Internal System Supply Example
A node with an Ethernet Controller (750-881) consists of 20 relay modules
(750-512) and 20 digital modules (750-405). Is an Internal System Supply
Module required?
750-881 Total Current for I/O Modules is 1700 mA
750-512 Current Consumption 100mA/module
750-405 Current Consumption 2mA/module
(Catalog W5V3 pg 40)
(Catalog W5V3 pg 135)
(Catalog W5V3 pg 119 )
750-512
750-405
2000mA
+ 40mA
2040mA
100mA /modules x 20 modules
2mA/modules x 20 modules
Answer: 2040mA > 1700mA; therefore, an Internal Supply Module is
required in the middle of this node. It’s placed before the module where the
current capacity is exceeded.
© WAGO Corporation, Germantown WI
42
395
Internal System Supply Module
Internal Supply 1
Internal Supply 2
Internal
System
Supply
Module
(750-613)
43
© WAGO Corporation, Germantown WI
Field Supply
The Coupler/Controller provides a connection for the 24VDC
field wiring. The field power is extended to adjacent modules
through Power Jumper Contacts.
+24 VDC
POWER
JUMPER
CONTACTS
0 VDC
GROUND
44
© WAGO Corporation, Germantown WI
Power Jumper Contacts
Power Jumper Contacts consist of blade and spring contacts built
into the sides of modules. Depending on the module type and
features, the contact configuration varies.
= Spring Contact
= Blade Contact
NOTE: Power Jumper Contacts
of adjacent I/O modules must
be compatible (i.e., blade
contacts must have a
corresponding spring contacts).
© WAGO Corporation, Germantown WI
45
396
Power Jumper Contacts
Power Jumper Contacts of adjacent I/O modules must be compatible
(i.e., blade contacts must have corresponding spring 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
46
© WAGO Corporation, Germantown WI
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).
New Field
Potential Starts
(e.g., 230VAC)
Existing Field
Potential Stops
(e.g., 24VDC)
47
© WAGO Corporation, Germantown WI
Fused Supply Module
Fused Supply Modules provide quick and easy access to fuses for
replacement. Additionally, a blown fuse indicator LED is
provided.
Blown
Fuse LED
Fuse
Replacement
Fuse
Holder
© WAGO Corporation, Germantown WI
48
397
Field Supply Example
This example illustrates three different voltage sources for field
devices (i.e., 24VDC, 230VAC, and 24VDC). Two Supply
Modules are used to introduce the new voltage sources.
Supply
Modules
PFC
Field
Supply
24V 230V
24V
49
© WAGO Corporation, Germantown WI
I/O Module Process Image
The coupler/controller generates an internal process image from
the data width and type of I/O modules, as well as the position of
modules in the node. This image is divided into an input and
output area.
Output Process Image (words)
AO (750-550) WORD 1
0
1
2
M
AO (750-550) WORD 2
1
0
Input Process Image (words)
AI (750-472) WORD 1
AI (750-472) WORD 2
0
1
2
M
3
2
1
0
50
© WAGO Corporation, Germantown WI
I/O Module Process Image Rules
1) Input modules are mapped into the input process image
2) Output modules are mapped into the output process image
3) Analog and specialty modules are mapped first into the
process image. They are mapped in the order of their position
after the controller. The analog module closest to the
controller is mapped first, and so on.
4) If there is not a digital offset programmed in the controller, the
digital modules are mapped after the analog modules, in the
form of words (16 bits per word). When the number of digit
points exceed 16, the next word is started.
Note: Most Specialty Modules have both input and output data;
therefore, they use both the input and output process image.
© WAGO Corporation, Germantown WI
51
398
Input Process Image Example
Input Process Image
0
1
2
3
4
5
6
7
...
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
AI MODULE 2, WORD 1
AI MODULE 2, WORD 2
AI MODULE 3, WORD 1
AI MODULE 3, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
0
1
0
1
0
Each 750-472 2-Channel Analog Input module produces 2 words
of data per module in the input process image. See page 51 of the
WAGO 750-841 manual for module process data requirements.
52
© WAGO Corporation, Germantown WI
Input Process Image Example
Input Process Image
0
1
2
3
4
5
6
7
...
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
AI MODULE 2, WORD 1
AI MODULE 2, WORD 2
AI MODULE 3, WORD 1
AI MODULE 3, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
Each 750-472 2-Channel Analog Input module produces 2 words
of data per module in the input process image. See page 51 of the
WAGO 750-841 manual for module process data requirements.
53
© WAGO Corporation, Germantown WI
Input Process Image Example
Input Process Image
0
1
2
3
4
5
6
7
...
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
AI MODULE 2, WORD 1
AI MODULE 2, WORD 2
AI MODULE 3, WORD 1
AI MODULE 3, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
Each 750-472 2-Channel Analog Input module produces 2 words
of data per module in the input process image. See page 51 of the
WAGO 750-841 manual for module process data requirements.
© WAGO Corporation, Germantown WI
54
399
Input Process Image Example
Input Process Image
0
1
2
3
4
5
6
7
...
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
AI MODULE 2, WORD 1
AI MODULE 2, WORD 2
AI MODULE 3, WORD 1
AI MODULE 3, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
7
8
6
5
4
3
2
1
0
Each 750-402 4-Channel Digital Input module produces 4-bits of
data per module in the input process image.
55
© WAGO Corporation, Germantown WI
Input Process Image Example
Input Process Image
0
1
2
3
4
5
6
7
...
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
AI MODULE 2, WORD 1
AI MODULE 2, WORD 2
AI MODULE 3, WORD 1
AI MODULE 3, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
0
1
0
Each 750-402 4-Channel Digital Input module produces 4-bits of
data per module in the input process image.
56
© WAGO Corporation, Germantown WI
Input Process Image Example
Input Process Image
0
1
2
3
4
5
6
7
...
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
AI MODULE 2, WORD 1
AI MODULE 2, WORD 2
AI MODULE 3, WORD 1
AI MODULE 3, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
Each 750-402 4-Channel Digital Input module produces 4-bits of
data per module in the input process image.
© WAGO Corporation, Germantown WI
57
400
Output Process Image Example
Output Process Image
0
1
2
3
4
5
...
AO MODULE 1, WORD 1
AO MODULE 1, WORD 2
AO MODULE 2, WORD 1
AO MODULE 2, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
7
8
6
5
4
3
2
1
0
The 750-550 2-Channel Analog Output module consumes 2 words
of data per module in the output process image. The 750-501 2Channel Digital Output module consumes 2-bits of data per
module in the output process image.
58
© WAGO Corporation, Germantown WI
Output Process Image Example
Output Process Image
0
1
2
3
4
5
...
AO MODULE 1, WORD 1
AO MODULE 1, WORD 2
AO MODULE 2, WORD 1
AO MODULE 2, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
0
The 750-550 2-Channel Analog Output module consumes 2 words
of data per module in the output process image. The 750-501 2Channel Digital Output module consumes 2-bits of data per
module in the output process image.
59
© WAGO Corporation, Germantown WI
Output Process Image Example
Output Process Image
0
1
2
3
4
5
...
AO MODULE 1, WORD 1
AO MODULE 1, WORD 2
AO MODULE 2, WORD 1
AO MODULE 2, WORD 2
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
0
The 750-550 2-Channel Analog Output module consumes 2 words
of data per module in the output process image. The 750-501 2Channel Digital Output module consumes 2-bits of data per
module in the output process image.
© WAGO Corporation, Germantown WI
60
401
Digital Input/Output Offset
(Programmable Fieldbus Controllers Only)
61
© WAGO Corporation, Germantown WI
Digital Input/Output Offset
Digital Outputs start at word 64
Digital Inputs start at word 64
Input Process Image
0
1
2
M
64
Output Process Image
AI MODULE 1, WORD 1
AI MODULE 1, WORD 2
1
1
1
0
9
8
7
6
5
4
3
2
1
0
0
1
2
M
64
AO MODULE 1, WORD 1
AO MODULE 1, WORD 2
1
0
62
© WAGO Corporation, Germantown WI
Internal Bus (K-bus)
+5VDC
COM
T_DIO
T_DIN
T_CLK
T_SEL
• The internal bus is the
communication link between the
coupler/controller and the I/O
modules, as well as a distribution
system for the system supply voltage
• The internal bus uses 6 spring
contacts. (see figure on the left)
• Data is communicated to I/O
modules in a serial fashion, similar
to a large shift register.
© WAGO Corporation, Germantown WI
63
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
P
F
C
4
C
H
4
C
H
2
C
H
4
C
H
D
I
G
I
T
A
L
D
I
G
I
T
A
L
A
N
A
L
O
G
A
N
A
L
O
G
DATA EXCHANGE PER BUS CYCLE
CYCLE 1 DIGITAL DATA
2CHAN WORD1
4CHAN WORD1
nN
CYCLE 2
2CHAN WORD2 4CHAN WORD2
CYCLE 3
4CHAN WORD3
CYCLE 4
4CHAN WORD4
The 4-Channel Analog module used in this node, forces the controller to perform
four bus cycles to exchange all module data.
64
© WAGO Corporation, Germantown WI
Internal Bus Cycle Time Comparison
TEST NODE 1
750-881
750-519
750-519
750-452
750-557
750-600
TEST NODE 2
Controller
4 Chan Digital Out
4 Chan Digital Out
2 Chan Analog In
4 Chan Analog Out
End Module
Calculated Update Time
Data Size
Number of K-Bus Cycles
420us
80 bits
4
750-881
750-519
750-519
750-452
750-552
750-552
750-600
Controller
4 Chan Digital Out
4 Chan Digital Out
2 Chan Analog In
2 Chan Analog Out
2 Chan Analog Out
End Module
Calculated Update Time
Data Size
Number of K-Bus Cycles
260us
80 bits
2
This comparison illustrates that using two 2 -Channel Analog module, instead of
one 4-Channel Analog module, improves the bus cycle.
65
© WAGO Corporation, Germantown WI
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
© WAGO Corporation, Germantown WI
66
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
12.1”-762-3121/000-001
32-Bit XScale 520Mhz
RAM:64M
Flash: 32M
10.4”-762-3104/000-001
32-Bit XScale 520Mhz
RAM:64M
Flash: 32M
Control Panel Target Visualization
•Offered in a wide variety of
screen sizes
•Optimize the screen size for the
application
•Powerful processors and large
memory
5.7”-762-3057/000-001
32 Bit ARM9 240MHz
RAM:64M
Flash: 32M
3.5”-762-3035/000-001
32 Bit ARM9 200MHz
RAM:64M
Flash: 32M
67
© WAGO Corporation, Germantown WI
PERSPECTO® CP TV
Memory
Expansion
10.4”, 12.1”, 15”
•Data Logging
5.7”
3.5”
•Trend data
•Event Data
758-879/000-000
1 GB
Industrial CF
Memory Card
758-879/000-001
Industrial SD
1 GB
Memory Card
758-879/000-002
1 GB
Industrial microSD Memory Card
CF Card SD Card microSD
(Maximum 2 GB)
(Maximum 2 GB)
Card
(Maximum 2 GB)
68
© WAGO Corporation, Germantown WI
PERSPECTO® CP TV
5.7”
12.1”& 10.4”
Multiple
Communication
Ports
Serial &
CAN bus
Ethernet
Port
© WAGO Corporation, Germantown WI
USB
Ports
Ethernet
Port
Battery
24V Power
USB
Ports
Serial Ports
1,2 & 3
Ethernet
Port
CAN bus
Ports 1 & 2
24V Power
Battery
USB
Port
24V Power
Serial
Ports 1,2
CAN bus
3.5
”
Battery
69
404
PERSPECTO® CP TV
RAS Server
Supervisory
System
767 SPEEDWAY
Distributed I/O
Database
Server
ETHERNET 2.0
PLCs
CF, SD,
MicroSD for
memory
Expansion
AC Drives
Serial
Barcode
Reader
SCADA
System
Serial
USB Mobile
Memory for
application
backup and
restore
CANopen
SPEEDWAY
Distributed
I/O
750/ 753
Series
CANopen
Distributed
I/O
J1939
Device
70
© WAGO Corporation, Germantown WI
TAKING IT TO THE EXTREME -
750XTR
WAGO-I/O-SYSTEM
750 XTR
71
© WAGO Corporation, Germantown WI
WAGO Automation Platforms
PERSPECTO
Industrial PC
PFC200
750 XTR Series
750 Series Standard
SPEEDWAY – IP67
© WAGO Corporation, Germantown WI
Automation Platforms
for your specific
applications
72
405
eXTReme I/O for extreme applications
TAKING IT TO THE EXTREME -
750XTR
Built on the benefits of the series
750:
•
•
•
•
•
•
•
•
•
•
Flexible I/O system
Network Independent
Couplers for distributive I/O
Powerful PLCs
Feature rich programming
software
Scalable solution (protect your
IP)
Quality and reliability
Small footprint
Low initial costs
Low cost of ownership
73
© WAGO Corporation, Germantown WI
eXTReme
Temperature
eXTReme Temperatures
Built for eXTReme Temperatures:
• Operating Temperature: of -40 °C to
+70 °C
• Relative Humidity: 95%
• Condensation: Permitted per IEC
60721-3-3 (except wind driven
precipitation and ice formation)
Benefits:
•
•
•
•
•
No air condition Required
Reduce cabinet dimensions
Lower energy consumption
Reduce maintenance
Reduce costs
74
© WAGO Corporation, Germantown WI
Rugged Applications
eXTReme
vibration and shock
Built for eXTReme environments:
• Vibration: 5g per EN 60068-2-6
• Shock: 25g/6MS/1000 shocks
• EMC protection 24V modules:
0.5kVAC/775 VDC, 1Kv impulse
• EMC protection 230 V modules:
2.5kVAC/3.5 VDC, 5.0KV impulse
voltage
Benefits:
• Use in mobile applications
• Install on high vibration tools
• Use in high voltage applications
© WAGO Corporation, Germantown WI
75
406
eXTReme altitudes
Built for eXTReme environments:
• Use up to 6,500 ft without de-rating
• 6,500 ft to 9,800 ft max operating temp.
65oC
• 9,800 to 13,000 ft max. operating temp.
60oC
• 13,000 to 16,000 ft max operating temp.
55oC
• Can be used as overvoltage category II
up to 26,000 ft with max operating temp.
40oC
Benefits:
• Use in high altitude applications
76
© WAGO Corporation, Germantown WI
750 XTR series offers many control options
Programmable Fieldbus
Controllers
•
ETHERNET
•
ETHERNET Telecontrol
•
CANopen
Coupler
•
ETHERNET
•
PROFIBUS
•
CANopen
Digital Inputs and Outputs
•
•
2 channels, 8 channels, 16 channels
24 V and 230 V
Analog Inputs and Outputs
•
Current signals
•
Voltage signals
•
Temperature
Communication, Supply and Segment
Modules
•
Serial interface
•
24V and 0-230V power supply
•
Filter
•
Potential multiplication module
•
End Module
77
© WAGO Corporation, Germantown WI
Series 750 XTR – I/O Modules
Digital Inputs and Outputs
750-1405/040-000
750-1415/040-000
750-508/040-000
750-1515/040-000
750-407/040-000
750-517/040-000
16 DI 24 V DC 3.0 ms /XTR
8 DI 24 V DC 3.0 ms/2-wire /XTR
2 DO 24 V DC 2.0 A/Diagnostics /XTR
8 DO 24 V DC 0.5 A/2-wire /XTR
2 DI 220 V DC 3.0 ms /XTR
2 DO 230 V AC 1.0 A/Relay 2CO /XTR
Analog Inputs and Outputs
750-468/040-000
750-457/040-000
750-453/040-000
750-455/040-000
750-464/040-000
750-469/040-000
750-559/040-000
750-557/040-000
750-563/040-000
4 AI 0–10 V DC S.E. /XTR
4 AI ±10 V DC S.E. /XTR
4 AI 0–20 mA S.E. /XTR
4 AI 4–20 mA S.E. /XTR
2/4 AI RTD configurable /XTR
2 AI Thermocouple configurable/XTR
4 AO 0–10 V DC /XTR
4 AO ±10 V DC /XTR
2 AO 0/4–20 mA/6–18 V DC/16 Bit /XTR
Communication, Supply and Segment Modules
750-652/040-000
750-602/040-000
750-624/040-001
750-613/040-000
750-626/040-000
750-612/040-000
750-1605/040-000
750-1606/040-000
750-0600/040-000
© WAGO Corporation, Germantown WI
Serial Interface RS232/RS485 /XTR .
24 V DC Power Supply /XTR
24 V DC Field Supply Filter/HI /XTR
24 V DC Power Supply (Bus) /XTR
24 V DC Supply Filter (Surge)/HI /XTR
0–230 V AC/DC Power Supply /XTR
Potential Multiplication 16+ /XTR
Potential Multiplication 16- /XTR
End Module /XTR
78
407
WAGO 750 Series I/O module comparison
Requirement
Operating
Temperature
Vibration
Shock
Temporary
Condensation
750 Series Standard
750 series - Extended
750 XTR Series
Temp.
0 oC to + 55o C
-20o C to +60o C
-40o C to + 70o C
4g
15g / 11ms / 3 axis
4g
15g / 11ms / 3 axis
5g
25G/ 6ms/ 3 axis
Not Permitted
Not Permitted
Per Class 3K7 EN
60721-3-3 ( except
wind driven rain
and ice building
60 V: 0,5 kV AC / 0,5
kV impulse voltage
60 V: 0,5 kV AC / 0,5 kV
impulse voltage
<60 V: 0,5 kV AC /
1,0 kVimpulse
voltage (VW1)
≥ 60 V: 1,5 kV AC / 2,5
kV impulse voltage
≥ 60 V: 1,5 kV AC / 2,5
kV impulse voltage
≥ 60 V: 2,5 kV AC /
5,0 kVimpulse
voltage (VW3)
Electric insulation (EN
60870-2-1)
79
© WAGO Corporation, Germantown WI
Taking it to the extreme –750 XTR
Characteristics
Built on proven WAGO-I/O-SYSTEM 750
Extreme extended temperature range -40 °C W +70 °C
Withstands temporary condensation
Increased vibration and shock resistance (5g acc.
EN60068-2-6)
● Increased electric strength (EN60870-2-1)
●
●
●
●
Advantages
●
●
●
●
No air conditioning / heating required
PLC for telecontrol applications (hardware and protocols!)
Couplers for distributive I/O
PLC for stand-alone applications
Benefits
● Easy configuration and maintenance
● Lower energy and maintenance costs
● Compact, flexible I/O system for eXTReme environments
© WAGO Corporation, Germantown WI
80
TAKING IT TO THE EXTREME -
750XTR
WAGO-I/O-SYSTEM
750 XTR
© WAGO Corporation, Germantown WI
81
408
Bluetooth® Ethernet Bridge (758-915)
• Wireless transmission of ETHERNET protocols
(like PROFINET, Modbus/TCP, ETHERNET IP, W)
via Bluetooth radio technology
•
•
•
•
•
•
•
•
•
Bluetooth version 2.0
Topology:
Point-to-Point
Frequency band:
ISM band, 2402 – 2480 MHz
Range:
Maximum 1,000 ft
Antenna:
internal antenna, circularly
polarized
Type of protection:
IP65
Operating temperature:
-30 W +65 °C
Dimensions:
91 x 66 x 36,2 compact
Inputs:
Power
M12, A-type encoded
ETHERNET M12, D-type encode
82
© WAGO Corporation, Germantown WI
Bluetooth® Ethernet Bridge (758-915)
Applications
Ethernet
Ethernet
Ethernet
Ethernet
750-915 can be used in applications where point to point
communications is required.
83
© WAGO Corporation, Germantown WI
Series 852 Unmanaged Ethernet Switches
852-101
5-Port
852-102
8-Port
• Function monitoring via relay contact
• DIP switches for enabling alarm functions
• Redundant DC power supply
• Wide supply voltage range: 9-48VDC
• Full compliance with IEEE802.3, 802.3u
© WAGO Corporation, Germantown WI
852-103
8TX/2FX ports
• Non-blocking, store-and-forward
switching
• Auto-negotiation on all 10/100BaseTX
ports
• Auto-MDI/MDIX (crossover) on all
10/100BaseTX ports
84
409
ECO 852-1111 Gigabit Switch
•Supports Ethernet Transmissions
•10, 100 or 1,000 Mbits/second
•Automatic data rate detection
•DIN rail mount
•Up to 2,000 devices can be
managed via MAC address list
•0C to +60C operating temperature
85
© WAGO Corporation, Germantown WI
Series 852-104 7TX/2FX Managed Ethernet Switch
• Web-based/SNMP
management
• Non-blocking, store-andforward switching
• Function monitoring via relay
contact
• Auto-negotiation on all
10/100BaseTX ports
• DIP switches for enabling
alarm functions
• Auto-MDI/MDIX (crossover)
on all 10/100BaseTX ports
• Redundant DC power supply
• VLAN (802.1q) VID
• Wide supply voltage range: 948VDC
• IGMP Snooping for multicast
filtering
• Full compliance with
IEEE802.3, 802.3u, 802.3x,
802.1d, 802.1q, and 802.1p
standards
• Port configuration, status,
statistics
• Xpress Ring (redundant ring
recovery < 50ms)
• SNMPv1/v2 and RMON
• Port Trunking
86
© WAGO Corporation, Germantown WI
WAGO-I/O CHECK 3
• A Windows application for the checking of
inputs and outputs of a node during startup.
•Used to configure some specialty modules.
•The communication with WAGO-IO-CHECK
via :
•750-920 RS232 cable
•750-923 USB cable
•Ethernet
•Software to force outputs on and off directly
at the buscoupler:
•Debugging wiring
•General trouble-shooting
•Programming adjustable modules
WAGO 750-923
USB cable
© WAGO Corporation, Germantown WI
87
410
WAGO-I/O CHECK 3
Verify that the menu item “Settings…Com-Port” is correct for
your setup. Select “Node…Read Configuration”.
88
© WAGO Corporation, Germantown WI
WAGO-I/O CHECK 3
Using menu item “Node…Control Mode…Direct”, outputs can
be written to.
89
© WAGO Corporation, Germantown WI
WAGO-I/O-CHECK 3
Certain I/O modules can be configure via WAGO-I/O-CHECK.
© WAGO Corporation, Germantown WI
90
411
Applications
Gas Measurement equipment
WAGO Products:
750 I/O system
•
•
•
•
Continuous mud sample
analysis
Huge cost saving by using
standard gas ejection system
Better quality sample analysis
Automated Gas analyzer
calibration
WAGO I/O
91
© WAGO Corporation, Germantown WI
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
Sherriff’s
Office
Jail
Control
Room
Kiosk #1
Jail Control
Room
Kiosk #2
- Visualizations
- Input to lock out
comms to Jail Control
Room IPC’s during a
jail overrun
92
© WAGO Corporation, Germantown WI
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.
© WAGO Corporation, Germantown WI
93
412
Applications
Industry:
Transportation
WAGO
Products:ProfiBus
PFC Relays,
Distribution blks,
Fuse blks, Double
Deck
Problem Solved:
Reduced parts
and added
reliability.
94
© WAGO Corporation, Germantown WI
Applications
Industry:
Fuel Cells as
Alternative
Energy
WAGO Products: 870,
280, 859, & 750-841
Problem Solved:
Quick start up, end of loose terminations and now
additional modularity with 750 series I/O
95
© WAGO Corporation, Germantown WI
Applications
This application illustrates communications between a
Allen-Bradley Controllogix system and a Yaskawa SMC3010 using a WAGO 750-841 as a gateway.
Because the Allen-Bradley Controllogix
uses the Ethernet/IP protocol, a gateway is
recommended to simply and quickly
establish communications via Ethernet.
Yaskawa SMC-3010, SMC-4000, and MP
series are capable of communications
using the Modbus TCP protocol. The Wago
750-841 PFC supports both the Ethernet/IP
and Modbus TCP protocol. Therefore with
minimal programming it may be used to
exchange data between an Allen-Bradley
Controllogix system with an Ethernet
module and a Yaskawa SMC motion
controller.
© WAGO Corporation, Germantown WI
96
413
Applications
Offshore Safety on drilling
and production platforms.
WAGO Products:
750-841, 750-87, I/S,
280 Series
Problem Solved: Function,
Dependability, Expansion,
Price.
97
© WAGO Corporation, Germantown WI
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
98
© WAGO Corporation, Germantown WI
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
© WAGO Corporation, Germantown WI
99
414
Applications
Retrofit Diesel Engine Emissions
Monitoring System
Offshore Drilling Rigs/Ships
Offshore Service Boats
Offshore Tug Boats
NOx monitoring equipment
installed on all diesel engines
750 Series and Terminal Blocks had
all Marine and Class 1, Division 2
Approvals.
100
© WAGO Corporation, Germantown WI
Applications
Industry:
Semiconductor
Application Description:
Metallization- Sputter
Deposition Systems for
processing wafers.
Problem Solved: The WAGO 750 Series I/O spec’d. as the
new preferred System Control Platform. The utilization of
WAGO products significantly reduced costly wiring and
offered a much more flexible off-the-shelf I/O solution.
101
© WAGO Corporation, Germantown WI
Applications
Flight Simulators
•
•
•
Wago 750-880 Ethernet
Wago TJS Terminal Blocks
Wago 788 Relays
Military, Commercial, Table Top FAA Cert.
Full Motion Wrap Around Screen & Enclosure
© WAGO Corporation, Germantown WI
102
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
103
© WAGO Corporation, Germantown WI
Applications
Seam Welding Machines
•
•
•
•
750-881
Thermocouple
Encoders
Various Other Analog & Discrete
Awnings
Inflatable life rafts
Inflatable furniture
Whitewater rafts
104
© WAGO Corporation, Germantown WI
Applications
Tug boat transfer Barges
APPLICATION:
Engine Monitoring:
Engine Data used to find the
right mix of Biofuel/Diesel
Safety Alarm system
Motion detection in the Pilot
room
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
•
•
750-880 & Remote I/O
WAGO Terminal Blocks
• Marine Stabilizer for Super
Yachts & Hydraulics
106
© WAGO Corporation, Germantown WI
Thank You
WAGO Corporation
P.O. Box 1015
Germantown, WI 53022
E-Mail: [email protected]
Internet: www.wago.com
© WAGO Corporation, Germantown WI
107
417
