High Pressure Spring Return PDF

“OLGAS-H-MHP + CONTROL CABINET”
M9899 Technical documentation
OLGAS-H-MHP
HIGH PRESSURE SPRING RETURN
HYDRAULIC ACTUATOR
WITH HYDRAULIC MANUAL OVERRIDE
M9899
Customer PENTAIR VALVES & CONTROLS

ITALIA S.R.L. – DIV. VENDITE ITALIA
Order P.O. 4500292316
Acknowledgement 15/1981
Project CERRO PABELLON
Final Customer ENEL GREEN POWER S.P.A.
Issue
0 13/10/2016
document Belletti A Secchi G
Rev. Date Description Prepared Approved
© Copyright by BIFFI Italia srl. All right reserved. BIFFI Acknow. 15/1981
Contents may change without notice

INDEX
1. ACKNOWLEDGEMENT SUMMARY TABLE
2. INSTRUCTION AND OPERATING MANUAL
2.1. Actuator
3. SAFETY INSTRUCTIONS FOR BIFFI ELECTRIC
COMPONENTS ENCLOSURE
3.1. Limit Switch Box
4. TECHNICAL DATA SHEET
5. DIAGRAMS
5.1. Operating diagrams
5.2. Wiring diagrams
6. OVERALL DIMENSION
7. ASSEMBLY TABLE AND PARTS LIST
7.1. Table 0A
8. CONTROL SYSTEM
8.1. ECU 1000
8.2. Instruction and operating manual

NOTES:
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1. ACKNOWLEDGEMENT SUMMARY TABLE
Overall dimensions
Operating Diagram
Actuator model
Wiring diagram
Tag number
Item
Q.ty
LV-0301C
OLGAS-H
01 3 LV-0301F SLAHE002 SEAKM004 DQB007PF
0.9S-0400-70-OP-MHP
LV-0301J
LV-0300A
LV-0300B
LV-0300D OLGAS-H
02 6 SLAHB005 SEAKM004 DPB029PF
LV-0300E 0.9C-0400-70-CL-MHP
LV-0300G
LV-0300H
OLGAS-H
03 1 LV-0006A SLAHB005 SEAKM004 DPE014P0
6C-2500-125-CL-MHP
OLGAS-H
04 1 LV-0006B SLAHB005 SEAKM004 DPE014P0
6C-2500-125-CL-MHP
OLGAS-H
05 1 PV-0206 SLAHB005 SEAKM004 DPA009PF
0.3C-0100-40-CL-MHP
OLGAS-H
06 1 PV-0205 SLAHB005 SEAKM004 DPA008PF
0.3S-008C-35-CL-MHP
PV-0201C
OLGAS-H
07 3 PV-0201F SLAHE002 SEAKM004 DQC004PF
1.5C-1100-95-OP-MHP
PV-0201J
OLGAS-H
08 1 FV-0306 SLAHB005 SEAKM004 DPB030PF
0.9C-0700-85-CL-MHP
PV-0508C
OLGAS-H
09 3 PV-0508F SLAHB005 SEAKM004 DPD007P0
3C-2000-110-CL-MHP
PV-0508J
PV-0504C
OLGAS-H
10 3 PV-0504F SLASE006 SEAKM006 DQC005PF
1.5C-1100-95-OP-MHP
PV-0504J
CFI-001 DW406400_1
11 2 CENTRALE COMUNE CFI SLAPZ030 SEANA018
CFI-002 DW406400_2
OLGAS-H
12 1 LV-0310C SLAHE002 SEAKM004 DQB007PF
0.9S-0400-70-OP-MHP
OLGAS-H
13 1 LV-0310F SLAHE002 SEAKM004 DQB007PF
0.9S-0400-70-OP-MHP
OLGAS-H
14 1 LV-0310J SLAHE002 SEAKM004 DQB007PF
0.9S-0400-70-OP-MHP
OLGAS-H
15 1 FV-0311C SLAHE002 SEAKM004 DQA001PF
0.3C-0150-45-OP-MHP
OLGAS-H
16 1 FV-0311F SLAHE002 SEAKM004 DQA001PF
0.3C-0150-45-OP-MHP
OLGAS-H
17 1 FV-0311J SLAHE002 SEAKM004 DQA001PF
0.3C-0150-45-OP-MHP
OLGAS-H
18 1 LV-0016 SLAHE002 SEAKM004 DQC004PF
1.5C-1100-95-OP-MHP
OLGAS-H
19 1 FV-0005 SLAHE002 SEAKM004 DQC003PF
1.5C-1200-110-OP-MHP

Overall dimensions
Operating Diagram
Actuator model
Wiring diagram
Tag number
Item
Q.ty
LV-0301C
CONTROL CABINET
20 3 LV-0301F SLAHE002 SEAKM004 DW3473C0
FOR ITEM 01
LV-0301J
LV-0300A
LV-0300B
LV-0300D CONTROL CABINET
21 6 SLAHB005 SEAKM004 DW3473C0
LV-0300E FOR ITEM 02
LV-0300G
LV-0300H
CONTROL CABINET
22 1 LV-0006A SLAHB005 SEAKM004 DW3474C0
FOR ITEM 03
CONTROL CABINET
23 1 LV-0006B SLAHB005 SEAKM004 DW3474C0
FOR ITEM 04
CONTROL CABINET
24 1 PV-0206 SLAHB005 SEAKM004 DW3473C0
FOR ITEM 05
CONTROL CABINET
25 1 PV-0205 SLAHB005 SEAKM004 DW3473C0
FOR ITEM 06
PV-0201C
CONTROL CABINET
26 3 PV-0201F SLAHE002 SEAKM004 DW3473C0
FOR ITEM 07
PV-0201J
CONTROL CABINET
27 1 FV-0306 SLAHB005 SEAKM004 DW3473C0
FOR ITEM 08
PV-0508C
CONTROL CABINET
28 3 PV-0508F SLAHB005 SEAKM004 DW3474C0
FOR ITEM 09
PV-0508J
PV-0504C
29 3 PV-0504F HPU FOR ITEM 10 SLASE006 SEAKM006 DW406500
PV-0504J
CONTROL CABINET
30 1 LV-0310C SLAHE002 SEAKM004 DW3473C0
FOR ITEM 12
CONTROL CABINET
31 1 LV-0310F SLAHE002 SEAKM004 DW3473C0
FOR ITEM 13
CONTROL CABINET
32 1 LV-0310J SLAHE002 SEAKM004 DW3473C0
FOR ITEM 14
CONTROL CABINET
33 1 FV-0311C SLAHE002 SEAKM004 DW3473C0
FOR ITEM 15
CONTROL CABINET
34 1 FV-0311F SLAHE002 SEAKM004 DW3473C0
FOR ITEM 16
CONTROL CABINET
35 1 FV-0311J SLAHE002 SEAKM004 DW3473C0
FOR ITEM 17
CONTROL CABINET
36 1 LV-0016 SLAHE002 SEAKM004 DW3473C0
FOR ITEM 18
CONTROL CABINET
37 1 FV-0005 SLAHE002 SEAKM004 DW3474C0
FOR ITEM 19

2. INSTRUCTION AND OPERATING MANUAL

2.1. Actuator

OLGAS-H – High pressure spring return hydraulic actuator
Use and maintenance manual
OLGAS
OLGAS-H
SPRING RETURN HIGH
PRESSURE HYDRAULIC
ACTUATOR
MAN 609
Updated applicable
4 18/04/16 regulation (chapter 1.1.1) Ermanni Orefici Vigliano
Added lifting procedure for
3 07/08/13 valve with horizontal axis Ermanni Stoto Vigliano
2 31/07/12 General update Ermanni Stoto Vigliano
1 08/02/10 General update Ermanni Stoto Vigliano
0 05/05/99 Document release Lazzarini Aliani Ziveri
Rev. Date Description Prepared Checked Approved
© Copyright by BIFFI Italia. All right reserved. Pag. 1

TABLE OF CONTENTS
1 General warnings ................................................................ 4
1.1 GENERALITIES .......................................................................... 4
1.1.1 Applicable regulation ............................................................... 4
1.1.2 Terms and conditions .............................................................. 4
1.2 IDENTIFICATION PLATE ........................................................... 5
1.3 INTRODUCING THE ACTUATOR .............................................. 5
1.4 DATA SHEET .............................................................................. 6
2 Installation ........................................................................... 6
2.1 CHECKS UPON ACTUATOR RECEIPT ..................................... 6
2.2 STORAGE ................................................................................... 7
2.3 ACTUATOR ASSEMBLY ON THE VALVE ................................. 7
2.3.1 Types of assembly .................................................................. 7
2.3.2 ACTUATOR HANDLING (VALVE STEM WITH VERTICAL
AXIS) ..................................................................................... 12
2.3.3 VALVE STEM WITH HORIZONTAL AXIS ............................ 15
2.4 hydraulic CONNECTIONS ........................................................ 18
2.5 ELECTRICAL CONNECTIONS (IF ANY) .................................. 19
2.6 COMMISSIONING .................................................................... 19
3 Operation and use ............................................................. 20
3.1 OPERATION DESCRIPTION .................................................... 20
3.2 RESIDUAL RISKS..................................................................... 21
3.3 OPERATIONS ........................................................................... 21
( refer to specific document: operating diagram furnished ) ............. 21
3.3.1 Emergency manual operation ............................................... 21
3.3.2 Remote control operations .................................................... 23
3.4 CALIBRATION OF THE ANGULAR STROKE .......................... 25
3.5 CALIBRATION OF MICROSWITCHES (biffi limit switch box) ... 29
3.6 CALIBRATION OF THE OPERATION TIME (if required) .......... 31
4 Operational tests and inspections...................................... 32
5 Maintenance ...................................................................... 33
5.1 PERIODIC MAINTENANCE ...................................................... 33
5.1.1 Check and restore oil level in the hydraulic control unit ( refer
to chapt. 7.2 table 5 ) ............................................................ 34
5.2 EXTRAORDINARY MAINTENANCE ........................................ 36
5.3 LUBRICATION OF MECHANISM 41
5.4 DISMANTLING AND DEMOLITION........................................... 42
6 Troubleshooting ................................................................ 43
6.1 FAILURE OR BREAKDOWN RESEARCH ............................... 43
7 Layouts .............................................................................. 44
7.1 SPARE PARTS ORDER ........................................................... 44
7.2 PARTS-LIST FOR MAINTENANCE AND REPLACING
PROCEDURE .................................................................................. 45
8 Date report for maintenance operations ............................ 52

NOTE:
BIFFI Italia S.r.l pays the highest attention to collecting and verifying the
documentation contained in this user manual. However BIFFI Italia S.r.l. is not
liable for any mistakes contained in this manual, for damage or accidents due to
the use of the latter. The information contained is of exclusive reserved ownership
of BIFFI Italia S.r.l and may be modified without prior notice. All rights reserved.

1 General warnings
The manual is an integral part of the machine, it should
be carefully read before carrying out any operation and
it should be kept for future references.
1.1 GENERALITIES
BIFFI Italia S.r.l actuators are conceived, manufactured and
controlled according to the Quality Control System in compliance with
EN-ISO 9001 international regulation.
1.1.1 Applicable regulation
UNI EN ISO 12100-1: 2005: Safety of machinery – Basic notions,

general design principles. Part 1-Basic terminology, method.
UNI EN ISO 12100-2: 2005: Safety of machinery – Basic notions,

general design principles. Part 2-Technical principles and
specification.
2006/42/EC: Machine directive.
97/23/EC: Directive for pressure PED equipment (until 18 July

2016) 2014/68/EU from 19 July 2016
2006/95/EC: Directive for low voltage equipment (until 19 April

2016) 2014/35/EU from 20 April 2016
2004/108/EC: Directive for the electromagnetic compatibility

(until19 April 2016) 2014/30/EU from 20 April 2016
94/9/CE: Directive and safety instructions for use in hazardous

Area(until 19 April 2016) 2014/34/EU from 20 April 2016
1.1.2 Terms and conditions
Biffi Italia srl guarantees that all the items produced are free of
defects in workmanship and manufacturing materials and meet
relevant current specifications, provided they are installed, used and
serviced according to the instructions contained in the present
manual. The warranty can last either one year from the date of
installation by the initial user of the product, or eighteen months from
the date of shipment to the initial user, depending on which event
occurs first. All detailed warranty conditions are specified in the
documentation forwarded together with the product. This warranty
does not cover special products or components not warranted by
subcontractors, or materials that were used or installed improperly or

were modified or repaired by unauthorized staff. In the event that a

fault condition be caused by improper installation, maintenance or
use, or by irregular working conditions, the repairs will be charged
according to applicable fees. The warranty and Biffi Italia srl
liability shall lapse in the event that any modification or
tampering whatsoever be performed on the actuator.
1.2 IDENTIFICATION PLATE

It is forbidden to modify the information and the marks without
previous written authorization by BIFFI Italia S.r.l.
The plate fastened on the actuator contains the following information
(Figure1).
Figure 1 – Data plate
1.3 INTRODUCING THE ACTUATOR

The hydraulic actuator OLGAS-H was engineered and is
manufactured to provide fail safe operation for any quarter turn
application such as ball, plug, butterfly valves or dampers, in both
On-Off and Modulating heavy duty service.
The actuator (see figure 2) is made up of a weatherproof scotch yoke
mechanism transforming the linear movement of the hydraulic
cylinder (on closing or opening) into the rotary movement, which is
necessary for operation. The spring module incorporates up to four
springs, fully encapsulated in a factory-welded cartridge: this ensure
safety to personnel and simplifies assembly. The spring action can
be easily changed in the field from “to close” in “to open” or vice-
versa. The angular stroke of the yoke is adjustable between 82° and
98° by means of the external mechanical stops screw ed into the
spring cartridge and into the end flange of the hydraulic cylinder. The
cover of the scotch yoke mechanism is arranged for the assembly of
the required accessories (positioner, signalling limit switches,
position transducer, etc.) by means of proper matching units. The

above mentioned accessories are operated by the actuator drive

sleeve. The housing of the scotch yoke mechanism has a flange with
threaded holes to fix the actuator to the valve either directly or, if
required, with the interposition of an adaptor flange or a mounting
bracket. The actuator yoke has a hole with keyways suitable for the
assembly of an insert bush the internal hole of which is machined (by
BIFFI or at Customer's care), according to the shape and dimensions
of the valve stem. BIFFI can supply different types of control system
following Customer's requirements.
The expected lifetime of actuator is approximately 25 years .
Spring cartridge Valve position indicator
Scotch-yoke
mechanism
Valve coupling
Hydraulic cylinder
Figure 2 – Identification of actuator parts
1.4 DATA SHEET

Supply fluid Hydraulic oil, special versions for fire-
resistant fluids
Operating temperature Standard: from –30°C to +100°C
Optional: from –60° to +140°C
Supply pressure Please refer to technical document:
“actuator data-sheet”
2 Installation
2.1 CHECKS UPON ACTUATOR RECEIPT
Check that the model, the serial number of the actuator and the
technical data reported on the identification plate correspond with
those of order confirmation (Sect. 1.2).
Check that the actuator is equipped with the fittings as provided for

by order confirmation.
Check that the actuator was not damaged during transportation: if
necessary renovate the painting according to the specification
reported on the order confirmation.
If the actuator is received already assembled with the valve, its
settings have already been made at the factory.
If the actuator is delivered separately from the valve, it is
necessary to check, and, if required, to adjust, the settings of the
mechanical stops (Sect. 3.4) and of micro-switches (if any) (Sect.
3.5).
2.2 STORAGE
(for handling and lifting procedure, please refer to following
paragraphs : 2.3.2 and 2.3.3)
If the actuator needs storage before installation, follow these steps:

Place it on a wood surface in order not to deteriorate the area of
valve coupling.
Make sure that plastic plugs are present on the pneumatic and
electrical connections (if present).
Check that the cover of the control group and of the limit switch box
(if any) are properly closed.
If the storage is long-term or outdoor:
Keep the actuator protected from direct weather conditions.
Replace plastic plugs of pneumatic and electrical connections (if
any) with metal plugs that guarantee perfect tightness.
Coat with oil, grease or protection disc, the valve coupling area.
Periodically operate the actuator (Sect. 3.3).
2.3 ACTUATOR ASSEMBLY ON THE VALVE

2.3.1 Types of assembly
For coupling to the valve, the housing is provided with a flange with
threaded holes according to Biffi standard tables (SCN6200
SCN6201). The number, dimensions and diameter of the holes are
made in accordance with ISO 5211, but for actuator models 0.3 to 6
the holes are drilled on the centreline in order to allow an easier
assembly of an intermediate flange, when required. This intermediate
flange ( or spool-piece ) can be supplied when the valve flange can
not directly match the actuator flange in its “standard” configuration.
For the biggest actuator models, the actuator flange can be
machined in accordance with the valve flange dimensions.
The yoke has bored with keyways for coupling to the valve stem, the
dimensions of which are according to Biffi standard tables SCN6200
and SCN6201.



If required, for the standard models size 0.3 to 6, Biffi can supply an
insert bush with un-machined bore in accordance with Biffi standard
table SCN6202 enclosed ( see following pages ). On request the
insert bush bore can be machined by Biffi to couple the valve stem,.
The particular execution of the flange and bushing allow the actuator
to be rotated by 90° in 4 different positions accor ding to the following
figure:

Position 2 Position 3 Position 4

Rotate insert-bush Rotate insert-bush 180° Rotate insert-bush
180° around vertical- around axis A-A, from 180° around axis A- A
standard position (1) position 2 from position 1
Insert bush turned upside down
Figure 3 – Insert bush + intermediate coupling flange
The Biffi insert bush with 2 external keys at 45° a llows to position the
keyway for the valve every 90°. Consequently actuat or can be
mounted in 4 positions at 90° on top of the valve. For biggest
actuator models, the bore of the yoke can be machined according to
the dimensions of valve stem.

2.3.2 ACTUATOR HANDLING (VALVE STEM WITH VERTICAL

AXIS)
The lifting and handling should be made by qualified staff

and in compliance with the laws and provisions in force.
The fastening points are appropriate for the lifting of the

actuator alone and not for the valve+actuator assembly.
Avoid that during the handling, the actuator passes above
the staff.
The actuator should be handled with appropriate lifting
means. The weight of the actuator is reported on the
delivery bill.
Picture 1 – Lifting points for OLGAS-H actuators
1-2 = Lifting points ( obligatory ) 3 = Balancing point

1 = point of support - 2 = supports for lateral positioning

3 = don’t lay the actuator on tie-rods of cylinder /s and
don’t lay the actuator on accessories ( manual override,
pneumatic control group etc. )
For the transport of OLGAS-H with hydraulic manual hand-pump, when

it was necessary put in horizontal position the tank of MHP, to avoid
leakage on oil level stick, substitute these with a blind-plug during the
transport (a specific warning label for transport in horizontal position is

attached on the MHP body); remove the blind plug and restore the
dipstick before operate the actuator with MHP.
BIFFI hydraulic manual hand-pump must be maintained with tank under

the hand-pump to operate the actuator with MHP properly
OMFB manual hand-pump should be transported and used with MHP

tank in horizontal position, but in position 3 of follow picture (extracted
from OMFB technical documentation) it’ necessary change the position
of suction pipe and breather cap :
Failure to comply with the following procedures may

impair product warranty.
Installation, commissioning and maintenance and

repair works should be carried out by qualified staff.
A non-conforming assembly could be the source of
serious accidents.
For actuator assembly on the valve:
Check that the assembly position, as shown on the

documentation, complies with system’s geometry.
Check the consistency of the parts of actuator-valve
coupling.
Operate the actuator so that it reaches the position matching valve

position (Section 3.3).
Lubricate valve stem with oil or grease.

Properly clean and remove grease from coupling flange surfaces.

Connect, if supplied separately, the adjustment insert to valve stem
and fasten it with the special fastening pins.
Lift the actuator using the special lifting points (Sect. 2.2).
Install the actuator so that valve stem inserts in the coupling area.
This coupling should be made without forcing.
Fasten the two parts with the threaded connections (screws, tie
rods, nuts). If holes of coupling flanges are not aligned, adequately
operate the actuator if necessary move the mechanical stops
backwards (Sect. 3.4).
Fasten threaded connections. Please refer to Table 1.
Table 1: nuts tightening torque
Tightening
Threading
torque (Nm)
M8 20
M10 40
M12 70
M14 110
M16 160
M20 320
M22 420
M24 550
M27 800
M30 1100
M33 1400
M36 1700
The screwing values in Table 1 were calculated considering the

materials ASTM A320 L7 for screws or tie rods and ASTM A194
gr.2H for the nuts.
2.3.3 VALVE STEM WITH HORIZONTAL AXIS
The actuator can also be lifted to assemble directly onto the valve
with stem with horizontal axis. To make a correct lifting procedure
proceed as follow:
1) Connect properly the actuator lifting points 1 with chains, and
connect by suitable slings the support brackets 2 and 3

2) Balance the weight and lift the actuator until to make possible the
rotation of actuator in its final mounting position, with cylinder on
top, or spring container placed on top, as showed in the following
images:

3) Clean the actuator flange and remove anything that might

prevent a perfect adherence to the valve flange and especially all
traces of grease.

4) Lift the actuator near to the valve in such a way that the insert
bush, assembled on the valve stem, enters the actuator drive
sleeve without forcing the coupling . When the insert bush has
entered the actuator drive sleeve, check the holes of the valve
flange. If they do not meet with the holes of the actuator flange or
the stud bolts screwed into them, the actuator drive sleeve must
be rotated; feed the actuator cylinder with air at proper pressure,
indicated on data-sheet for actuator.
5) Tighten the nuts of the connecting stud bolts evenly with the
torque prescribed in the table. The stud bolts must be made of
ASTM A320 L7 steel; the nuts must be made of ASTM A194
grade 2 steel.
6) If possible, operate the actuator to check that it moves the valve
smoothly.
2.4 HYDRAULIC CONNECTIONS
Check that the values of hydraulic supply available are
compatible with those reported on the identification
plate of the actuator.
The connections should be made by qualified staff.

Use pipes, fittings and connections appropriate as for
type, material and dimensions.
Connect the actuator to the hydraulic feed line with fittings and pipes
in accordance to the plant specifications. They must be sized
correctly in order to guarantee the necessary oil flow for the
operation of the actuator, with pressure drops not exceeding the
maximum allowable value. The shape of the connecting piping must
not cause excessive stress to the inlets of the actuator. The piping
must be suitably fastened so as not to cause excessive stress or
loosening of threaded connections, if the system undergoes strong
vibrations. Every precaution must be taken to ensure that any solid or
liquid contaminants, which may be present in the hydraulic pipe-work
to the actuator, are removed to avoid possible damages to the unit or
loss of performance. The inside of the pipes used for the connections
must be well-cleaned before use: wash them with suitable
substances and blow through them with oil or nitrogen. The ends of
the tubes must be well debarred and cleaned. Once the connections
are completed, operate the actuator and check that it functions
correctly, that the operation times meet the plant requirements and
that there are no leakages in the hydraulic connections.

2.5 ELECTRICAL CONNECTIONS (IF ANY)

Use components appropriate as for type, material and
dimensions. The connections should be made by qualified
staff. Before carrying out any operation, cut line power off
Safety provisions :
2006/95/EC: Directive for low voltage equipment (until 19
April 2016) 2014/35/EU from 20 April 2016
2004/108/EC: Directive for the electromagnetic
compatibility (until19 April 2016) 2014/30/EU from 20 April
2016
94/9/CE: Directive and safety instructions for use in
hazardous Area(until 19 April 2016) 2014/34/EU from 20
April 2016
Remove plastic plugs from cables entries
Screw firmly the cable glands.
Introduce connection cables.
Make the connections in compliance with applicable wiring diagrams
on the documentation supplied.
Screw the cable gland.
Replace the plastic plugs of unused entries with metal plugs.
2.6 COMMISSIONING
Installation, commissioning and maintenance and repair
works should be made by qualified staff.
Any calibration relative to functional aspects of the
actuator are preset at the factory.
Before any modifications please contact BIFFI Italia S.r.l.
Upon actuator commissioning please carry out the following checks:
Check that the values of hydraulic supply available in the system are
compatible with those reported on the identification plate of the
actuator (Figure 2) and on the documentation supplied.
Check the power voltage of electrical components complies with the
one reported on the documentation supplied.
Check the absence of leakages in the cylinder and in hydraulic
connections.
Check that paint is intact and in case renovate it according to the
specification on order confirmation.
Carry out all kinds of operations and check their proper execution
(Sect. 3.3).
Make a complete functional test in order to verify all the operations
are executed according to operating schematic diagram supplied.

3 Operation
Operation and use
3.1 OPERATION DESCRIPTION
The actuator is operated by:

1) Pressurized motor fluid.
2) Elastic return of compression helicoidally spring.
In the first case the alimentation fluid pressurizes a chamber of the

cylinder and compresses the spring (Figure 4); this determines the
linear motion of the piston and the consequent rotation motion of the
scotch yoke mechanism to which valve stem is coupled. The fluid
contained in the other chamber is discharged through the return line.
In the second case, cutting off or in case of lack of pressure to the
cylinder and to the pilot of the fast discharge valve, the opening of
the latter is determined, the fast discharge of motor fluid, the quick
extension of the spring and the consequent fast operation of the
actuator. The motor fluid going out from one chamber of the cylinder
partially returns in the other chamber and partially flows through the
discharge line.
For local or remote operations, please refer to technical
documentation furnished with actuators.
For all the relevant information please refer to the specific

documentation supplied.

3.2 RESIDUAL RISKS
The actuator has parts under pressure.

Use the due caution.
Use individual protections provided for by the laws and
provisions in force.
3.3 OPERATIONS
( refer to specific document: operating diagram furnished )
3.3.1 Emergency manual operation
Picture 5 – Olgas with hydraulic manual hand-pump
The OLGAS-H actuators can have an emergency manual override in

addition to the local and/or remote control panel which controls the oil
supplied by a power pack for the “normal” actuator operation.
The emergency manual override mounted on the actuator, consists
of an hydraulic manual override and a hydraulic manual selector to
choose the actuator “Normal operation”, with oil supply from a power
pack, or the “Emergency manual operation”. The compact hydraulic
manual override consists of :
- hand pump to deliver oil from the tank to the actuator cylinder to
control the actuator operation against the spring
- stop valve which allows the connection of the actuator cylinder to
the oil tank to control the actuator operation by spring

- relief valve to prevent the oil pressure delivered by the hand pump
from exceeding the maximum allowable value
- oil tank.
On request the emergency manual override can be included in the
power pack
Picture 6 – Olgas-h with hydraulic power pack
Close the stop valve 5-S

before start with manual
operation.
Actuated the pump 5-P until to
reach the complete operation
Check the correct operation of
the actuator through the visual
position indicator.
Open the stop valve 5-S to
operate to fail-safe position
Note that the stop valve 5-S
must be in open position to
allow the operation with
hydraulic supply.
(see chapt.7.2 table 5: sectional
drawing for hydraulic control unit
MHP)

3.3.2 Remote control operations

BIFFI has the ability to apply advanced engineering technology to the
design and manufacture of hydraulic controls and accessories.
The experience and the knowledge acquired in the actuator industry
allow BIFFI to meet with the highest requirements for control modes
and operating conditions by correct selection of schematics,
components, materials and protection treatment.
The actuator service can be On-Off or Modulating. Actuator control
can be local or remote by electric, or hydraulic signals.
The control system can include devices for automatic operation or
stay put in case of emergency conditions (electric or hydraulic supply
failure, high temperature, low or high pipeline pressure etc.).
The control systems have where is possible a "manifold design": the
components are connected by a flange to the manifold or assembled
into the cavities machined into the manifold. This allows to have a
very "compact" unit to reduce the number of connections by fittings
and pipes and then to make the assembly and disassembly of each
component easier, and to minimise the risk of oil leakage also in
case the system undergoes strong vibrations. Control systems can
be supplied as panel mount or enclosed into a weatherproof cabinet.
Control systems can be supplied separate or assembled onto the
actuator. The actuator housing has dedicated supports for the
mounting of control systems and accessories.
Picture 7 – OLGAS-H with hydraulic control system
BIFFI has the ability to apply advanced engineering technology to the

design and manufacture of hydraulic power packs, in order to meet
with the highest requirements for operating modes and working
conditions by a correct selection of schematics, components,

materials and protection treatment. The energy supply for the power
pack operation can be electric (direct current or alternate current)
and/or pneumatic (low pressure or high pressure). Hand pump
manual override available on request for oil supply to the actuator in
case of energy supply failure.
The power pack components can be supplied panel mounted or
enclosed into a weatherproof cabinet. Sunshade is also available on
request. Power pack can be supplied separate or assembled onto
the actuator (if the dimensions and the weight allow so).
Picture 8 – OLGAS-H with hydraulic power pack

3.4 CALIBRATION OF THE ANGULAR STROKE

The angular stroke of the yoke can be adjusted between 82°÷98°
(±4° with respect to the nominal positions of complet e opening and
closing) by means the mechanical stops screwed at the end of
spring-cartridge, and into the end flange of the pneumatic cylinder
(Picture 8).
Picture 9 – Mechanical stops
For the adjustment of the mechanical stop on the end flange of

cylinder, follow these steps (Figure 10):
Remove with the specific wrench (c2) the plug of cylinder end-
flange.
Insert a wrench for Allen keys (c1) in the through hole until
reaching the adjustment pin.
Turn counter-clockwise to increase the angular stroke, turn
clockwise to decrease it.
When the adjustment is over tighten the plug with the wrench c2.

Figure 10 – Mechanical stop of the cylinder
HYDRAULIC WRENCH WRENCH

CYLINDER C1 C2
DIAMETER (mm) (mm)
From 16 8 19
To 28
From 28 8 22
To 40
From 45 12 27
To 60
From 70 14 36
To 175
From 200 22 36
To 235
From 235 22 36
To 300

For the adjustment of the travel stop screw proceed as follows:

(see figures “B”)
figures “B”
1) Loosen the lock nut “d”.

2) If the actuator angular stroke is stopped before reaching the end
position, unscrew the stop screw “v” by turning it anticlockwise
until the valve reaches the correct position.

3) If the stop-screw is too hard to be operated, reduce or remove the

cylinder pressure, in order to move the mechanism far from the
screw. Operate the setting-screw and then pressurize again the
cylinder to reach end position.
4) If the actuator angular stroke is stopped beyond the end position,
screw the stop screw by turning it clockwise until the valve
reaches the correct position.
5) Tighten the lock nut, after having correctly placed the threaded
seal washer “s” and “w”.
To operate the adjustments refer to followings tables:
SPRING WRENCH C1 WRENCH

CONTAINER (mm) C2
SIZE (mm)
006 46 41
008 46 41
009 46 41
0100 46 41
0150 46 41
SPRING WRENCH C1 WRENCH

CONTAINER (mm) C2
SIZE (mm)
0200 17 60
0350 17 60
0400 17 60
0700 17 60
1100 17 80
1200 17 80
2000 17 80
2500 17 100
3800 17 100
5100 17 100
5400 17 100
8300 17 100
9600 17 100
9800 17 100
11000 17 100
15000 17 130
15600 17 130

3.5 CALIBRATION OF MICROSWITCHES (BIFFI LIMIT

SWITCH BOX ONLY)
Operate only the micro-switch corresponding to the
direction of operation being carried out, as clearly
reported on the micro-switch.
If different micro-switches assembly or limit switch box is
supplied, please refer to the specific documentation.
Micro-switches are placed inside a special box (Picture 10).
For micro-switches calibration please refer to the relative wiring
diagram and follow these steps:
Unscrew the fastening screws of the cover (Picture 10).
Remove the cover paying attention not to deteriorate the gasket
and the cylindrical and flat coupling surfaces.
Operate the actuator (in opening or closing) with local pneumatic
or hydraulic operation (Section 3.3)
Unscrew the screw of the operating cam relative to the micro-
switch to calibrate and adjust it according to the settings (Picture
11).
Tighten the screw.
Operate the actuator and adjust any other micro-switch with the
procedure already described.
Position the cover making sure the cam-carrier shaft grips with
the index dragging shaft.
Check that the cover and the index show the proper position of
the valve (Picture 12).
Tighten the screws.
Picture 10 – Micro- Picture 11 – Cam adjustment

switches box

If the index (Picture 12), does not signal the proper position of the
valve but is turned by 90°:
Remove the roll pin placed on the position indicator (index).
Turn the indicator until reaching its proper positioning.
Put the roll pin back in its position.
End of stroke micro-switches should be operated

before the stop of the stroke of the actuator due to
mechanical stops. Adjust the relative cams properly.
Position pin
indicator
(index)
Picture 12 – Position indicator and pin for

micro-switches box

3.6 CALIBRATION OF THE OPERATION TIME (IF

REQUIRED)
The calibration of the operation time is made by Biffi Italia S.r.L
according to customer requirements and to technical data-sheet
included in technical documentation. If necessary it’s possible to
modify or reset the operating time through two flow regulation valves
(optional) placed on inlets of hydraulic cylinder (see Picture 12 and
the applicable operating diagram).
Picture 12 – Adjustment of operating time by flow-regulator

valve (please refer to specific operating diagram, item 526-530)
To carry out the adjustment, operate the hand-wheel (turn clockwise

the hand-wheel to increase the operating time or turn the hand-wheel
counter-clockwise to decrease the operation time)

4 Operational tests and inspections
Important: To ensure the guaranteed SIL grade, according to

IEC 61508, the functionality of actuator must be
checked with regular intervals of time, as described
in the Safety Manual

5 Maintenance
Before carrying out any maintenance operation, it is
necessary to close the hydraulic feed line and exhaust
the pressure from the actuator cylinder and from the
control unit, to ensure safety of maintenance staff
Installation, commissioning and maintenance and
repair works should be carried out by qualified staff.
5.1 PERIODIC MAINTENANCE

OLGAS actuators are designed to operate long-term in heavy-duty
operating conditions, without maintenance needs.
Periodicity and regularity of inspections is particularly

influenced by specific environmental and working
conditions.
They can be initially determined experimentally and
then be improved according to actual maintenance
conditions and needs.
Before start up and afterwards every 6 months check
accumulator pre-charging pressure (if present : please
check the value from technical data-sheet supplied)
Anyway every 2 years of operation the following is recommended:

Check that the actuator operates the valve correctly and with the
required operating times. If the actuator operation is very infrequent,
carry out a few opening and closing operations with all the existing
controls (remote control, local control, emergency controls, etc.), if
this is allowed by the conditions of the plant.
Check there are no hydraulic or pneumatic leakages. If necessary
tighten the nuts of the pipe-fittings..
Check oil level (Pict. 13) into the hydraulic control unit (see chapt.
5.1.1)
Check the actuators did not undergo accidental damage with oil
leakages found on site (Sect. 4.1.1).
Check that improper closing of control-group cover (if present) did
not produce the presence of condensation on it.
Check the integrity of worn out parts (gaskets, pads etc.).
If there is an oil filter on the actuator, bleed the condense water
accumulated in the cup by opening the drain cock. Disassemble the
cup periodically and wash it with soap and water; disassemble the
filter: if this is made up of a sintered cartridge, wash it with nitrate
solvent and blow through with oil. If the filter is made of cellulose, it
must be replaced when clogged.

Picture 13 – Level measuring stick
5.1.1 Check and restore oil level in the hydraulic control unit (
refer to chapt. 7.2 table 5 )
Operate the distributor lever to “manual operation” to operate valve

and to compress completely the actuator spring.
Move the actuator into his “totally compressed spring” position

Unscrew the dipstick (1).
Check that the oil level into the tank (4) is in correspondence of the
“MAX LEVEL” notch of the dipstick.
Screw and tighten the dipstick.
If necessary substitute or added the oil, proceeding as follow:
Remove the dipstick (1) from the tank cover (22).
Unscrew the plug (27) and the washer (9) to drain all the oil.
If some dirt or/and sludge is found in the oil drained from the tank,
before filling with new oil in the tank, disassemble the oil tank tube,
by unscrewing the two cap nuts (2), and clean the internal surfaces
of the tank. If necessary substitute the gaskets (21) of the tank.
Replace the plug (27) and the washer (9) into the plate (11) and
tighten.
Pour the new oil into the tank through the dipstick hole (1) on the
cover (22).
Replace the dipstick (1).
Add oil (refer to Table 2) if in the tank the oil level is BELOW THE
MINIMUM (Picture 13: minimum level is in correspondence to the
end of dipstick ) until to reach the optimal (MAXIMUM) oil level .

Operate the distributor lever to “Remote” position

For refill use oil of the same brand as the one in the actuator .
tThe cleanliness level for actuator without control-system is
NAS 8 minimum. For actuators with control system the
cleanliness level is that required by singles components, in any
case Biffi Italia S.r.L respect the customer requirements to
scope of supply, for applicable cleanliness level, refer to
document: technical data-sheet for actuators
Table 2: features of hydraulic oil suggested by BIFFI Italia S.r.l for refilling
in different working condition:
Standard temperature conditions (-30°C/+85°):
Producer AGIP
Name ARNICA 22
Viscosity at 40° C 20.9 mm²/s
Viscosity at 100° C 4.73 mm²/s
Viscosity index ASTM 153
Flash point 192° C
Pour point -42° C
Specific weight (at 15°C) 0,857 Kg/l
Equivalent oils: SHELL TELLUS PLUS 22
CHEVRON HYDRAULIC OIL AW ISO 22
MOBIL DTE22
EXXON UNIVIS N22
EQUIVIS ZS22
BP ENERGOL HLP-HM22
CASTROL DYSPIN AWS22
Low temperature conditions (until -46°C):
Manufactured SHELL
Name AEROSHELL
FLUID 41
Viscosity at -54° C 2300 cST
Viscosity at 40° C 14,1 cST
Viscosity index (ISO 2909) >200
Flash point 105° C
Pour point <-60° C
Specific weight 0,87 Kg/dm3
(or equivalent)
Low temperature conditions (until -60°C):
Manufactured SYNTESIS
Name SYNTRASS-CS
500

Viscosity at -30° C 39cST

Flash point 152° C
Pour point -68° C
Specific weight 0,897 Kg/dm3
(or equivalent)
5.2 EXTRAORDINARY MAINTENANCE

If there are leaks in the hydraulic cylinder, or a malfunction in the
mechanical components, or in case of scheduled preventive
maintenance, the actuator must be disassembled and seals must be
replaced with reference to the follow general sectional drawing and
adopting the following procedures:
If the actuator can be operated, it is essential to take it to fail
safe position, with the spring totally extended, otherwise the
actuator should be disassembled from the valve and follow
these steps:
Remove the plug (27) from the cylinder end flange
Record the length between end flange (26) and stop-setting
screw (21), as in figure A

Bring the adjustment screw back to the maximum (20) to let the
spring loosen.
Before disassembling the cylinder, make sure the above

operation of spring release is done.
5.2.1 Replacement of cylinder seal
1) Unscrew the plug (27) from the cylinder end flange

2) Measure the distance of the stop screw (21) with reference to the
end flange (26) surface, so as to be able to easily restore the
setting of the actuator mechanical stop, once the maintenance
procedures have been completed.
3) Unscrew the stop screw (21) by turning it anticlockwise with an
Allen wrench until the screw is completely with drawn inside the
end flange threaded hole.
4) Unscrew the nuts (28) from the tie rods (19) : they must be
gradually unscrewed all at the same time.
5) Slide off the end flange (26) and the tube (22).
6) If the actuator control unit requires the cylinder chamber head
flange side to be also filled with gas, and the piston rod seal ring
(51) to be replaced, remove the screw (36) and the cover (35).
Unscrew the piston rod (18) threaded end from the adaptor bush
(33) of the guide block (14). Slide off the piston rod (18) from the
head flange (34).
7) Disassemble the head flange (34) from the mechanism housing
(8) by removing the screws (17) only if the gaskets (46) and (48)
have to be replaced because damaged.
Seals replacement
Prior to reassemble check that the actuator components are in good

conditions and clean. Lubricate all the surfaces of the parts, which
move in contact with other components, by recommended oil
(SHELL Omala S4 WE 320 or equivalent). If the O-ring must be
replaced, remove the existing one from its groove, clean the groove
carefully and lubricate it with protective oil film. Assemble the new O-
ring into its groove and lubricate it with a protective oil film.
1) Replace the O-ring (50) of the head flange (34).
2) Replace the O-ring (50) of the end flange (26).
To replace the piston rod seal rings (51) proceed as follows :
1) Remove the existing Teflon seal ring (51) with its O-ring from their
groove.

2) Clean the groove carefully and lubricate it with a protective oil film.
3) Assemble the new O-ring into its groove and lubricate it with a
protective oil film.
4) Assemble the new Teflon seal ring (51) into the flange groove,
inside its rubber O-ring, by bending it : take care that the bending
radius is as large as possible to avoid damaged the seal. Then
enlarge the seal ring with your fingers so as to restore its round
shape: pay attention not to utilise any tools, which can damage the
seal ring.
To replace the piston seal ring (53) proceed as follows :

1) Remove the existing Teflon seal ring (51) with its O-ring from their
groove.
2) Clean the groove carefully and lubricate it with a protective oil film.
3) Assemble the new O-ring into its groove and lubricate it with a
protective oil film.
4) Assemble the new Teflon seal ring (51) on its rubber O-ring by
introducing one side of it into the groove, then enlarge it with your
fingers so as to fit it into the groove: take care to enlarge it
uniformly without any tools which could possibly damage it. The
elastic memory of the kind of Teflon the seal ring is made of allows
the ring to shrink back to its previous dimension after a short time.
Reassemble :
1) Assemble the new gasket (46-48) after cleaning the surfaces of
housing (8), the flange (47) and head flange (34) which are in
contact.
2) Assemble the head flange (34), replace the washers if damaged,
tighten the screws (17) to the recommended torque.
3) Lubricate the piston rod (18) surface, with a protective oil film and
introduce it into the head flange hole, taking care not to damage
the O-ring (48). Carefully clean the threaded end of the piston rod
(18) and the threaded hole of the adaptor bush (33) of guide block
(14). Spread some sealant Loctite 452, or equivalent, on the rod
threaded end and tighten.
4) Carefully clean the inside of the tube (22) and check that the entire
surface, particularly that of the bevels, is not damaged. Lubricate
with a protective oil film the tube internal surface and the bevels at
the ends. Slide the tube onto the piston taking care not to
damaged the Teflon seal ring (53): the tube bevel has to smoothly
compress the seal ring; take care also not to damage the head
flange O-ring (50).

5) Assemble the end flange by centring it on the inside diameter of

the tube, taking care not to damage the O-ring (50).
6) Assemble the nuts (28) onto the tie rods (19). Tighten the nuts to
the recommended torque, alternating between opposite corners.
7) Restore a generous coating of grease on the contact surfaces of
the yoke (11) and the bushings (41), on the yoke grooves, on the
sliding blocks (39), on guide bar (9).
8) Assemble the new gasket (10) after cleaning the surfaces of the
housing (8) and cover (35)
9) Lubricate with protective oil the O-ring (40).
10) Assemble the cover (35) and the screws (36). Tighten the screws
to the recommended torque.
11) Screw the stop screw (21) by turning it clockwise with an Allen
wrench until it reaches its original position (the same distance with
reference to the end flange surface).
12) Screw the plug (25) into the cylinder end flange.
Carry out a few operations (Sect. 3.3) to check there

are no leakages from the gaskets.


5.3 LUBRICATION OF MECHANISM

For normal duty the scotch yoke mechanism of the actuator is
lubricated "for life". In case of high load and high frequency of
operation it may be necessary to periodically restore lubrication: it is
advisable to apply a generous coating of grease on the contact
surfaces of the yoke and bushings, on the yoke link grooves, on the
sliding blocks, on the guide bar.
For this operation it is necessary to disassemble the mechanism
cover. In larger actuators the lubrication can be performed through
the inspection holes of the cover after removing the plugs.
It’s necessary restore the grease into spring-cartridge (for this
operation remove the plug on end-flange of spring-cartridge and
restore a generous coating of grease)
The following grease is used by BIFFI for standard working
temperature and suggested for re-lubrication:
AGIP MU/EP/2 AEROSHELL GREASE 7 or

equivalent
To be used in standard temperature To be used in low temperature
conditions (-30°C/+85°C) conditions
(-60°C/+65°C)
NLGI consistency: 2
Worked penetration: 280 dmm Colour: Buff
ASTM Dropping Point: 185°C Physical state: Semi-solid at
ambient temperature
Base oil viscosity at 40°C: 160 mm²/s
Odour : Slight
ISO Classification: L-X-BCHB 2
Density : 966 Kg/m³ at 15°C
DIN 51 825: KP2K – 20
Flash Point : ›215°C (COC)(Based
on synthetic oil)
Equivalent to: ESSO BEACON EP2 Dropping point : 260°C (ASTM D-
BP GREASE LTX2 566)
SHELL ALVANIA GREASE R2 Product code : 001A0065
ARAL ARALUB HL2 Infosafe No.: ACISO GB/eng/C
CHEVRON DURALITH GREASE EP2
CHEVRON SPHEEROL AP2
TEXACO MULTIFAK EP2
MOBILPLEX 47
PETROMIN GREASE EP2

5.4 DISMANTLING AND DEMOLITION
Before starting the disassembly a large area should be created

around the actuator so to allow any kind of movement without
problems of further risks created by work-site.
Before disassembling the actuator it is necessary to close the
hydraulic supply line and discharge pressure from the cylinder
of the actuator, from the control unit and from the accumulator
tank, if present. If the actuator can be operated, it is essential to
take it to fail safe position, with the spring totally extended
If actuator is still mounted onto the valve, loosen the threaded
connections between valve and actuator (screws, tie rods, nuts)
Lift the actuator using the proper lifting points (see chapter 2.2).
If the actuator needs storage, before demolition, see chapter 2.3.
The demolition of the actuator both concerning any electrical
and mechanical parts should be made by specialized staff
Separate the parts composing the actuator according to their nature
(ex. metallic, and plastic materials, fluids etc.) and send them to
differentiated waste collection sites, as provided for by the laws and
provisions in force.

6 Troubleshooting
6.1 FAILURE OR BREAKDOWN RESEARCH
Event Possible cause Remedy

Actuator does not Lack of power supply Restore it
work
Lack of hydraulic Open line interception
supply valve
Failure of the spring Call BIFFI Italia S.r.l.
Customer Service
Blocked valve Repair or replace
Wrong position of the Restore correct
distributor of the position
manual hydraulic group
Failure of the control Call BIFFI Italia S.r.l.
group Customer Service
Unexpected Call BIFFI Italia S.r.l.
intervention of torque Customer Service
limit-device
Actuator too slow Low supply pressure Restore (Sect. 1.4)

Wrong calibration of Restore (Sect. 3.6)
flow regulator valves
Bad functioning of Call BIFFI Italia S.r.l.
quick exhaust valve Customer Service
Wear of the valve Replace
Actuator too fast High supply pressure Restore (Sect. 1.4)
Bad functioning of Call BIFFI Italia S.r.l.
booster/quick exhaust Customer Service
valve
Wrong calibration of Restore (Sect. 3.6)
flow regulator valves
Leakages on Deterioration and/or Call BIFFI Italia S.r.l.
hydraulic or damage to gaskets Customer Service.
pneumatic circuits
Incorrect position of Wrong adjustment of Restore (Sect. 3.4)
the valve mechanical stops
Wrong warning of Restore (Sect. 3.5)
microswitches
Hydraulic manual handle positioned on Position the handle on
pump does not work remote control the indication of the
operation to make
Leakages on the check Call BIFFI Italia S.r.l.
valve of the hydraulic Customer Service
control group

7 Layouts
7.1 SPARE PARTS ORDER
For spare parts order to the relevant BIFFI office please make
reference to BIFFI order confirmation concerning all the supply, and
serial number of the actuator (Sect. 1.2) for any specific spare part
for a specific actuator model.
Please send every spare-parts request to :
BIFFI ITALIA s.r.l. - Servizio Assistenza Tecnica Clienti
Tel. : 0523-944523__________
Fax: 0523-941885__ e-mail: spareservice@biffi.it________
please specify :
1. actuator model;
2. BIFFI acknowledgement ;
3. spare parts code;
4. quantity;
5. transport condition;
6. involved people.

7.2 PARTS-LIST FOR MAINTENANCE AND REPLACING

PROCEDURE
Table 1: Scotch-yoke mechanism

Table 2: hydraulic cylinder

Table 3: Spring cartridge

Table 4: assembly kit

Table 5: Hydraulic control unit MHP



8 Date report for maintenance

operations
Last maintenance operation date : ( in factory, on delivery ): …..
……… exec. by : …………

……… exec. by : …………
……… exec. by : …………
Next maintenance operation date: ……… exec. by : …………

……… exec. by : …………
……… exec. by : …………
Start-up date : ( in factory, on delivery ).…………………….
( on plant ) .…………………….

Instruction and operating manual
BIFFI ITALIA srl

Loc. Caselle S. Pietro n. 420, 29017 Fiorenzuola d’Arda (PC) ITALY
Tel. (0523) 94.44.11 - Fax (0523) 94.18.85 – e_mail: biffi_italia@biffi.it
Società unipersonale – Direzione e coordinamento di Pentair Valves & Controls Inc.,
Stati Uniti.
Cap. Soc. € 1.820.000 i. v. – Registro Imprese di Piacenza / Cod. Fisc. / P. IVA n. 01018580330
R.E.A. di Piacenza n. 121628 - Meccanografico PC 002799
© Copyright by BIFFI Italia srl. All right reserved.

3. SAFETY INSTRUCTIONS FOR BIFFI

ELECTRIC COMPONENTS ENCLOSURE

3.1. Limit Switch Box

Enclosure for limit switches and/or position transmitter
Safety Instruction and Operating Manual – MAN 673
MAN 673
Safety Instruction and Operating Manual
Enclosures Type:
34285-79
34286-79
© Copyright by BIFFI Italia. All right reserved.

Updated applicable
4 18/04/2016 regulation (chapter 1.1.1)
Ermanni Orefici
3 12/04/2011 Revision Montagna Alfieri
2 22/11/2007 Revision Montagna Alfieri
1 25/09/2006 Revision Masini Alfieri
0 18/09/2006 Issue document Masini Alfieri
Rev. Date Description Prepared Approved
BIFFI ITALIA has taken every care in collecting and verifying the documentation
contained in this Instruction and Operating Manual.
The informations herein contained are reserved property of BIFFI ITALIA.

INDEX
1 GENERAL SAFETY INSTRUCTIONS 1
2 CHECK FOR RIGHT APLICATION 2
2.1 Applicable standards and regulations: 3
2.2 Terms and conditions 3
2.3 Manufacturer’s Liability 3
3 STORAGE AND PRE-INSTALLATION 4
3.1 Storage procedure 4
3.2 Checks to be performed before installation 4
4 INSTALLATION 5
4.1 Working condition 5
4.2 Electrical connections 5
4.3 Removing the electrical enclosures’ covers 6
4.4 Identification of entries 7
4.5 Cable entries 8
4.6 Setting of internal LSWE 10
4.7 Instructions for the explosion-proof enclosures 11
4.8 Installation in ambient with explosive dusts 12
5 MAINTENANCE 12
5.1 Periodic Inspections 12
5.2 Repairs 13
5.3 Spare Parts 13
© Copyright by BIFFI Italia. All right reserved. Page i

© Copyright by BIFFI Italia. All right reserved. Page ii

1 GENERAL SAFETY INSTRUCTIONS
The devices to which this Instruction and Operating Manual (IOM) applies
are Limit Switch Enclosures Series 34285-79 and Series 34286-79, which
are designed for use on actuators for industrial valves suitable to be installed
on heavy industrial, chemical, petrochemical, plants.
The LSWE are produced by BIFFI ITALIA and identified by Product
designation: LSWE type 34xxxxx
Warning: It is assumed that the installation, the setting,

the commissioning and the maintenance and
repair works are carried out by qualified
personnel and checked by responsible
Specialists.
The LSWE are designed in accordance with the applicable International

Rules and Specifications but in any case the following Regulation must be
observed:
• the general installation and safety regulations
• the proper use of personal protective devices (glasses, clothing, gloves,)
• the proper use of tools, lifting and transport equipment.
Warning: In case the LSWE must be installed in

HAZARDOUS AREA, as defined by the local
Rules, it is mandatory to check if the nameplate
of the LSWE specifies the appropriate degree of
protection.
Maintenance and repair works are carried out by
qualified personnel and checked by responsible
Specialists.
© Copyright by BIFFI Italia. All right reserved. Page 1

2 CHECK for RIGHT APLICATION

Before the installation check for protection mode and for the maximum
ambient temperature written on the label: installation in ambient with the
presence of explosive atmosphere not covered by the specified grade of
protection, or which could reach temperature higher than the maximum
specified on the label, will invalidate the safety and the warranty.
Two versions are available:

Series 34285-79 without internal heater with T(amb) = 85 °C max;
Series 34286-79 with internal heater with T(amb) = 80°C max.
Important After de-energization the temperature of the internal

components of the enclosure type 34285-79 remains
below 85°C for both T6 and T5 classes.

2.1 Applicable standards and regulations:
2006/42//EC Machinery Directive.

2006/95/EC: Directive for low voltage equipment (until 19 April 2016)
2014/35/EU from 20 April 2016
2004/108/EC: Directive for the electromagnetic compatibility (until19 April 2016)
2014/30/EU from 20 April 2016
94/9/CE: Directive and safety instructions for use in hazardous area (until 19
April 2016) 2014/34/EU from 20 April 2016
EN ISO 12100-1 Safety of machinery - Basic concepts, general principles
for design.
Part 1-Basic terminology, methodology.
EN ISO 12100-2 Safety of machinery - Basic concepts, general principles
for design.
Part 2-Technical principles and specification.
EN 60079-0: 2009 IEC 60079-0:2007
EN 60079-1: 2007 IEC 60079-1: 2007
EN 60079-31: 2009 IEC 60079-31: 2008
2.2 Terms and conditions

Biffi Italia guarantees each single product to be free from defects and to
conform to current goods specifications. Except when differently specified,
the warranty period in one year from the date of installation by the first user,
or eighteen months from the date of shipment to the first user, whichever
occurs first. No warranty is given for products which have been subject to
improper storage, improper installation, misuse, or which have been
modified or repaired by unauthorised personnel.
Repair works due to improper use will be charged at standard rates.
2.3 Manufacturer’s Liability
Biffi Italia declines all liability in the event of:

• Use of product in contravention of local safety at work legislation.
• Incorrect installation, disregard or incorrect application of the
instructions provided on the product nameplate and in this Instruction
and Operating Manual.
• Modification of the product without Biffi’s authorisation.
• Work done on the product by unqualified or unsuitable personnel.
3 STORAGE AND PRE-INSTALLATION
3.1 Storage procedure

Important:
Not performing the following procedures will
invalidate the product guarantee.
The LSWE leaves the factory in perfect condition. When mounted on the
actuator they are guaranteed by the actuator test certificate. In order to
maintain these characteristics until the LSWE is installed on site, proper
procedures must be taken for preservation during the storage period.
BIFFI LSWEs are weatherproof to IP66/68. IPX8 is rated for a submersion
at a depth of 50 metres for 96 hours. This condition can only be maintained
if the units are correctly installed/connected on site and if they have been
correctly stored. The standard plastic plugs used to close the cable entries
are not weatherproof, they just prevent the entry of undesired objects during
transport.
STORAGE for a BRIEF PERIOD (less than one year):
- if the LSWE are supplied with standard plastic plugs, remove them from
the cable entries and replace them with weatherproof plugs.
STORAGE for a LONG PERIOD (more than one year):
- if the LSWE are supplied with standard plastic plugs, replace them with
weatherproof plugs.
3.2 Checks to be performed before installation

The electrical supply cables must be in accordance with the wiring diagram
(see the wiring diagram that comes with the LSWE).
If a long storage period has occurred, before reinstalling the LSWE, the
following checks must be carried out:
- the status of the O-Ring seals.
- the installation of the plugs or cable glands on the cable entries.
- whether the enclosure covers or the LSWE body are cracked or broken.

4 INSTALLATION
4.1 Working condition
The LSWE Series 34285-79 are suitable for the following ambient
temperatures:
from -60°C/-40°C/-30°C up to +70°C (*)
from -60°C/-40°C/-30°C up to +85°C (*)
The LSWE Series 34286-79 are suitable for the following ambient
temperatures:
from -60°C/-40°C/-30°C up to +65°C (*)
from -60°C/-40°C/-30°C up to +80°C (*)

Note (*): different temperatures depend from material of construction and seals
and temperature classes.
Important: For the correct utilisation with respect to the

safety and the functionality of the enclosures
components, check the "temperature ambient
range" embossed on the nameplate.
4.2 Electrical connections

Before applying voltage to the LSWE check that the electrical parameters
(supply voltage and current) shown on the nameplate, are correct for this
installation.
Important: The installation and maintenance must be

carried out in accordance to the applicable rules
regarding the electrical installations in
hazardous area (other than mines) classified as
Zone 1 (gas): IEC/EN 60079-10; IEC/EN 60079-14;
IEC/EN 60079-17 and/or other national
standards.

4.3 Removing the electrical enclosures’ covers
Warning: Pay attention do not damage the joint surface of

the covers.
Important: In case the screws of the cover must been

replaced a Stainless Steel ASTMA193/A193M
Class 2 Grade B8M must be used with minimum
yield strength of 665 N/mm2
Using a 6mm Allen key, loosen the four

screws fixing the cover and remove it.
At the end of wiring connections replace
the cover and fix the 4 screws with a
tightening torque from 15 to 20 Nm.
Connect the external wiring in

accordance to the attached
wiring diagram.

4.4 Identification of entries
LSWE is equipped with maximum 4 entries.

With reference to the above picture, the thread form/size for each entry is as follows:
Standard Alternatives
Entry Size
NPT NPT Metric ISO 965
A ¾” 1” ½” M25x1,5
M25x1,5 M32x1,5
B ¾” 1” M25x1,5 M32x1,5
C ¾” 1” M25x1,5 M32x1,5
D ¾” 1” M25x1,5 M32x1,5
Important When alternative entries are used, indication of the

dimensions is imprinted directly on the housing close
to the entry.

4.5 Cable entries

The sealing of cables and conduit entries should be carried out in accordance
with National Standards or the Regulatory Authorities that have certified the
LSWEs. This is particularly true for units that are certified for use in hazardous
areas where the method of sealing must be to an approved standard and cable
glands, reducers, plugs and adapters must be approved and separately certified.
External Ground Stud
Important: To prevent any water infiltration through the line

cable conduits, be sure the cable glands used
have the minimum degree of protection required
by the plant.
Remove the cable entry plugs.

To guarantee weatherproof and explosionproof fit, screw the cable glands
tightly (at least 5 turns) and block them with a thread sealant. The use of a
thread sealant is necessary in case of explosionproof capability.
If some parts of the cable glands have been removed during work on the cable
entries put them back into place now to avoid losing the dismantled parts.
Important: The cables MUST be selected considering the

maximum Temperature of the cable indicated on
the label fixed to the Limit Switches Enclosure.

Unused entries:
• for explosionproof construction:
unused entries must be plugged with metal explosionproof plugs and blocked
with a thread sealant;
• for weatherproof construction:
replace the plastic standard protection plugs supplied with the LSWE with
metal plugs.

4.6 Setting of internal LSWE
Important: The removal of any other covers without Biffi's

approval will void the warranty. Biffi will not
accept responsibility for any damage or
deterioration that may occur as a result of cover
removal
Terminate the ground connections to the ground stud marked. One internal and
one external ground studs are provided. Check the wiring diagram (always
enclosed with the LSWE), to ensure a correct electrical connection. All
terminations should be made with insulated ring or spade connectors using the
appropriate crimping tool. This operation will ensure easy and correct electrical
connection.
The internal terminals of the LSWE are also numbered according to the wiring
diagram. To set the limit switches proceed as follows (see wiring diagram):
Unscrew the clamp screw of the cover. Remove the cover taking care not to
damage the cylindrical and flat coupling surfaces, the O-ring or the gasket.
Bring the valve to the fully open position. Loosen the screw related to the cam,
which actuates the "OPEN VALVE" microswitch.
Set the cam position so as to cause the microswitch operation: after tripping,
turn the operating cam once more and tighten the screw. Bring the valve to the
fully closed position and proceed with the setting of operating cam related to
the "CLOSED VALVE" microswitch with a similar procedure as for "OPEN
VALVE" limit switch setting.
Reassemble the cover and tighten the screws. The limit switches enclosure is
equipped with the indicator, which locates the position of the valve with
reference to the inscriptions "open" and "closed" written on the cover. If
necessary, for a correct indication of the valve position, the indicator can be
turned by 90° with reference to the upper shaft, by removing the pin and
reassembling it in the position at 90°; the cover can also be rotated by 90° with
reference to the box, so that the inscriptions are in the right position, by moving
the position of the reference pin by 90°.

4.7 Instructions for the explosion-proof enclosures
During the dismantling and subsequent reassembling of the explosion-proof

enclosures (covers, cable glands, joints) be careful to bring these enclosures
back to their original condition to maintain their integrity.
In particular, be sure the joint surfaces of all enclosures are spread with a film
of Aeroshell grease.
So the following procedure must be followed:
• Do not damage the explosion-proof mating surfaces on the housing and on
the electrical enclosures covers.
• Reinstall all the screws that go with the dismantled parts, and block them
with a thread sealant after spreading them with a film of copper- or
molybdenum-based grease. This will keep screws from sticking and make
maintenance operations easier.
• Check that the bolts and screws are the same dimension and quality as the
original ones (as stated on this Manual), or of a better quality.
Warning: Do not operate the LSWE electrically when the

electrical enclosures are removed. Operating the
unit with the electrical enclosures removed
could cause personal injury.
• Replace the weatherproof seals that may have been removed (O-Ring for
the cover, O-Rings for the transmission shaft).

4.8 Installation in ambient with explosive dusts
Important: The installation and maintenance must be

carried out in accordance with IEC/EN 61241-14
Special attention must do to these following points:

• before the assembly the joint surfaces must be greased with Aeroshell
grease.
• the cable glands must have a protection degree at minimum IP66/68
(IEC/EN 60529).
• periodically verify the quantity of dust deposited on the enclosure and
clean it in the case the quantity becoming more than 5mm.
5 MAINTENANCE
Warning: In case the Limit Switches Enclosures Series 34285-

79/34286-79 are installed in HAZARDOUS AREAS,
as defined by the local Rules, the maintenance and any
repair works must be carried out by personnel
specifically qualified and fully trained for works in
HAZARDOUS AREAS.
5.1 Periodic Inspections
a) Inspect the Limit Switches Enclosure at regular intervals: frequency of

inspection may depend form the installation and working conditions: in
general one inspection for year is recommended.
b) Kip the Limit Switches Enclosure external surface clean: if the Limit
Switches Enclosure is installed in a dusty environment the specification
stated in IEC/EN 61241-14 be followed ensuring in particular that the
dust layer does not exceed 5 mm.
c) Check the condition of cable connection and mounting bolts: any loose
connection must be amended.

5.2 Repairs
When needed, repair must only be carried out with Manufacturer’s original
spare parts.
Warning The values of gaps of explosion-proof joints are lower

than the maximum specified on Table 2 of IEC/EN
60079-1 Standard. In case the maintenance should
require the replacement of any component which forms
part of an explosion-proof joint, only an original spare
provided by BIFFI MUST be used. Direct repair or
reconstruction of the above components are not
permitted without the BIFFI permission. Not
performing this procedure will invalidate the product
safety and contractual guarantee.
When needed, repair must only be carried out with Manufacturer’s original
spare parts.
5.3 Spare Parts
Original spare parts must be required to the Manufacturer: to ensure that

right spare is provided, serial number printed on the Limit Switches
Enclosure label must be specified when spares are ordered.

BIFFI ITALIA s.r.l. –

Loc. Caselle S. Pietro –
29017 Fiorenzuola d’Arda -Piacenza - ITALY –
Tel. (0523) 944411 - Fax (0523) 941885
E_mail: biffi_italia@biffi.it

4. TECHNICAL DATA SHEET
ITEM NUMBER 01 02 03 04 05
LV-0300A
LV-0300B
LV-0301C
LV-0300D
Tag number LV-0301F LV-0006A LV-0006B PV-0206
LV-0300E
LV-0301J
LV-0300G
LV-0300H
OLGAS-H OLGAS-H OLGAS-H OLGAS-H OLGAS-H
Actuator model
0.9S-0400-70-OP 0.9C-0400-70-CL 6C-2500-125-CL 6C-2500-125-CL 0.3C-0100-40-CL
Ambient temperature (°C) From -35 To +35 °C From -35 To +35 °C From -35 To +35 °C From -35 To +35 °C From -35 To +35 °C
Medium data
Medium type: Oil Oil Oil Oil Oil
Medium name and manufacturer: Aeroshell Fluid 41 Aeroshell Fluid 41 Aeroshell Fluid 41 Aeroshell Fluid 41 Aeroshell Fluid 41
Minimum supply pressure (Bar g) 98 98 98 98 98
Operating times
To open: (Sec.) 5 5 5 5 5
To close: (Sec.) 5 5 5 5 5
Solenoid valve
Supply voltage: (V) N/A N/A N/A N/A N/A
Supply type N/A N/A N/A N/A N/A
Power consumption: (W) N/A N/A N/A N/A N/A
Microswitches
Type: SPDT SPDT SPDT SPDT SPDT
BIFFI BIFFI BIFFI BIFFI BIFFI
Manufacturer - Model:
Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT
Protections of electric components enclosure

Weatherproof (for limit switch box+positioner): IP66 IP66 IP66 IP66 IP66
Explosionproof (for limit switch box+positioner): Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2
Weatherproof (for solenoid valve): N/A N/A N/A N/A N/A
Explosionproof (for solenoid valve): N/A N/A N/A N/A N/A
Settings
Relief valve (item 395) : (Bar g) N/A N/A N/A N/A N/A
Electric pressure switch (item 519) : (Bar g) N/A N/A N/A N/A N/A
Electric control signal for positioner

Valve closed: (mA) 4 4 4 4 4
Valve open: (mA) 20 20 20 20 20
ITEM NUMBER 06 07 08 09 10
PV-0201C PV-0508C PV-0504C
Tag number PV-0205 PV-0201F FV-0306 PV-0508F PV-0504F
PV-0201J PV-0508J PV-0504J
OLGAS-H OLGAS-H OLGAS-H OLGAS-H OLGAS-H
Actuator model
0.3S-008C-35-CL 1.5C-1100-95-OP 0.9C-0700-85-CL 3C-2000-110-CL 1.5C-1100-95-OP
Medium data
Minimum supply pressure (Bar g) 98 98 98 98 97
Operating times
To open: (Sec.) 5 5 5 5 5
To close: (Sec.) 5 5 5 5 5
Solenoid valve
Microswitches
BIFFI BIFFI BIFFI BIFFI BIFFI
Manufacturer - Model:
Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT

Weatherproof (for limit switch box+positioner): IP66 IP66 IP66 IP66 IP66
Explosionproof (for limit switch box+positioner): Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2
Settings

Valve closed: (mA) 4 4 4 4 4
Valve open: (mA) 20 20 20 20 20

ITEM NUMBER 11 12 13 14 15
CFI-001
Tag number LV-0310C LV-0310F LV-0310J FV-0311C
CFI-002
CENTRALE OLGAS-H OLGAS-H OLGAS-H OLGAS-H
Actuator model
COMUNE CFI 0.9S-0400-70-OP 0.9S-0400-70-OP 0.9S-0400-70-OP 0.3C-0150-45-OP
Medium data
Minimum supply pressure (Bar g) 98 98 98 87
Operating times
To open: (Sec.) N/A 5 5 5 5
To close: (Sec.) N/A 5 5 5 5
Solenoid valve
Microswitches
Type: N/A SPDT SPDT SPDT SPDT
BIFFI BIFFI BIFFI BIFFI
Manufacturer - Model: N/A
Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT

Weatherproof (for limit switch box+positioner): N/A IP66 IP66 IP66 IP66
Explosionproof (for limit switch box+positioner): N/A Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2
Settings

Valve closed: (mA) N/A 4 4 4 4
Valve open: (mA) N/A 20 20 20 20
ITEM NUMBER 16 17 18 19 20
LV-0301C
Tag number FV-0311F FV-0311J LV-0016 FV-0005 LV-0301F
LV-0301J
OLGAS-H OLGAS-H OLGAS-H OLGAS-H CONTROL CABINET
Actuator model
0.3C-0150-45-OP 0.3C-0150-45-OP 1.5C-1100-95-OP 1.5C-1200-110-OP FOR ITEM 01
Medium data
Minimum supply pressure (Bar g) 87 87 98 98 N/A
Operating times
To open: (Sec.) 5 5 5 5 N/A
To close: (Sec.) 5 5 5 5 N/A
Solenoid valve
Supply voltage: (V) N/A N/A N/A N/A 125
Supply type N/A N/A N/A N/A DC
Power consumption: (W) N/A N/A N/A N/A 30
Microswitches
BIFFI BIFFI BIFFI BIFFI
Manufacturer - Model: N/A
Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT Magnum XT-90 SPDT

Weatherproof (for limit switch box+positioner): IP66 IP66 IP66 IP66 N/A
Explosionproof (for limit switch box+positioner): Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 Ex-d IIB +H2 N/A
Weatherproof (for solenoid valve): N/A N/A N/A N/A IP66/67
Settings
Relief valve (item 395) : (Bar g) N/A N/A N/A N/A 110
Electric pressure switch (item 519) : (Bar g) N/A N/A N/A N/A 40

Valve closed: (mA) 4 4 4 4 N/A
Valve open: (mA) 20 20 20 20 N/A

ITEM NUMBER 21 22 23 24 25
LV-0300A
LV-0300B
LV-0300D
Tag number LV-0006A LV-0006B PV-0206 PV-0205
LV-0300E
LV-0300G
LV-0300H
CONTROL CABINET CONTROL CABINET CONTROL CABINET CONTROL CABINET CONTROL CABINET
Actuator model
FOR ITEM 02 FOR ITEM 03 FOR ITEM 04 FOR ITEM 05 FOR ITEM 06
Medium data
Minimum supply pressure (Bar g) N/A N/A N/A N/A N/A
Operating times
To open: (Sec.) N/A N/A N/A N/A N/A
To close: (Sec.) N/A N/A N/A N/A N/A
Solenoid valve
Supply voltage: (V) 125 125 125 125 125
Supply type DC DC DC DC DC
Power consumption: (W) 30 30 30 30 30
Microswitches
Type: N/A N/A N/A N/A N/A
Manufacturer - Model: N/A N/A N/A N/A N/A

Weatherproof (for limit switch box+positioner): N/A N/A N/A N/A N/A
Explosionproof (for limit switch box+positioner): N/A N/A N/A N/A N/A
Weatherproof (for solenoid valve): IP66/67 IP66/67 IP66/67 IP66/67 IP66/67
Settings
Relief valve (item 395) : (Bar g) 110 110 110 110 110
Electric pressure switch (item 519) : (Bar g) 40 40 40 40 40

Valve closed: (mA) N/A N/A N/A N/A N/A
Valve open: (mA) N/A N/A N/A N/A N/A
ITEM NUMBER 26 27 28 29 30
PV-0201C PV-0508C PV-0504C
Tag number PV-0201F FV-0306 PV-0508F PV-0504F LV-0310C
PV-0201J PV-0508J PV-0504J
CONTROL CABINET CONTROL CABINET CONTROL CABINET CONTROL CABINET
Actuator model HPU FOR ITEM 10
FOR ITEM 07 FOR ITEM 08 FOR ITEM 09 FOR ITEM 12
Medium data
Operating times
Solenoid valve
Supply voltage: (V) 125 125 125 125/24 125
Microswitches

Settings
Relief valve (item 35): (Bar g) 110 110 110 110 110
Electric pressure switch : (Bar g) 40 40 40 40 40


ITEM NUMBER 31 32 33 34 35
Tag number LV-0310F LV-0310J FV-0311C FV-0311F FV-0311J
CONTROL CABINET CONTROL CABINET CONTROL CABINET CONTROL CABINET CONTROL CABINET
Actuator model
FOR ITEM 13 FOR ITEM 14 FOR ITEM 15 FOR ITEM 16 FOR ITEM 17
Medium data
Operating times
Solenoid valve
Supply voltage: (V) 125 125 125 125 125
Microswitches

Settings
Relief valve (item 35): (Bar g) 110 110 100 100 100
Electric pressure switch : (Bar g) 40 40 40 40 40

ITEM NUMBER 36 37
Tag number LV-0016 FV-0005
CONTROL CABINET CONTROL CABINET
Actuator model
FOR ITEM 18 FOR ITEM 19
Ambient temperature (°C) From -35 To +35 °C From -35 To +35 °C
Medium data
Medium type: Oil Oil
Medium name and manufacturer: Aeroshell Fluid 41 Aeroshell Fluid 41
Minimum supply pressure (Bar g) N/A N/A
Operating times
To open: (Sec.) N/A N/A
To close: (Sec.) N/A N/A
Solenoid valve
Supply voltage: (V) 125 125
Supply type DC DC
Power consumption: (W) 30 30
Microswitches
Type: N/A N/A
Manufacturer - Model: N/A N/A

Weatherproof (for limit switch box+positioner): N/A N/A
Explosionproof (for limit switch box+positioner): N/A N/A
Weatherproof (for solenoid valve): IP66/67 IP66/67
Explosionproof (for solenoid valve): N/A N/A
Settings
Relief valve (item 35): (Bar g) 110 110
Electric pressure switch : (Bar g) 40 40

Valve closed: (mA) N/A N/A
Valve open: (mA) N/A N/A

5. DIAGRAMS

5.1. Operating diagrams

5.2. Wiring diagrams

6. OVERALL DIMENSION

7. ASSEMBLY TABLE AND PARTS LIST

7.1. Table 0A

Hydraulic cylinder
Spring cartridge
Manual override
Actuator model
Assembly kit
Scotch yoke
Tag number
mechanism
Item
Q.ty
5
1
4
LV-0301C
OLGAS-H
01 3 LV-0301F 22FG01S018 B2280702680 227A040000 212A009291 8920380006
0.9S-0400-70-OP-MHP
LV-0301J
LV-0300A
LV-0300B
LV-0300D OLGAS-H
02 6 22FG01C028 B2280702680 227A040000 212A009291 8920380006
LV-0300E 0.9C-0400-70-CL-MHP
LV-0300G
LV-0300H
OLGAS-H
03 1 LV-0006A 229A06C040 B2281255080 227A250000 212A060291 8920380006
6C-2500-125-CL-MHP
OLGAS-H
04 1 LV-0006B 229A06C040 B2281255080 227A250000 212A060291 8920380006
6C-2500-125-CL-MHP
OLGAS-H
05 1 PV-0206 22FG00C004 B228A040208 227A010000 212A003293 8920380009
0.3C-0100-40-CL-MHP
OLGAS-H
06 1 PV-0205 22FG00S010 B228A035208 227A008C00 212A003297 8920380009
0.3S-008C-35-CL-MHP
PV-0201C
OLGAS-H
07 3 PV-0201F 22FG02C014 B2280952680 227A110000 212A015294 8920380006
1.5C-1100-95-OP-MHP
PV-0201J
OLGAS-H
08 1 FV-0306 22FG01C029 B228A08526Z8 227A070000 212A009290 8920380006
0.9C-0700-85-CL-MHP
PV-0508C
OLGAS-H
09 3 PV-0508F 229A03C020 B2281104680 227A200000 212A030290 8920380006
3C-2000-110-CL-MHP
PV-0508J
PV-0504C
OLGAS-H
10 3 PV-0504F 22FG02C014 B2280952680 227A110000 212A015294 N/A
1.5C-1100-95-OP-MHP
PV-0504J
CFI-001
11 2 CENTRALE COMUNE CFI N/A N/A N/A N/A N/A
CFI-002
OLGAS-H
12 1 LV-0310C 22FG01S018 B2280702680 227A040000 212A009291 8920380006
0.9S-0400-70-OP-MHP
OLGAS-H
13 1 LV-0310F 22FG01S018 B2280702680 227A040000 212A009291 8920380006
0.9S-0400-70-OP-MHP
OLGAS-H
14 1 LV-0310J 22FG01S018 B2280702680 227A040000 212A009291 8920380006
0.9S-0400-70-OP-MHP
OLGAS-H
15 1 FV-0311C 22FG00C004 B228A045228 227A015000 212A003292 8920380006
0.3C-0150-45-OP-MHP
OLGAS-H
16 1 FV-0311F 22FG00C004 B228A045228 227A015000 212A003292 8920380006
0.3C-0150-45-OP-MHP
OLGAS-H
17 1 FV-0311J 22FG00C004 B228A045228 227A015000 212A003292 8920380006
0.3C-0150-45-OP-MHP
OLGAS-H
18 1 LV-0016 22FG02C014 B2280952680 227A110000 212A015294 8920380006
1.5C-1100-95-OP-MHP
OLGAS-H
19 1 FV-0005 22FG02C015 B2281102680 227A120000 212A015290 8920380006
1.5C-1200-110-OP-MHP
LV-0301C
CONTROL CABINET
20 3 LV-0301F N/A N/A N/A N/A N/A
FOR ITEM 01
LV-0301J
LV-0300A
LV-0300B
21 6 N/A N/A N/A N/A N/A
LV-0300G
LV-0300H
CONTROL CABINET
22 1 LV-0006A N/A N/A N/A N/A N/A
FOR ITEM 03
CONTROL CABINET
23 1 LV-0006B N/A N/A N/A N/A N/A
FOR ITEM 04
CONTROL CABINET
24 1 PV-0206 N/A N/A N/A N/A N/A
FOR ITEM 05
CONTROL CABINET
25 1 PV-0205 N/A N/A N/A N/A N/A
FOR ITEM 06
PV-0201C
CONTROL CABINET
26 3 PV-0201F N/A N/A N/A N/A N/A
FOR ITEM 07
PV-0201J
CONTROL CABINET
27 1 FV-0306 N/A N/A N/A N/A N/A
FOR ITEM 08
PV-0508C
CONTROL CABINET
28 3 PV-0508F N/A N/A N/A N/A N/A
FOR ITEM 09
PV-0508J
PV-0504C
29 3 PV-0504F HPU FOR ITEM 10 N/A N/A N/A N/A N/A
PV-0504J
CONTROL CABINET
30 1 LV-0310C N/A N/A N/A N/A N/A
FOR ITEM 12
CONTROL CABINET
31 1 LV-0310F N/A N/A N/A N/A N/A
FOR ITEM 13
CONTROL CABINET
32 1 LV-0310J N/A N/A N/A N/A N/A
FOR ITEM 14
CONTROL CABINET
33 1 FV-0311C N/A N/A N/A N/A N/A
FOR ITEM 15
CONTROL CABINET
34 1 FV-0311F N/A N/A N/A N/A N/A
FOR ITEM 16
CONTROL CABINET
35 1 FV-0311J N/A N/A N/A N/A N/A
FOR ITEM 17
CONTROL CABINET
36 1 LV-0016 N/A N/A N/A N/A N/A
FOR ITEM 18
CONTROL CABINET
37 1 FV-0005 N/A N/A N/A N/A N/A
FOR ITEM 19

Limit switches box
3/2 Hand actuated

Actuator model
Mounting kit for
box/positioner
limit switches
Tag number
Microswitch
transmitter
+ position
Signalling
Tank
valve
Item
Q.ty
10
6
9
LV-0301C
OLGAS-H
01 3 LV-0301F 2P041XK460 8890010511 212A009M0Y 8943071611 8920380106
0.9S-0400-70-OP-MHP
LV-0301J
LV-0300A
LV-0300B
LV-0300D OLGAS-H
02 6 2P041XK460 8890010511 212A009M0Y 8943071611 8920380106
LV-0300E 0.9C-0400-70-CL-MHP
LV-0300G
LV-0300H
OLGAS-H
03 1 LV-0006A 2P041XK460 8890010511 212A060M0Y 8943071711 8920380107
6C-2500-125-CL-MHP
OLGAS-H
04 1 LV-0006B 2P041XK460 8890010511 212A060M0Y 8943071711 8920380107
6C-2500-125-CL-MHP
OLGAS-H
05 1 PV-0206 2P041XK460 8890010511 212A003M0Y 8943071611 8920380106
0.3C-0100-40-CL-MHP
OLGAS-H
06 1 PV-0205 2P041XK460 8890010511 212A003M0Y 8943071611 8920380106
0.3S-008C-35-CL-MHP
PV-0201C
OLGAS-H
07 3 PV-0201F 2P041XK460 8890010511 212A015M0Y 8943071611 8920380106
1.5C-1100-95-OP-MHP
PV-0201J
OLGAS-H
08 1 FV-0306 2P041XK460 8890010511 212A009M0Y 8943071611 8920380106
0.9C-0700-85-CL-MHP
PV-0508C
OLGAS-H
09 3 PV-0508F 2P041XK460 8890010511 212A030M0Y 8943071711 8920380107
3C-2000-110-CL-MHP
PV-0508J
PV-0504C
OLGAS-H
10 3 PV-0504F 2P041XK461 N/A 212A015M0Y N/A N/A
1.5C-1100-95-OP-MHP
PV-0504J
CFI-001
11 2 CENTRALE COMUNE CFI N/A N/A N/A N/A N/A
CFI-002
OLGAS-H
12 1 LV-0310C 2P041XK460 8890010511 212A009M0Y 8943071611 8920380106
0.9S-0400-70-OP-MHP
OLGAS-H
13 1 LV-0310F 2P041XK460 8890010511 212A009M0Y 8943071611 8920380106
0.9S-0400-70-OP-MHP
OLGAS-H
14 1 LV-0310J 2P041XK460 8890010511 212A009M0Y 8943071611 8920380106
0.9S-0400-70-OP-MHP
OLGAS-H
15 1 FV-0311C 2P041XK460 8890010511 212A003M0Y 8943071611 8920380106
0.3C-0150-45-OP-MHP
OLGAS-H
16 1 FV-0311F 2P041XK460 8890010511 212A003M0Y 8943071611 8920380106
0.3C-0150-45-OP-MHP
OLGAS-H
17 1 FV-0311J 2P041XK460 8890010511 212A003M0Y 8943071611 8920380106
0.3C-0150-45-OP-MHP
OLGAS-H
18 1 LV-0016 2P041XK460 8890010511 212A015M0Y 8943071611 8920380106
1.5C-1100-95-OP-MHP
OLGAS-H
19 1 FV-0005 2P041XK460 8890010511 212A015M0Y 8943071711 8920380106
1.5C-1200-110-OP-MHP
LV-0301C
CONTROL CABINET
20 3 LV-0301F N/A N/A N/A N/A N/A
FOR ITEM 01
LV-0301J
LV-0300A
LV-0300B
21 6 N/A N/A N/A N/A N/A
LV-0300G
LV-0300H
CONTROL CABINET
22 1 LV-0006A N/A N/A N/A N/A N/A
FOR ITEM 03
CONTROL CABINET
23 1 LV-0006B N/A N/A N/A N/A N/A
FOR ITEM 04
CONTROL CABINET
24 1 PV-0206 N/A N/A N/A N/A N/A
FOR ITEM 05
CONTROL CABINET
25 1 PV-0205 N/A N/A N/A N/A N/A
FOR ITEM 06
PV-0201C
CONTROL CABINET
26 3 PV-0201F N/A N/A N/A N/A N/A
FOR ITEM 07
PV-0201J
CONTROL CABINET
27 1 FV-0306 N/A N/A N/A N/A N/A
FOR ITEM 08
PV-0508C
CONTROL CABINET
28 3 PV-0508F N/A N/A N/A N/A N/A
FOR ITEM 09
PV-0508J
PV-0504C
29 3 PV-0504F HPU FOR ITEM 10 N/A N/A N/A N/A N/A
PV-0504J
CONTROL CABINET
30 1 LV-0310C N/A N/A N/A N/A N/A
FOR ITEM 12
CONTROL CABINET
31 1 LV-0310F N/A N/A N/A N/A N/A
FOR ITEM 13
CONTROL CABINET
32 1 LV-0310J N/A N/A N/A N/A N/A
FOR ITEM 14
CONTROL CABINET
33 1 FV-0311C N/A N/A N/A N/A N/A
FOR ITEM 15
CONTROL CABINET
34 1 FV-0311F N/A N/A N/A N/A N/A
FOR ITEM 16
CONTROL CABINET
35 1 FV-0311J N/A N/A N/A N/A N/A
FOR ITEM 17
CONTROL CABINET
36 1 LV-0016 N/A N/A N/A N/A N/A
FOR ITEM 18
CONTROL CABINET
37 1 FV-0005 N/A N/A N/A N/A N/A
FOR ITEM 19

Control Cabinet
Actuator model
Tag number
H. P.U.
Lever
Item
Q.ty
11
12
13
LV-0301C
OLGAS-H
01 3 LV-0301F 8920369931 N/A N/A
0.9S-0400-70-OP-MHP
LV-0301J
LV-0300A
LV-0300B
LV-0300D OLGAS-H
02 6 8920369931 N/A N/A
LV-0300E 0.9C-0400-70-CL-MHP
LV-0300G
LV-0300H
OLGAS-H
03 1 LV-0006A 8920369931 N/A N/A
6C-2500-125-CL-MHP
OLGAS-H
04 1 LV-0006B 8920369931 N/A N/A
6C-2500-125-CL-MHP
OLGAS-H
05 1 PV-0206 8920369931 N/A N/A
0.3C-0100-40-CL-MHP
OLGAS-H
06 1 PV-0205 8920369931 N/A N/A
0.3S-008C-35-CL-MHP
PV-0201C
OLGAS-H
07 3 PV-0201F 8920369931 N/A N/A
1.5C-1100-95-OP-MHP
PV-0201J
OLGAS-H
08 1 FV-0306 8920369931 N/A N/A
0.9C-0700-85-CL-MHP
PV-0508C
OLGAS-H
09 3 PV-0508F 8920369931 N/A N/A
3C-2000-110-CL-MHP
PV-0508J
PV-0504C
OLGAS-H
10 3 PV-0504F N/A N/A N/A
1.5C-1100-95-OP-MHP
PV-0504J
CFI-001
11 2 CENTRALE COMUNE CFI N/A 2112750000 N/A
CFI-002
OLGAS-H
12 1 LV-0310C 8920369931 N/A N/A
0.9S-0400-70-OP-MHP
OLGAS-H
13 1 LV-0310F 8920369931 N/A N/A
0.9S-0400-70-OP-MHP
OLGAS-H
14 1 LV-0310J 8920369931 N/A N/A
0.9S-0400-70-OP-MHP
OLGAS-H
15 1 FV-0311C 8920369931 N/A N/A
0.3C-0150-45-OP-MHP
OLGAS-H
16 1 FV-0311F 8920369931 N/A N/A
0.3C-0150-45-OP-MHP
OLGAS-H
17 1 FV-0311J 8920369931 N/A N/A
0.3C-0150-45-OP-MHP
OLGAS-H
18 1 LV-0016 8920369931 N/A N/A
1.5C-1100-95-OP-MHP
OLGAS-H
19 1 FV-0005 8920369931 N/A N/A
1.5C-1200-110-OP-MHP
LV-0301C
CONTROL CABINET
20 3 LV-0301F N/A N/A 2112750060
FOR ITEM 01
LV-0301J
LV-0300A
LV-0300B
21 6 N/A N/A 2112750060
LV-0300G
LV-0300H
CONTROL CABINET
22 1 LV-0006A N/A N/A 2112750040
FOR ITEM 03
CONTROL CABINET
23 1 LV-0006B N/A N/A 2112750040
FOR ITEM 04
CONTROL CABINET
24 1 PV-0206 N/A N/A 2112750050
FOR ITEM 05
CONTROL CABINET
25 1 PV-0205 N/A N/A 2112750050
FOR ITEM 06
PV-0201C
CONTROL CABINET
26 3 PV-0201F N/A N/A 2112750020
FOR ITEM 07
PV-0201J
CONTROL CABINET
27 1 FV-0306 N/A N/A 2112750060
FOR ITEM 08
PV-0508C
CONTROL CABINET
28 3 PV-0508F N/A N/A 2112750030
FOR ITEM 09
PV-0508J
PV-0504C
29 3 PV-0504F HPU FOR ITEM 10 N/A 2112750010 N/A
PV-0504J
CONTROL CABINET
30 1 LV-0310C N/A N/A 2112750060
FOR ITEM 12
CONTROL CABINET
31 1 LV-0310F N/A N/A 2112750060
FOR ITEM 13
CONTROL CABINET
32 1 LV-0310J N/A N/A 2112750060
FOR ITEM 14
CONTROL CABINET
33 1 FV-0311C N/A N/A 2112750070
FOR ITEM 15
CONTROL CABINET
34 1 FV-0311F N/A N/A 2112750070
FOR ITEM 16
CONTROL CABINET
35 1 FV-0311J N/A N/A 2112750070
FOR ITEM 17
CONTROL CABINET
36 1 LV-0016 N/A N/A 2112750020
FOR ITEM 18
CONTROL CABINET
37 1 FV-0005 N/A N/A 2112750030
FOR ITEM 19


ITEM 7 (MOD.: XCKJ110511H29) (CODE: 8890010511)
References, Limit switches
characteristics OsiSense XC Standard, industrial format EN 50041
Metal, conforming to CENELEC EN 50041, type XCK J
Complete switches, plug-in body
With 1 cable entry
Type of head Plunger (fixing by the body) Rotary (fixing by the body)
(switches supplied for actuation from left AND right)
1 Form B (1) Form C (1) Form A (1) Form D (1)
2
Type of operator Metal end plunger Steel roller Thermoplastic Steel roller Variable length Round
plunger roller lever (2) lever (2) thermoplastic thermoplastic
roller lever (2) rod lever, Ø 6 mm
(2) (4)
References of complete switches with 1 ISO M20 x 1.5 cable entry(3)

3 Single-pole CO XCK J1161H29 XCK J1167H29 XCK J110511H29 XCK J110513H29 XCK J110541H29 XCK J110559H29
11
13
snap action
2 3.2(A) 11-12 11-12 11-12 11-12
11-12 11-12
12
14
13-14 13-14 13-14 13-14 13-14 13-14

11-12 11-12 11-12 11-12 11-12 11-12
13-14 13-14 13-14 13-14 13-14 13-14
0 6mm 0 mm 0 0 0 0
0.9 1.5
4 Weight (kg) 0.430 0.455 0.480 0.490 0.485 0.485

Contact operation closed open (A) = cam displacement
References of complete switches with 1 Pg 13.5 cable entry (3)

For complete switches with entry for Pg 13.5 cable gland, delete H29 from the end of the reference.
Example: XCK J1161H29 becomes XCK J1161.
5 References of complete switches with 1 entry for 1/2" NPT conduit (3)
For complete switches with entry for 1/2" NPT (USAS B2-1) conduit, replace H29 at the end of the reference by H7.
Example: XCK J1161H29 becomes XCK J1161H7.
Characteristics
Switch actuation On end By 30° cam By any moving part
Type of actuation
6
Maximum actuation speed 0.5 m/s 1 m/s 1.5 m/s
Mechanical durability 30 25 30
(in millions of operating cycles)
Minimum tripping force or torque 20 N 16 N 0.25 N.m
7 Cable entry 1 entry tapped M20 x 1.5 for ISO cable gland
Clamping capacity 7 to 13 mm
(1) Form conforming to EN 50041, see page 1/177.
(2) Adjustable throughout 360° in 5° steps, or in 45° steps by reversing the lever or its mounting.
(3) Switches with gold contacts: please consult our Customer Care Centre.
(4) Value taken with actuation by moving part at 100 mm from the fixing.
10
1/104
Dimensions Limit switches
OsiSense XC Standard, industrial format EN 50041
Metal, conforming to CENELEC EN 50041, type XCK J
Complete switches, plug-in body
With 1 cable entry
XCK J1611H29 XCK J1167H29 XCK J110511H29, XCK J110513H29
57 1
17 5 41
5
17
41
63
50
37
140
127
114
60
60
60
. . .
25 (1)
25
36 =
(1)
30 =
25
36 =
(1)
30 = 62 = 30 = 3
42.5 42.5 42.5
XCK J110541H29 XCK J110559H29
5.5
52
44
48 26.2
4
(2)
40…85
62…107
(4)
(5)
5
139…184
(3)
60
60
. .
25 (1) 25 (1) 6
60 = 30 = 60 = 30 =
42.5 42.5
(1) 1 tapped entry for ISO M20 x 1.5 or Pg 13.5 cable gland or for 1/2" NPT conduit.
(2) Ø 6 rod, length 200 mm.
(3) 289 max.
(4) 190 max.
(5) 212 max.
7
10
1/105
ITEM 9 (MOD.: 3KH-DN13-1/2"NPT-4428-SB01 -40°C ) (CODE: 8943071611)
Mehrwegekugelhahn, 3KH
Multi-way ball valve, 3KH
ITEM 9 (3KH-DN20-3/4"NPT-4428-SB01 -40°C) (CODE: 894071711)
DIN ISO 228 Rohrinnengewinde

DIN ISO 228 Female thread
Type DN LWL/T L D I a H h m K V SW i d d1 H1 H2
3KH-G1/8 4 5 100 - 70 55 58 40 22 160 14 12 10 G1/8 6,5 - 101

3KH-G1/4 6 5 100 - 70 55 58 40 22 160 14 12 14 G1/4 6,5 - 101
3KH-G3/8 10 8 115 - 80 65 68 50 27 200 14 14 14 G3/8 6,5 72 -
3KH-G1/2 13 13 136 - 100 80 78 60 31 200 14 14 16,3 G1/2 9 82 -
3KH-G5/8 16 13 139 - 100 80 78 60 31 200 14 14 18 G5/8 9 82 -
3KH-G3/4 20 18 154 138 113 85 88 67 36,5 320 16,5 17 18 G3/4 8,5 96 -
3KH-G1 25 23 172 138 119 85 103 82 47,5 320 16,5 17 20 G1 8,5 112 -
3KH-G1 1/4 25/32 23 180 138 119 85 103 82 47,5 320 16,5 17 22 G1 1/4 8,5 112 -
3KH-G1 1/2 25/40 23 180 138 119 85 103 82 47,5 320 16,5 17 24 G1 1/2 8,5 112 -
ANSI B1.20.1 NPT Innengewinde

ANSI B1.20.1 NPT Female thread
3KH-1/8”NPT 4 5 100 - 70 55 58 40 22 160 14 12 10,5 1/8”NPT 6,5 - 101

3KH-1/4”NPT 6 5 100 - 70 55 58 40 22 160 14 12 13,7 1/4”NPT 6,5 - 101
3KH-3/8”NPT 10 8 115 - 80 65 68 50 27 200 14 14 13,5 3/8”NPT 6,5 72 -
3KH-1/2”NPT 13 13 160 - 100 80 78 60 31 200 14 14 17 1/2”NPT 9 82 -
3KH-3/4”NPT 20 18 164 138 113 85 88 67 36,5 320 16,5 17 18,3 3/4”NPT 8,5 96 -
3KH-1”NPT 25 23 186 138 119 85 103 82 47,5 320 16,5 17 21,6 1”NPT 8,5 112 -
3KH-1 1/4”NPT 25/32 23 186 138 119 85 103 82 47,5 320 16,5 17 22,1 1 1/4”NPT 8,5 112 -
3KH-1 1/2”NPT 25/40 23 186 138 119 85 103 82 47,5 320 16,5 17 22,1 1 1/2”NPT 8,5 112 -
140
Stahl
Steel
Bitte Druckstufen der

Rohrverbindungen
beachten!
Please note the

pressure ratings of
the tube connections!
DIN ISO 228 ANSI B1.20.1 DIN 2353 L DIN 2353 S SAE J 514
Bestelltext / Order text: 3KH-DN4-G1/8-112A-SB01

Bestellnr. / Order no.: 02256 L SB01
Weitere Bohrbilder Seite 322 bis 325

Further Porting patterns page 322 up to 325 T SB02
Werkstoffe / Materials 112A 112A 1128 1128

Gehäuse / Body Stahl / Steel Stahl / Steel Stahl / Steel Stahl / Steel
Kugelküken / Trunnion ball Stahl / Steel Stahl / Steel Stahl / Steel Stahl / Steel
Kugeldichtungen / Ball seats POM POM POM POM
O-Ringe / O-rings NBR NBR FPM FPM
Tmin / Tmax -20°C / 100°C -20°C / 100°C -20°C / 100°C -20°C / 100°C
Bohrbild / Porting pattern L=SB01 T=SB02 L=SB01 T=SB02
Griff Gewkg PN Best.Nr. Kat. PN Best.Nr. Kat. PN Best.Nr. Kat. PN Best.Nr. Kat.
Lever Weightkg [MPa] Order no. [MPa] Order no. [MPa] Order no. [MPa] Order no.
Al 1,60 50 02256 2 50 02254 3 50 25762 2 50 25867 3

Al 1,60 50 20046 2 50 22349 3 50 19767 2 50 25868 3
Zn 2,70 50 19241 2 50 20460 3 50 20502 2 50 21512 3
Zn 4,90 40 19151 2 40 20459 3 40 25763 2 40 17220 3
Zn 4,90 40 02661 2 40 02659 3 40 03162 2 40 03171 3
Al 6,70 31,5 19242 2 31,5 20458 3 31,5 03163 2 31,5 03172 3
Al 8,30 31,5 19243 2 31,5 20457 3 31,5 25765 2 31,5 03173 3
Al 8,50 31,5 27190 3 31,5 02203 3 31,5 25766 3 31,5 25871 3
Al 8,50 25 30663 3 25 02209 3 25 25767 3 25 17304 3
112A L=SB01 112A T=SB02 1128 L=SB01 1128 T=SB02

Al 1,60 50 33210 3 50 19444 3 50 25768 3 50 25872 3

Al 1,60 50 14380 3 50 33212 3 50 15716 3 50 25873 3
Zn 2,80 50 04578 3 50 19446 3 50 25770 3 50 25874 3
Zn 5,20 40 16523 3 40 19447 3 40 25771 3 40 25875 3
Al 6,80 31,5 17256 3 31,5 17314 3 31,5 15718 3 31,5 25876 3
Al 8,50 31,5 19442 3 31,5 33213 3 31,5 25773 3 31,5 25877 3
Al 8,80 31,5 19443 3 31,5 19449 3 31,5 16745 3 31,5 19455 3
Al 8,80 25 33211 3 25 33214 3 25 25775 3 25 25879 3
141
DIN 2353 Leichte Reihe

DIN 2353 Light series
Type DN RA LWL/T L D I a H h m K V SW i d d1 H1 H2
3KH-6L 4 6 5 105 - 70 55 58 40 22 160 14 12 10 M1 2x1,5 6,5 - 101

3KH-8L 6 8 5 105 - 70 55 58 40 22 160 14 12 10 M 14x1,5 6,5 - 101
3KH-10L 8 10 8 114 - 80 65 68 50 27 200 14 14 11 M 16x1,5 6,5 72 -
3KH-12L 10 12 8 114 - 80 65 68 50 27 200 14 14 11 M 18x1,5 6,5 72 -
3KH-15L 13 15 13 137 - 100 80 78 60 31 200 14 14 12 M 22x1,5 9 82 -
3KH-18L 16 18 13 137 - 100 80 78 60 31 200 14 14 12 M 26x1,5 9 82 -
3KH-22L 20 22 18 152 138 113 85 88 67 36,5 320 16,5 17 14 M 30x2 8,5 96 -
3KH-28L 25 28 23 166 138 119 85 103 82 47,5 320 16,5 17 14 M 36x2 8,5 112 -
3KH-35L 25/32 35 23 170 138 119 85 103 82 47,5 320 16,5 17 16 M 45x2 8,5 112 -
DIN 2353 Schwere Reihe

DIN 2353 Heavy series
3KH- 8S 4 8 5 105 - 70 55 58 40 22 160 14 12 12 M 16x1,5 6,5 - 101

3KH-10S 6 10 5 105 - 70 55 58 40 22 160 14 12 12 M 18x1,5 6,5 - 101
3KH-12S 8 12 8 116 - 80 65 68 50 27 200 14 14 12 M 20x1,5 6,5 72 -
3KH-14S 10 14 8 120 - 80 65 68 50 27 200 14 14 14 M 22x1,5 6,5 72 -
3KH-16S 13 16 13 141 - 100 80 78 60 31 200 14 14 14 M 24x1,5 9 82 -
3KH-20S 16 20 13 145 - 100 80 78 60 31 200 14 14 16 M 30x2 9 82 -
3KH-25S 20 25 18 160 138 113 85 88 67 36,5 320 16,5 17 18 M 36x2 8,5 96 -
3KH-30S 25 30 23 176 138 119 85 103 82 47,5 320 16,5 17 20 M 42x2 8,5 112 -
3KH-38S 25/32 38 23 180 138 119 85 103 82 47,5 320 16,5 17 22 M 52x2 8,5 112 -
SAE J 514 UN/UNF Innengewinde

SAE J 514 UN/UNF Female thread
3KH-7/16”UNF 6 5 100 - 70 55 58 40 22 160 14 12 12 7/16”UNF 6,5 - 101

3KH-9/16”UNF 10 8 115 - 80 65 68 50 27 200 14 14 13 9/16”UNF 6,5 72 -
3KH-3/4”UNF 13 13 144 - 100 80 78 60 31 200 14 14 15 3/4”UNF 9 82 -
3KH-1 1/16”UN 20 18 164 138 113 85 88 67 36,5 320 16,5 17 20 1 1/16”UN 8,5 96 -
3KH-1 5/16”UN 25 23 180 138 119 85 103 82 47,5 320 16,5 17 20 1 5/16”UN 8,5 112 -
142
Stahl
Steel
112A L=SB01 112A T=SB02 1128 L=SB01 1128 T=SB02

Al 1,60 50 02217 2 50 02215 3 50 25746 2 50 25851 3

Al 1,80 50 02223 2 50 02221 3 50 25747 2 50 25852 3
Zn 2,60 50 02600 2 50 02598 3 50 25748 2 50 25853 3
Zn 2,60 50 02612 2 50 24278 3 50 25749 2 50 25854 3
Zn 4,70 40 02630 2 40 02628 3 40 25750 2 40 25855 3
Zn 4,70 40 22027 2 40 02647 3 40 25751 2 40 25856 3
Al 6,60 31,5 20370 2 31,5 24007 3 31,5 25752 2 31,5 25857 3
Al 8,00 31,5 02319 2 31,5 02317 3 31,5 25753 2 31,5 25858 3
Al 8,12 31,5 02856 2 31,5 02857 3 31,5 03130 2 31,5 03139 3
112A L=SB01 112A T=SB02 1128 L=SB01 1128 T=SB02

Al 1,60 50 02304 2 50 02303 3 50 25754 2 50 25859 3

Al 1,60 50 02308 2 50 02309 3 50 19002 2 50 25860 3
Zn 2,60 50 22863 2 50 02604 3 50 25756 2 50 25861 3
Zn 2,60 50 02618 2 50 02616 3 50 25757 2 50 25862 3
Zn 4,70 40 23058 2 40 02634 3 40 25758 2 40 25863 3
Zn 4,70 40 23059 2 40 02653 3 40 25759 2 40 25864 3
Al 6,60 31,5 02268 2 31,5 29891 3 31,5 25760 2 31,5 25865 3
Al 8,00 31,5 02274 2 31,5 02272 3 31,5 25761 2 31,5 25866 3
Al 8,30 31,5 02852 2 31,5 02853 3 31,5 03094 2 31,5 03103 3
112A L=SB01 112A T=SB02 1128 L=SB01 1128 T=SB02

Al 1,60 50 37193 3 50 37364 3 50 31546 3 50 39103 3

Zn 2,80 50 37194 3 50 37365 3 50 25631 3 50 39104 3
Zn 5,20 40 37195 3 40 37366 3 40 37197 3 40 39105 3
Al 6,80 31,5 37196 3 31,5 37367 3 31,5 37198 3 31,5 39106 3
Al 8,50 31,5 32203 3 31,5 37368 3 31,5 22853 3 31,5 39107 3
143
DIN ISO 228 Rohrinnengewinde

DIN ISO 228 Female thread
3KH-G1/8 4 5 100 75 70 40 58 40 22 160 14 12 10 G1/8 6,5 - 101

3KH-G1/4 6 5 100 75 70 40 58 40 22 160 14 12 14 G1/4 6,5 - 101
3KH-G3/8 10 8 115 90 80 45 68 50 27 200 14 14 14 G3/8 6,5 72 -
3KH-G1/2 13 13 136 110 100 60 78 60 31 200 14 14 16,3 G1/2 9 82 -
3KH-G5/8 16 13 139 110 100 60 78 60 31 200 14 14 18 G5/8 9 82 -
3KH-G3/4 20 18 154 138 113 85 88 67 36,5 320 16,5 17 18 G3/4 8,5 96 -
3KH-G1 25 23 172 138 119 85 103 82 47,5 320 16,5 17 20 G1 8,5 112 -
3KH-G1 1/4 25/32 23 180 138 119 85 103 82 47,5 320 16,5 17 22 G1 1/4 8,5 112 -
3KH-G1 1/2 25/40 23 180 138 119 85 103 82 47,5 320 16,5 17 24 G1 1/2 8,5 112 -
ANSI B1.20.1 NPT Innengwinde

ANSI B1.20.1 NPT Female thread
3KH-1/8”NPT 4 5 100 75 70 40 58 40 22 160 14 12 10,5 1/8”NPT 6,5 - 101

3KH-1/4”NPT 6 5 100 75 70 40 58 40 22 160 14 12 13,7 1/4”NPT 6,5 - 101
3KH-3/8”NPT 10 8 115 90 80 45 68 50 27 200 14 14 13,5 3/8”NPT 6,5 72 -
3KH-1/2”NPT 13 13 160 110 100 60 78 60 31 200 14 14 17 1/2”NPT 9 82 -
3KH-3/4”NPT 20 18 164 138 113 85 88 67 36,5 320 16,5 17 18,3 3/4”NPT 8,5 96 -
3KH-1”NPT 25 23 186 138 119 85 103 82 47,5 320 16,5 17 21,6 1”NPT 8,5 112 -
3KH-1 1/4”NPT 25/32 23 186 138 119 85 103 82 47,5 320 16,5 17 22,1 1 1/4”NPT 8,5 112 -
3KH-1 1/2”NPT 25/40 23 186 138 119 85 103 82 47,5 320 16,5 17 22,1 1 1/2”NPT 8,5 112 -
144
Edelstahl
Stainless Steel
Bitte Druckstufen der

Rohrverbindungen
beachten!
Please note the

pressure ratings of
the tube connections!
DIN ISO 228 ANSI B1.20.1 DIN 2353 L DIN 2353 S SAE J 514
Bestelltext / Order text: 3KH-DN4-G1/8-442A-SB01 L SB01

Bestellnr. / Order no.: 37287
Weitere Bohrbilder Seite 322 bis 325

Further Porting patterns page 322 up to 325 T SB02
Werkstoffe / Materials 442A 442A 4428 4428

Gehäue/ Body Edelstahl / AISI 316 Edelstahl / AISI 316 Edelstahl / AISI 316 Edelstahl / AISI 316
Kugelküken / Trunnion ball Edelstahl / AISI 316 Edelstahl / AISI 316 Edelstahl / AISI 316 Edelstahl / AISI 316
Kugeldichtungen / Ball seats POM POM POM POM
O-Ringe / O-rings NBR NBR FPM FPM
Tmin / Tmax -30°C / 100°C -30°C / 100°C -20°C / 100°C -20°C / 100°C
Bohrbild / Porting pattern L=SB01 T=SB02 L=SB01 T=SB02
Al 1,60 50 37287 4 50 37347 4 50 37292 4 50 39088 4

Al 1,60 50 12130 4 50 10548 4 50 32285 4 50 20675 4
Zn 2,70 50 10836 4 50 37348 4 50 37293 4 50 31637 4
Zn 4,90 40 14623 4 40 37349 4 40 36503 4 40 39089 4
Zn 4,90 40 37288 4 40 37350 4 40 37294 4 40 39090 4
Al 6,70 31,5 37289 4 31,5 31516 4 31,5 37295 4 31,5 39091 4
Al 8,30 31,5 29130 4 31,5 25433 4 31,5 37296 4 31,5 39092 4
Al 8,50 31,5 37290 4 31,5 37351 4 31,5 37297 4 31,5 39093 4
Al 8,50 25 37291 4 25 37352 4 25 37298 4 25 39094 4
442A L=SB01 442A T=SB02 4428 L=SB01 4428 T=SB02

Al 1,60 50 37299 4 50 37353 4 50 37305 4 50 39095 4

Al 1,60 50 28248 4 50 37354 4 50 37306 4 50 39096 4
Zn 2,80 50 29181 4 50 37355 4 50 37307 4 50 39097 4
Zn 5,20 40 37300 4 40 37356 4 40 37308 4 40 39098 4
Al 6,80 31,5 37301 4 31,5 29129 4 31,5 34995 4 31,5 39099 4
Al 8,50 31,5 37302 4 31,5 37357 4 31,5 37309 4 31,5 39100 4
Al 8,80 31,5 37303 4 31,5 37358 4 31,5 37310 4 31,5 39101 4
Al 8,80 25 37304 4 25 32572 4 25 37311 4 25 39102 4
145
DIN 2353 Leichte Reihe

DIN 2353 Light series
3KH-6L 4 6 5 105 75 70 40 58 40 22 160 14 12 10 M 12x1,5 6,5 - 101

3KH-8L 6 8 5 105 75 70 40 58 40 22 160 14 12 10 M 14x1,5 6,5 - 101
3KH-10L 8 10 8 114 90 80 45 68 50 27 200 14 14 11 M 16x1,5 6,5 72 -
3KH-12L 10 12 8 114 90 80 45 68 50 27 200 14 14 11 M 18x1,5 6,5 72 -
3KH-15L 13 15 13 137 110 100 60 78 60 31 200 14 14 12 M 22x1,5 9 82 -
3KH-18L 16 18 13 137 110 100 60 78 60 31 200 14 14 12 M 26x1,5 9 82 -
3KH-22L 20 22 18 152 138 113 85 88 67 36,5 320 16,5 17 14 M 30x2 8,5 96 -
3KH-28L 25 28 23 166 138 119 85 103 82 47,5 320 16,5 17 14 M 36x2 8,5 112 -
3KH-35L 25/32 35 23 170 138 119 85 103 82 47,5 320 16,5 17 16 M 45x2 8,5 112 -
DIN 2353 Schwere Reihe

DIN 2353 Heavy series
3KH- 8S 4 8 5 105 75 70 40 58 40 22 160 14 12 12 M 16x1,5 6,5 - 101

3KH-10S 6 10 5 105 75 70 40 58 40 22 160 14 12 12 M 18x1,5 6,5 - 101
3KH-12S 8 12 8 116 90 80 45 68 50 27 200 14 14 12 M 20x1,5 6,5 72 -
3KH-14S 10 14 8 120 90 80 45 68 50 27 200 14 14 14 M 22x1,5 6,5 72 -
3KH-16S 13 16 13 141 110 100 60 78 60 31 200 14 14 14 M 24x1,5 9 82 -
3KH-20S 16 20 13 145 110 100 60 78 60 31 200 14 14 16 M 30x2 9 82 -
3KH-25S 20 25 18 160 138 113 85 88 67 36,5 320 16,5 17 18 M 36x2 8,5 96 -
3KH-30S 25 30 23 176 138 119 85 103 82 47,5 320 16,5 17 20 M 42x2 8,5 112 -
3KH-38S 25/32 38 23 180 138 119 85 103 82 47,5 320 16,5 17 22 M 52x2 8,5 112 -
SAE J 514 UN/UNF Innengewinde

SAE J 514 UN/UNF Female thread
3KH-7/16”UNF 6 5 100 75 70 40 58 40 22 160 14 12 12 7/16”UNF 6,5 - 101

3KH-9/16”UNF 10 8 115 90 80 45 68 50 27 200 14 14 13 9/16”UNF 6,5 72 -
3KH-3/4”UNF 13 13 144 110 100 60 78 60 31 200 14 14 15 3/4”UNF 9 82 -
3KH-1 1/16”UN 20 18 164 138 113 85 88 67 36,5 320 16,5 17 20 1 1/16”UN 8,5 96 -
3KH-1 5/16”UN 25 23 180 138 119 85 103 82 47,5 320 16,5 17 20 1 5/16”UN 8,5 112 -
146
Edelstahl
Stainless Steel
442A L=SB01 442A T=SB02 4428 L=SB01 4428 T=SB02

Al 1,60 50 37199 4 50 37328 4 50 37267 4 50 39072 4

Al 1,80 50 37200 4 50 37329 4 50 37268 4 50 39073 4
Zn 2,60 50 37262 4 50 32511 4 50 37269 4 50 39074 4
Zn 2,60 50 34556 4 50 37330 4 50 37270 4 50 39075 4
Zn 4,70 40 37263 4 40 37331 4 40 37271 4 40 39076 4
Zn 4,70 40 37264 4 40 37332 4 40 37272 4 40 39077 4
Al 6,60 31,5 37265 4 31,5 37333 4 31,5 37273 4 31,5 39078 4
Al 8,00 31,5 37266 4 31,5 37334 4 31,5 37274 4 31,5 39079 4
Al 8,12 31,5 41942 4 31,5 41943 4 31,5 41944 4 31,5 41945 4
442A L=SB01 442A T=SB02 4428 L=SB01 4428 T=SB02

Al 1,60 50 37275 4 50 37335 4 50 37279 4 50 39080 4

Al 1,60 50 37276 4 50 37336 4 50 37280 4 50 39081 4
Zn 2,60 50 31678 4 50 37337 4 50 37281 4 50 39082 4
Zn 2,60 50 18678 4 50 37338 4 50 37282 4 50 39083 4
Zn 4,70 40 32300 4 40 37339 4 40 37283 4 40 39084 4
Zn 4,70 40 37277 4 40 37340 4 40 37284 4 40 39085 4
Al 6,60 31,5 37278 4 31,5 37341 4 31,5 37285 4 31,5 39086 4
Al 8,00 31,5 29468 4 31,5 15986 4 31,5 37286 4 31,5 39087 4
Al 8,30 31,5 41946 4 31,5 41947 4 31,5 41948 4 31,5 41949 4
442A L=SB01 442A T=SB02 4428 L=SB01 4428 T=SB02

Al 1,60 50 37312 4 50 37359 4 50 37317 4 50 39108 4

Zn 2,80 50 37313 4 50 37360 4 50 37318 4 50 39109 4
Zn 5,20 40 37314 4 40 37361 4 40 37319 4 40 39110 4
Al 6,80 31,5 37315 4 31,5 37362 4 31,5 37320 4 31,5 39111 4
Al 8,50 31,5 37316 4 31,5 37363 4 31,5 37321 4 31,5 39112 4
147
ITEM 5 (MOD.:GRI PM SS-25+VS(-54°+72°C)10690310127) (CODE : 8920380006)
ITEM 5 (MOD.: GRI PM SS-12+VS(-54°+72°C)10690319137) (CODE: 8920380009)
CODICE FAMIGLIA
FAMILY CODE 106
POMPE A MANO
CON VALVOLA DI SICUREZZA SERIE PMS+VS
SERIES
HAND PUMPS WITH SAFETY VALVE 12-25-45
Pompe a mano con azionamento a doppio effetto per impianti a semplice
Rev: AD
effetto, direttamente flangiabili su serbatoio, con rubinetto di scarico a tenuta

conica e valvola di sicurezza registrabile incorporati.
Sono disponibili in tre diverse cilindrate per consentire le più svariate applica-
zioni e per limitare lo sforzo sulla leva in ogni situazione. Hanno il corpo in ghi-
Codice foglio:997-106-01010
sa sferoidale con trattamento in cataforesi anticorrosione e lo stelo nichelato.
ITEM 10 (MOD.: S/5 LT.5 X PM (10680010050))

Double acting hand pumps (CODE: 8920380106)
suitable to operate single acting applications. They can be fitted
also onto tank and are equipped with tapered lowering valve and with built-in adjustable sa-
fety valve. These hand pumps can have 3 different sizes to perform various applications and
ITEM 10 (MOD.:S/7 LT.7 X PM (10680010078)) (CODE: 8920380107) to achieve smoother loads on the lever. They are available with nodular cast-iron body with
cataphoresis anti-corrosion treatment and nickel-plated spool.
Codice di ordinazione (senza leva)

Order code (without lever)
FULCRO 12 FULCRO 25 FULCRO 45
Senza
Serbatoio 106-019-00013 106-010-00012 106-010-00021
Without Tank
1 106-018-00014 106-008-00016 106-009-00060
Codice fascicolo: 997-400-10610 Rev:AG
Con serbatoi
2 106-018-00023 106-008-00025 106-009-00051

Litri / Litres
With Tank
3 106-018-00032 106-008-00034 106-009-00015

5 106-018-00041 106-008-00043 106-009-00024
7 106-018-00050 106-008-00052 106-009-00033
10 106-018-00069 106-008-00061 106-009-00042
Ingombro
Overall Dimension
A A1 B C D1 D2 E
mm mm mm mm ° ° mm
FULCRO 12 143187120 2,8 18,5 45 35

FULCRO 25 142193127 3,7 20 45 35
FULCRO 45 141193138 3,7 20 45 42
Data: Lunedì 27 luglio 2009
Schema Idraulico
Hydraulic layout
P1 P
pag.5
O.M.F.B. S.p.A. Hydraulic Components
We reserve the right to make any changes without notice.
Edition 2004.05 No reproduction, however partial, is permitted.
Via Cave, 7/9 25050 Provaglio d’Iseo (Brescia) Italy Tel.: +39.030.9830611
Fax: +39.030.9839207-208 Internet:www.omfb.it e-mail:info@omfb.it
SCHEMA RICAMBIO POMPE A MANO FULCRO SERIE PMS+VS 106
FULCRO HAND PUMP PMS+VS SERIES SPARE PARTS
Rev: AD
kit ricambi / kit’s
N° FULCRO Codice Gruppo
N° 12 25 45 P. Number Assembly
Kit valvola aspirazione Suction valve kit
39
• • 500-002-00016
• 500-002-00025
Kit pistone Piston assembly
40
• 500-012-00032
• 500-012-00014
• 500-012-00023
Kit portaleva Hand lever holder kit
41
• • • 500-009-00135
Kit volantino Lowering valve kit
42
• • • 500-007-00048
Kit valvola di sicurezza Safety valve assembly
43
• • • 106-906-00037
pag.6
106 SCHEMA RICAMBIO POMPE A MANO FULCRO SERIE PMS+VS
FULCRO HAND PUMP PMS+VS SERIES SPARE PARTS
N° FULCRO Codice Descrizione Quantità
N° 12 25 45 P. Number Description Quantity
1 • • • 506-000-00392 Guarnizione portafiltro Suction cap 1
2 • • • 550-001-00012 Filtro acciaio rotondo Steel strainer 1
• • 540-005-00019
3 Corpo valvola di aspirazione Suction valve casing 1
• 540-005-00037
• • 506-002-00201
4 Guarnizione OR O-ring 1
• 506-003-00095
Rev: AD
5 • • • 510-009-00116 Sfera tenuta Ball 1

6 • • • 512-005-00689 Molla valvola di aspirazione Spring for suction valve 1
7 • • • 550-001-00101 Guidamolla Spring-guide 1
8 • • • 501-001-00113 Anello elastico Circlip 1
• 537-002-00037
9 • 537-002-00019 Cilindro acciaio Steel stem 1
• 537-002-00028
• • 116-009-01255
10 Rondella tenuta cilindro Washer 1
• 116-009-01308
11a • 506-000-00516 Guarnizione speciale Special gasket 2
• 506-000-00258
11 Guarnizione speciale Special gasket 1
• 506-000-00267
• 532-002-00082
12 • 532-002-00028 Pistone Piston 1
• 532-002-00037
13a • 550-004-00046 Anello antiestrusore Locking ring 2
• 506-002-00158
13 Guarnizione OR O-ring 1
• 506-002-00229
• 535-001-00121
14 • 535-001-00069 Stelo Piston rod 1
• 535-001-00078
• 501-011-00086
15 • 501-011-00111 Anello elastico Circlip 1
• 501-011-00148
• 517-001-00567
16 • 517-001-00585 Corpo pompa a mano Hand pump housing 1
• 517-001-00601
17 • • • 116-009-00158 Rondella utilizzi Washer 2
18 • • • 116-006-00259 Nipplo utilizzi Pressure nipple 1
19 • • • 526-001-00095 Spinotto lunghezza 26mm Gudgeon Pin 26mm 2
20 • • • 501-015-00028 Anello elastico Circlip 6
• 506-000-01640
21 • 506-000-01659 Guarnizione a labbro Lip seal 1
• 506-000-01668
• 506-000-01613
22 • 506-000-01622 Guarnizione raschiapolvere Wiper seal 1
• 506-000-01631
23 • • • 526-001-00086 Spinotto Gudgeon Pin 1
24 • • • 538-001-00081 Biella Brackets 2
25 • • • 502-002-00012 Vite blocco leva Locking lever screw 1
26 • • • 539-001-00212 Portaleva Lever holder 1
27 • • • 115-006-00117 Tappo utilizzo Pressure port plug 1
28 • • • 543-004-00023 Spillo tenuta Pin 1
29 • • • 506-000-00589 Guarnizione OR O-ring 1
30 • • • 506-002-00014 Guarnizione OR O-ring 1
31 • • • 500-001-00357 Volantino Lowering wheel 1
32 • • • 510-009-00045 Sfera tenuta valvola di sicurezza Safety valve sealing ball 1
33 • • • 542-001-00073 Guidamolla Spring-guide 1
34 • • • 512-005-01428 Molla valvola di massima Spring 1
35 • • • 506-019-10102 Anello O-ring 1

36 • • • 504-000-00458 Grano registro valvola di sicurezza Setting screw for safety valve 1
37 • • • 116-009-00201 Rondella tenuta valvola di massima Washer 1
38 • • • 540-006-00116 Tappo chiusura valvola di sicurezza Safety valve cover 1
pag.7
ITEM 11 (MOD.: PMS/PMI L=590 (10600000078)) (CODE: 8920369931)
POMPE A MANO FULCRO SERIE PMS+VS
106
FULCRO HAND PUMP PM+VS SERIES
Dati Tecnici
Technical data
Tipo pompa Taratura standard Taratura massima Cilindrata Peso
Pump type Standard pressure setting Max. pressure setting Displacement Weight
Completa / Full Tiro / Pull Spinta / Push
bar bar cm3 cm3 cm3 Kg
Rev: AD
FULCRO 12 160 300 12 6,1 5,9 2,8
FULCRO 25 160 300 25 13,4 11,6 2,9
FULCRO 45 160 270 45 23,7 21,3 3,2
Fluido idraulico
Minerale o sintetico compatibile con guarnizioni:
Mineral or synthetic compatible with the following Sforzo in fase di pompaggio
Fluid seals:
NBR, FKM, FPM, Nylon con leva standard
Viscosità cinematica T media ambiente (°C) < -10 -10÷10 10÷35 > 35 Load while pumping with standard lever
consigliata Average ambient temp. (°C)
Kinematic viscosity
suggested VG (cSt = mm2/s) 22 32 46 68 F Kg
FULCRO 12
160
Pres. di aspirazione -0,3 ÷ 2 bar
Inlet pressure 140
120
Kit di guarnizioni 100
Seal kit 80
FULCRO 12 FULCRO 25 FULCRO 45 60

TIRO
106-900-00408 106-900-00453 106-900-00506

PULL
40

SPINTA
PUSH
20
0
bar
0
100
150
250
350
200
300
400
450
50
F Kg
FULCRO 25
PIA.APP.GRP.PMP. PMS-PMI
106-000-00032 MOUNTING PLATE FOR TANK PMS-PMI
160
140
120
100
80
TIRO
PULL
60
SPINTA
40
AST. CON IMP.PMS/PMI L.600 MM 35x15 PUSH
106-000-00078 LEVER FOR PMS/PMI L. 600 MM 35x15 20
0
bar
200
300
450
400
100
150
250
350
0
50
FULCRO 45
F Kg
160
MAGGIORAZIONE RITORNO A MOLLA X PMS
106-000-00247 SPRING RETURN FOR PMS 140
120
TIRO
100
PULL
80
SPINTA
PUSH
60
40
20
KIT MONTAGGIO POMPE PMS/PMI

106-960-00700 MOUNTING KIT FOR PUMPS PMS/PMI
0
bar
200
450
50
100
150
250
300
350
400
0
pag.8
SERB. 3LT. (COD. : 106-800-00034)
CODICE FAMIGLIA
5LT. (COD. : 106-800-00043) FAMILY CODE 106-800
GRUPPO SERBATOI COMPLETI
CON VASCA IN PLASTICA O ALLUMINIO
PLASTIC OR ALUMINIUM TANK ASSEMBLY
Serbatoio da 1 litro in alluminio. Serbatoio da 2 litri in: Serbatoio da 3 litri in:

Rev: AA
1 litre tank in aluminium. 2 litres tank: 3 litres tank:

Plastica Alluminio Plastica Alluminio
Plastic Aluminium Plastic Aluminium
Serbatoio da 5 litri in: Serbatoio da 7 litri in: Serbatoio da 10 litri in:

5 litres tank: 7 litres tank: 10 litres tank:
Plastica Alluminio Plastica Alluminio Plastica Alluminio
Plastic Aluminium Plastic Aluminium Plastic Aluminium
Codice fascicolo: 997-400-10610 Rev:AD
MATERIALE CODICE DI
CAPACITÀ DESCRIZIONE PESO
SERBATOIO ORDINAZIONE CAPACITY DESCRIPTION WEIGHT
TANK’S MATERIAL ORDER CODE
106-800-00025 2 SRB. CMP.PM S/2/ TANK 2 LT 1,8
Data: Martedì 15 gennaio 2008
PLASTICA 106-800-00043 5 SRB. CMP.PM S/5/ TANK 5 LT 2

PLASTIC
106-800-00105 1 SRB. CMP.PM S/1/ TANK 1 LT
ALLUMINIO 106-800-00301 3 SRB. CMP.PM S/3/ TANK 3 LT 2
ALUMINIUM 106-800-00507 5 SRB. CMP.PM S/5/ TANK 5 LT 2,5
pag.19
SCHEMA RICAMBIO SERBATOI PLASTICA
106
PLASTIC TANKS SPARE PARTS
N° Serbatoio l / tank Codice Q.

N° 2 3 5 7 10 P. Number Q.
1 • • • • • 509-005-00131 1
2 • • • • • 514-003-00089 1
3 • • • • • 509-006-00121 2
• • • • 506-000-00463 1 1
4
Rev: AA
• 506-000-01435 1
5a 514-003-00070 1 09 3
• 514-008-00020 1 2
• 514-008-00039 1
5b
• 514-008-00057 1 3
• 514-008-00075 1
5c • 514-008-00100 1 4
6a • • • • 502-002-10207 8 10
6b • 502-002-00478 8 5b
7 • 538-000-00331 2 6a
8 • 501-024-00063 8
KIT RICAMBIO / KIT’S
9 • • • • • 106-800-01015 4
• 106-800-01024
• 106-800-01033 5c
10
• 106-800-01051
• 106-800-01060 7
11
11 • 106-800-01097
8
6b
Lt 2

Lt 3
Lt 5
Lt 10
Lt 7

pag.20
SCHEMA RICAMBIO SERBATOI ALLUMINIO
106
ALUMINIUM TANKS SPARE PARTS
N° Serbatoio l / tank Codice Q. 1

N° 1 2 3 5 7 10 P. Number Q. 10 8a
3
1 • • • • • • 509-005-00131 1
2 • • • • • 514-003-00089 1
3 • • • • • • 509-006-00121 2 4
4 • 502-000-00872 10 5 10
Rev: AA
5 • 509-000-00912 1
6 • 506-000-02158 1 6
7 • • • • • 507-003-00182 1
8a • 514-003-00105 1
• 514-005-00069 1
• 514-005-00078 1
8b
• 514-005-00087 1 1
• 514-005-00041 1
8c • 514-005-00050 1 11 3
9 • • • • • 502-002-00441 8 2
KIT RICAMBIO / KIT’S 3
10 • 106-800-00105
11 • • • • • 106-800-01015 7
• 106-800-02023 12 8b
• 106-800-02032
12
• 106-800-02050 9
• 106-800-02078
13 • 106-800-02103
7
8c
13
9
Lt 2
Lt 3
Lt 5
Lt 10
Lt 1
Lt 7
pag.21
8. CONTROL SYSTEM

8.1. ECU 1000

ECU 1000 Installation and Maintenance
DTDE 326
ECU 1000
INSTALLATION
and
MAINTENANCE
MANUAL
ECU1000 electronic cards
ECU1000 cabinets
Copyright by BIFFI ITALIA. All right riserved DTDE326-e0 Pag. i

INDEX
1 INTRODUCTION 1
2 REFERENCE DOCUMENTS 1
3 GENERAL SAFETY INSTRUCTIONS 1

3.1 Manufacturer 1
3.2 Intended Use 1
3.3 Terms and conditions 3
3.4 Manufacturer’s Liability 3
3.5 Applicable Standards and Regulations 3
4 STORAGE 3
5 DEVICE DESCRIPTION 4
5.1 Block diagram 4
5.2 General features 4
5.3 Inputs and Outputs 5
5.3.1 Digital inputs up to 110Vdc 6
5.3.2 Extension connector 6
5.3.3 Service voltages 6
5.4 Bus interface 6
5.5 ECU1000 power supply module 6
5.6 ECU1000 Electronic cards 7
5.7 ECU1000 cabinet block diagram 8
5.8 ECU1000 cabinet 9
5.9 Installation 10
5.9.1 Installation in hazardous area 11
5.10 Checks to be performed before installation 11
5.11 Cables and Electrical Connections 11
5.11.1 Cables connection 11
5.11.2 Earth connection 12
5.11.3 Cables requirements – EMC protection 13
5.11.4 Wire dimension and type 13
5.11.5 Unused entries 13
5.12 Start-up Procedure 13
6 DECOMMISSIONING 15
7 TROUBLE SHOOTING 16
7.1 Local Operator Interface of ECU1000 off 16
7.2 Local Operator Interface of ECU1000 available 16
7.2.1 Trouble-shooting by Local Operator Interface 16
7.2.1.1 Failure, Alarm and Maintenance Request 16
7.2.1.2 I/O check 17
7.2.2 Trouble-shooting by BIFFI-Assistant SW tool 17
Copyright by BIFFI ITALIA. All right riserved DTDE326-e0 Pag. ii

8 ECU1000 CABINET CODE 18
9 ROUTINE TEST OF ECU1000 CABINET 18
REV. DATE PREPARED APPROVED NOTES

0 30/07/2013 M. Giuliani A. Affaticati Issue
Copyright by BIFFI ITALIA. All right reserved DTDE326-e0 Pag. iii

1 Introduction
The documents DTDE326, DTDE327 and DTDE328 are the Installation, Operation and Maintenance manuals of the
ECU1000, Electronic Control Unit for electro-hydraulic actuators.
The DTDE326 “Installation and Maintenance”, provides the instructions for the installation and maintenance of cabinet
with ECU1000. The DTDE327 “Control functions and Local Operator Interface” provides the instructions to use the
Local Operator Interface, the Positioner and the additional functions to control and monitor the actuator. The
DTDE328 “Functions description, Input characterization-Recorder-Graph-Logger-PST-HPU-On/Off control-Optional
local lamps-PWM module” provides detailed instructions relevant to further ECU1000 functions as Input
characterization, Recorder, Graph, Logger, PST, HPU, On/Off control and Optional local lamps. The manuals
DTDE326, DTE327 and DTDE328 provide the instructions relevant to the complete set of ECU1000 functions. Only
functions requested by the application and needed to allow the correct actuator control and operation will be activated in
the factory setting. The warnings reported in this manual consider the risk analysis of the document DTDE331.
2 Reference documents
DTDE 327 “Control functions and Local Operator Interface” of ECU1000

DTDE328 “Functions description”, Input characterization-Recorder-Graph-Logger-PST-HPU-On/Off control-Optional
local lamps-PWM module”
DTDE300 ECU1000 “Product description”
DTDE330 “ECU1000 BIFFI-Assistant User Manual”
DTDE331 ECU1000 “Cabinet data and risk assessment”
Electrical diagram of cabinet with ECU1000 device code 193AR000xxx
Factory test procedure of cabinet with ECU1000 device code 193AR000xxx
Hydraulic diagram and installation and operation manuals of mechanical and hydraulic equipment controlled by the
ECU1000 cabinet 193AR000xxx
3 General Safety Instructions

3.1 Manufacturer
Manufacturer with respect to Machinery Directive 2006/42/EC is BIFFI Italia, as specified on the machinery label.
3.2 Intended Use

The ECU1000 electronic device described in the reference documents is designed to control an electro-hydraulic
actuator for process valves. The main functions are:
• to acquire the feedbacks from sensors of HA (Hydraulic Actuator), HCU (Hydraulic Control Unit), HPU
(Hydraulic Power Unit)
• to acquire the setpoints from control room
• to process the acquired data and send operational commands to HA, HCU, integral HPU
• to monitor the complete system
• to send to control room signals relevant to status and alarms of complete system
• to log events, alarms and failures
BIFFI Italia will not be liable for any possible damage or physical injury resulting from use in other than the designated
applications or by lack of care during installation, operation, adjustment and maintenance of the machine. Such risks lie
entirely with the user. Depending on the specific working conditions, additional precautions may be requested.
Considering that Biffi Italia has no direct control over particular applications, operation or maintenance conditions, it is
the operator’s responsibility to comply with all applicable safety rules. Please inform Biffi Italia urgently if you face
unsafe situations not described in the mentioned IOM’s. It is the sole responsibility of the operator to ensure that the
local health and safety regulations are adhered to.
Copyright by BIFFI ITALIA. All right riserved DTDE326-e0 Pag. 1

Warning: • It is assumed that the installation, the setting, the commissioning, the
maintenance and repair works are carried out by qualified personnel and
checked by responsible Specialists.
• The door of cabinet must be kept “closed” by the key (or equivalent tool).
Operating the unit or working on the Electronics with the cabinet door “open”
could cause personal injury and damage the equipment
Warning: The ECU1000 controls the actuator, it could control the HPU, it could drive
generic electric, mechanic, pneumatic and hydraulic devices. To avoid unwanted
movement of mechanic parts or leakage of pressurized fluids and risk injury of
people and damage of equipment and ambient, any mechanic, electric, hydraulic
and pneumatic device controlled by the ECU1000 device should be placed in safe
condition before executing any installation, commissioning or maintenance
operation (see relevant instruction manuals of actuator, HPU, etc.)
Warning: The end user shall provide circuit-breakers and fuses in the marshalling cabinet of
control room, to switch off the Mains and any other voltage applied to ECU1000
cabinet. Before opening the door of the ECU1000 cabinet it is mandatory to check
that any voltage (Mains or Control voltage) is off.
Breakers, fuses, differential breakers, in general any disconnecting device
• shall be in accordance with the local national standards and plant rules.
• shall be sized to be in accordance to the power required by the ECU1000
cabinet and the connected electrical loads with a maximum of 10A.
• shall be suitable located and easily reached
• shall be marked as the disconnecting device for the equipment
• shall not interrupt the protective earth conductor
Warning: Any repair work other than the operations outlines in the mentioned IOM’s will be
strictly reserved to qualified BIFFI ITALIA personnel or to personnel directly
authorised by the Company itself.
Warning: The electronic parts of the ECU1000 and all the options can be damaged by a
discharge of static electricity. Before you start, touch a grounded metal surface to
discharge any static electricity.
Warning: If the device is located in hazardous area a ‘’hot permit’’ must be obtained before
opening the explosion proof enclosures. Moreover the area must be cleaned from
explosive mixture since time keeper battery and residual capacitor charge could
generate electrical spark and cause explosion. The installation must be carried out
in accordance to the applicable Ex-d Standards regarding the electrical
installations in hazardous areas and any other applicable national standard and
rule.
ECU1000 devices are designed in accordance with the applicable International Rules and Specifications, but the
following Regulations must be observed in any case:
• the general and safety regulations
• the plant specific regulations and requirements
• the proper use of personal and protective devices (glasses, clothing, gloves, etc)
• the proper use of tools, lifting and transport equipment.

3.3 Terms and conditions

Biffi Italia guarantees each single product to be free from defects and to conform to current goods specifications. The
warranty period is one year from the date of installation by the first user, or eighteen months from the date of shipment
to the first user, whichever occurs first. No warranty is given for products which have been subject to improper storage,
improper installation, misuse, or corrosion, or which have been modified or repaired by unauthorised personnel. Repair
work due to improper use will be charged at standard rates.
3.4 Manufacturer’s Liability

Biffi Italia declines all liability in the event of:
• use of the device in contravention of local safety at work legislation
• incorrect installation, disregard or incorrect application of the instructions provided on the device nameplate
and in this manual
• modifications without Biffi’s authorisation
• work done on the unit by unqualified or unsuitable persons
3.5 Applicable Standards and Regulations

EN ISO 12100-1: Safety of machinery - Basic concepts, general principles for design. Part 1-Basic terminology,
methodology.
EN ISO 12100-1: Safety of machinery - Basic concepts, general principles for design. Part 2-Technical principles and
specification.
EN 60204/1: Electrical equipment of industrial machines. Part 1- General requirements.
2006/42/EC: Machinery directive.
2004/108/EC: EMC Directive
94/9/EC: ATEX Directive (if used in hazardous area)
2006/95/EC: Low Voltage Directive
IEC 60068-2-6, IEC 60068-2-57: Vibration Test
IEC 61010-1 Safety requirements for electrical equipment for measurement, control and laboratory use
4 Storage
Important:
Not performing the following instructions will invalidate the product guarantee.
All ECU1000 cabinets leave the factory in perfect condition. When mounted together with the actuator they are
guaranteed by the actuator test certificate; in other cases they are guaranteed by an individual certificate. In order to
maintain these characteristics until the ECU1000 is installed on site, proper attention must be observed for preservation
during the storage period.
The standard plastic plugs used to protect the cable entries during the transport are not waterproof; they just prevent the
entry of undesired objects during transport: during the storage it is recommended to replace them with waterproof
version.
In any case storage is recommended in close ambient without excessive humidity.

5 Device Description
This paragraph summarizes only the main important functions of cabinet with ECU1000. Detailed description of
functions is available in the manuals DTDE327 and DTDE328.
5.1 Block diagram

Main voltage I/O’s to control room BUS control
ECU1000 HA, HCU, HPU
Optional BUS card
12Vdc I/O’s to
Main power 24Vdc Base card Control card control room
supply HA, HCU,
I/O HPU
Optional driver Local

card with PWM I/O’s to HCU Display card
control
Cabinet
The ECU1000 is supplied at 24VDC. A power supply module should be provided in the cabinet to generate the
requested 24 VDC. The optional driver card is requested to drive proportional valves by PWM signals.
5.2 General features
• Control of any BIFFI hydraulic actuator (OLGA-H, OLGAS-H, HLA, HLA-S, single acting spring return or
double acting, modulating and on-off service)
• Standard functions:
1. Positioning of modulating actuator (heavy duty, low drain-heavy duty, stepping)
2. Control of integral HPU with single or dual pump. Automatic switch of electrical pumps
3. Control of on-off actuator
4. Partial Stroke Test
5. Input characterization
6. Failsafe function
7. ESD function
8. Interlock function
9. Stay in position by dedicated SOV
10. Outputs to control Servovalves, Proportional Valves, on-off Solenoid Operated Valves (SOV’s),
contactors of Electrical Motor of hydraulic pumps
11. Inputs to read 4-20mA transmitters and switches
12. Optional module to drive proportional valves by PWM signals
• Hardwired and BUS remote control
• Local control
• Local Operator Interface with graphic OLED display and pushbuttons, visible from -40°C
• User friendly navigation in the menu. English language menu.
• Diagnostic function
• Full local parameterization.
• Access to parameter protected by four levels of password
• Configuration data saved in 3 separated permanent memories
• 2 Watch-dog timer working in parallel
• Real Time Clock and battery to maintain date and time
• CRC function to validate communication messages and memory content
• Bluetooth wireless communication
• Temperature, humidity and acceleration sensors of electronic cards
• Electronic NAME PLATE of electronic cards
• Failure, Alarm, Event, Connection loggers, graph and recorder
• BIFFI-Assistant, SW tool for PC for connection to actuator via Bluetooth or RS232

• Operating temperature of electronics from -40 °C to +75 °C

• Electronics suitable to “On-field” operation inside an IP65 or Ex-d cabinet containing:
o ECU1000 electronic cards
o Power supply module
o Line filter, fuses, surge arrester, optional magnetothermal switch
o DIN RAIL terminals for connection with control room, HA, HPU and HCU
o Optional Heater
5.3 Inputs and Outputs
Each input and output is configurable and can be associated either to signals to/from control room and HA, HCU, HPU.
• Analogue inputs
4 x 4-20mA analogue inputs, insulating amplifiers and surge arresters. Max voltage drop at 20mA=9V
1 x 4-20mA analogue input, insulating amplifier and surge arresters. Jumper (J6) to select High/Low impedance mode.
Impedance in High impedance mode >100Kohm. Impedance in Low impedance mode <250ohm.
• Analogue output
1 x 4-20mA analogue output, insulating amplifier and surge arresters. Max resistive load 250 ohm, active or passive
current loop, max voltage 24V.
• Digital inputs
10 x digital inputs, optocoupled, max voltage 30Vdc, surge arresters. Max absorbed current 7mA. Logical_0 < 5V,
Logical_1 >15V
• Digital output
1 x digital outputs, optocoupled, surge arresters, max 24V
• Servovalve / proportional valve control

1 x analogue output configurable by jumpers, insulating amplifier and surge arresters
o +-10V, +-10mA, +-15mA, +-50mA, +-100mA
1 x digital output, optocoupled, surge arrester
o enable control to servovalve / proportional valve or general output
1 x digital input, optocoupled, surge arrester
o fault status of servovalve / proportional valve or general input
The Servovalve/Proportional Valve stage is supplied at 24VDC and is protected by a 4A T fuse in the ECU1000
cabinet.
• Output relays
4 x single side stable, SPDT contact, voltage free, max 30Vdc/230Vac/1A
5 x single side stable, SPST NO contact, voltage free, max 30Vdc/230Vac/1A
2 x single side stable, SPST NO contact, voltage free, max 30Vdc/230Vac/1A (on demand latching relay)
According to user request, to the application and to the electrical diagram, some contact is available to the end user as
remote signalling and the remaining contacts are available to control the electrical components of HA, HCU and HPU.
The set of condition to switch each relay is configurable.
The contacts of the output relays are available on the connectors CN39, CN40 and
Important: CN41 (see par.5.7, RL0 to RL10). If the voltages through the contacts are different
(e.g. 230Vac and 24Vdc), it is suggested to group the contacts with the same voltage
in the same connector. Each contact should be protected by 1AT fuse, not provided
in the ECU1000 cabinet. If the contacts work as control of an external load, the
fuse should be provided in the cabinet containing the electrical load. If the contacts
work as signalling to control room, the fuse should be installed in the marshalling
cabinets of the control room at customer care. Reinforced insulation is provided
between each group of relays connected to connectors CN39, CN40, CN41; basic
insulation is provided between each relay connected to the same connector; the end
user shall provide the same insulation in the external load.

5.3.1 Digital inputs up to 110Vdc

It is necessary to add a resistor in series to each input that works at more than 30Vdc, to limit the input current. The
additional resistors can be mounted by the end user in the marshalling cabinet of the control room or by Biffi in the
ECU1000 cabinet. The following table provides the values of resistors.
Voltage Value Voltage Value

48Vdc 2W-6800 Ohm 110Vdc 2W-22000 Ohm
5.3.2 Extension connector

It allows increasing the number of I/O lines to connect an optional driver card card with 2 PWM channel e 2 analog
inputs or a generic proportional valve with PWM control input
5.3.3 Service voltages

1 x out: 24Vdc/100mA isolated to supply the Position transmitter
1 x out: optional 24Vdc/100mA isolated to supply remote controls
5.4 Bus interface
Upon request the ECU1000 can be provided with HART bus (mode actuator) and Modbus RTU buses
5.5 ECU1000 power supply module
The following power supply modules can be provided in the ECU1000 cabinet:
• Vin=24 Vdc , Vout=24Vdc/max 10A
• Vin=110Vdc, Vout=24Vdc/max 10A
• Vin=110Vac/50 or 60 Hz, Vout=24Vdc/max 10A
• Vin=230Vac/50 or 60 Hz, Vout=24Vdc/max 10A
The power supply module depends on the type of main supply provided by the end user, and is protected by fuses (or
magnetothermal switch), line filter, surge arresters, and reversed polarity (only in case of DC supply).

5.6 ECU1000 Electronic cards
CONTROL CARD
DISPLAY CARD
Insulating spacer Aluminium plate BASE CARD

5.7 ECU1000 cabinet block diagram
Mounted on the
cabinet door
Aluminium plate
4A T fuse
Cables to connectors
CN_xx Optional
Heater Fuse 24Vdc
Surge arresters
DIN rail terminals 24V/15W 4A T Optional driver
and bus card
Fuse Power supply Cables to connectors
1A T PE CN_xx Surge arresters
Vout 24Vdc
Cables to Cables to
actuator control room Line filter and DIN rail terminals
Surge arresters
Fuses1A T are requested in the
marshalling cabinet of control Chassis IE
Remove J1 to
room to limit the max current Magnetothermal separate PE and IE
of output relay contacts
switch or fuses
J1 ECU1000
Fuses or breaker are requested in the Main Cables to Cables to cabinet
marshalling cabinet of control room to DIN rail PE bar IE bar actuator
Supply control room
switch the main supply of cabinet terminals
PE PE: Protection Earth
IE: Instrumentation Earth

5.8 ECU1000 cabinet
The ECU1000 cabinet is suitable to be used outdoor. The cabinet is provided with glass windows to allow viewing the display and 3 pushbuttons to move in menu of ECU1000
or for local command.
Two types of cabinet are available:
• Cabinet AISI 316, IP65 to be used in standard environment. The cabinet door needs a tool to be open. (type CP456025, manufacturer MP Gamma, or equivalent)
• Cabinet Ex-d IIB T5 to be used in hazardous area. The cabinet door needs an appropriate key to be open. (type EJB 51, manufacturer Nuova ASP, or equivalent)
Different types of cabinets can be provided on request.
Cable entry
Cabinet for standard outdoor Cabinet for hazardous
environment environment
Warning: • The door of cabinet must be kept always closed by key (or tool), to avoid damage of
Electronics due to wet or pollution or personal injury of people. The key to open the
door (or the alternative tool) must be kept by authorized and qualified personnel
• The cabinet must be connected to “earth”

5.9 Installation
The standard ECU1000 is suitable to work in the temperature range -40°C +75°C. Special version can be done in case
of different temperature range.
The ECU1000 cabinet can be supplied as part of the actuator or separately. If ordered as part of an actuator, the factory
mounts the ECU1000 cabinet together with the actuator, makes the connections (pneumatic, hydraulic and electrical) to
the actuator, sets up and calibrates the instrument. In both cases the mounting bracket shall withstand a force of four
times the weight of the ECU1000 cabinet. The following general instructions should be observed.
Important:
Check that the working temperature range is correct. If the temperature is higher
than the rated values it needs to add a sunshine shield to the ECU1000 cabinet
Warning: The ECU1000 cabinet is not provided with specific means for lifting and
transporting. Manually move the cabinet according to the effective rules of health
and safety of the installation country.
Warning: It is assumed that the installation, the setting, the commissioning, the maintenance
and repair works are carried out by qualified personnel and checked by
responsible Specialists.
Warning: Avoid personal injury or property damage due to handling of mechanical parts.
Before proceeding with any installation operation, the following precautions
should be used
• Always wear protective clothing, gloves, and protection glasses to prevent
personal injury.
• If installation is in hazardous area, personal injury or property damage
may result from fire or explosion. Preventive measures may include:
remote venting of the unit, re-evaluating the hazardous area classification,
ensuring adequate ventilation, and the removal of any ignition sources.
Require hot permit before any operation.
• Check with process or safety engineer for any additional measures that
must be taken to protect against process media.
Important: If the installation is in hazardous area, it must be carried out in accordance to the
applicable standards IEC/EN 60079-14 and IEC/EN 60079-17 regarding the
electrical installations in Hazardous Areas (other than mines) classified as Zones 1,
2 (gas) and Zones 21, 22 (dust) following IEC/EN 60079-10-1 and IEC/EN 60079-
10-2 and any other applicable national standards and rules.

5.9.1 Installation in hazardous area
Special attention should be paid to the following:

• before any assembly operation the joint surfaces must be greased.
• the cable glands must have a protection degree at minimum IP66/68 (EN/IEC 60529).
• periodically verify the quantity of dust deposited on the enclosure and clean it in the case the quantity
becoming more than 5 mm.
5.10 Checks to be performed before installation
Warning: Before the installation it is mandatory to check if the nameplate associated to the
extension for additional entry specifies the appropriate degree of protection and
ambient temperature limits as requested by the Rules applicable to the
plant/location where units are installed.
1) The electrical supply cables must be suitable for the power rating
2) Gather the necessary tools for the assembly and setting of the ECU1000 controls;
3) Verify that the fixing elements (screws, nuts etc.) used for fastening the ECU1000 cabinet can sustain at least four
times the weight of the ECU1000
4) If a long storage period has occurred, before installing the ECU1000:
• Check the installation of the plugs or cable glands on the cable entries.
• Check whether the enclosure covers of the ECU1000 cabinet are cracked or broken.
5.11 Cables and Electrical Connections
5.11.1 Cables connection
The sealing of cables and/or conduit entries must be carried out in accordance with National Standards or the
Regulatory Authorities. Method of sealing and cable glands must be approved and separately certified for use in
hazardous areas.
Warning: The end user shall provide circuit-breakers and fuses in the marshalling cabinet of
control room, to switch off the Mains and any other voltage applied to ECU1000
cabinet. Before opening the door of the ECU1000 cabinet it is mandatory to check
that any voltage (Mains or Control voltage) is off.
Breakers, fuses, differential breakers, in general any disconnecting device
• shall be in accordance with the local national standards and plant rules.
• shall be sized to be in accordance to the power required by the ECU1000
cabinet and the connected electrical loads with a maximum of 10A.
• shall be suitable located and easily reached
• shall be marked as the disconnecting device for the equipment
• shall not interrupt the protective earth conductor
Important: To prevent any water infiltration through the line cable conduits, be sure the cable
glands have the minimum degree of protection required by the plant. The cable
glands shall be selected in accordance to the cables section
If rigid conduits make the connection, place a flexible pipe connection between the
conduit and the terminal board.

To guarantee weatherproof and explosion-proof fit, screw the cable glands tightly (at least 5 turns) and block them with
a thread sealant. The use of a thread sealant is necessary in case of explosion-proof capability.
If some parts of the cable glands have been removed during work on the cable entries put them back into place now to
avoid losing the dismantled parts.
Important: The cables MUST be selected considering as maximum working temperature of

cables the maximum working temperature of ECU1000 device.
Cables should be connected to DIN RAIL terminals provided inside the ECU1000 cabinet.
Important: The avoid malfunction and electromagnetic interferences due to cables coupling, it
is recommended to use separated cables for power and signals and if it is possible
also separated conduits. Use of shielded cables for analogue or data signals is
requested.
5.11.2 Earth connection
The ECU1000 cabinet must be connected to EARTH trough the External EARTH stud. The wire section shall be at
least equal to the section of power supply wires.
For the earth connection of the cables dedicated DIN RAIL terminals or EARTH bar are provided.
The chassis is connected to PE (Protection Earth). Power supply module, line filter and surge arresters are connected to
PE. The electronics of ECU1000 and shield of cable for signals are connected to IE (Instrumentation Earth). PE and IE
are isolated. According to plant requirement the end user should use case A or B. The ECU1000 cabinet is supplied
according to case A.
Case A Surge arresters, line filter, ECU1000 cabinet ECU1000 electronic
power supply module boards
Chassis
earth stud PE IE
J1
PE bar IE bar
PE cable
If the end user uses the case B the jumper J1 should be removed
Case B Surge arresters, line filter, ECU1000 cabinet ECU1000 electronic

power supply module boards
Chassis
earth stud PE IE
PE bar IE bar
PE cable IE cable

5.11.3 Cables requirements – EMC protection

The table below resumes the specifications of cables for connecting the ECU1000 cabinet.
CONNECTION TYPE CABLES REQUIREMENT Note: “Shielded” must be considered as a

External Power Supply Not shielded more strict condition than “Armoured”.
Relay output Multicore, not shielded
It is possible to use a shielded cable instead
Digital Input Multicore, not shielded
of a required armoured cable but it is not
Digital Output Multicore, not shielded
possible to use an armoured cable instead of
Analogue Output Pair, Shielded
a required shielded cable.
Analogue Input Pair, Shielded
5.11.4 Wire dimension and type

Before making any connection to ECU1000 cabinet, checks the electrical parameters present (voltage and current
limits) on the nameplate and in this manual. The connections are available on DIN RAIL TERMINALS.
Max dimension of the wires: 2.5 mm2 for the standard DIN Rail Terminals.
The dimension and type of the wires must respect the current regulations of the installation country.
5.11.5 Unused entries
Warning: Replace the plastic plugs with new plugs that guarantee the protection IP degree
required.
If the cabinet is in hazardous area use only certified explosion-proof plugs and
block with a thread sealant to guarantee the tightening. Not performing the above
prescription will invalidate the safety protection in case of presence of hazardous
atmospheres.
5.12 Start-up Procedure

In this section is described a step-by-step procedure to start-up the ECU1000.
All the points must be performed in the order they appears.
generate electrical spark and cause explosion.
Warning: Electrical start-up should be done when the mechanical setting of the actuator
which is connected to ECU1000 is completed. Refers to instruction manuals of
Hydraulic Actuator, Hydraulic Power Unit, Hydraulic Control Unit.
Warning: Check that the breaker of the main electrical power in the marshalling cabinet of
control room is off
Check that any control voltage applied to cabinet is off
• Check that the cables coming from control room and actuator are connected to the cabinet terminals according
to electrical diagram. Check that the screws of terminals are correctly tighten
• Check that earth connections are reliable and according to the instructions in the previous paragraphs
• Switch on the main switch inside the ECU1000 cabinet
• Close the door of the ECU1000 cabinet

• Check that the actuator is in safe position and no mechanical damage or undesired movement of actuator can
occur. Check that no leakage or dangerous pressure (oil or air) is present in the mechanics and hydraulic
controlled by the ECU1000. Check that hydraulic piping is correctly connected.
• Switch on the breaker of the main electrical power in the marshalling cabinet of control room is off. In general
the ECU1000 is supplied already with the configuration requested by the application. No special configuration
operations are required except the setting of travel limits and tuning of positioner function.
• Check the Local Operator interface of the ECU1000. The manuals

DTDE 327 and DTDE328 contain the instructions to use the
Local Operator Interface and detailed description of each
ECU1000 function
•
.
• Check the Failure and Alarm. Remove the conditions that cause Failure and Alarm. Refer to manuals DTDE
327 and DTDE328 to see the Failure and Alarm description and conditions.
• Apply the control signals to the ECU1000 cabinet. If the actuator is for modulating service, it starts in
AUTOMATIC mode. Apply a control signal (4-20mA) that keeps the actuator in safe position (closed or open)
• When hydraulic pressure is correct set the actuator travel limits (see DTDE 327 and DTDE328)
• Switch to local control mode and move the actuator by pushbuttons the Up/Open and Down/Close.
• Check that output and input signals to control room and actuator are correct
• Tune the actuator response by means of the Local Operator Interface facilities
• Check the variables as follows:
o From HOME VIEW
o Press Up/Open to wake up the display
o Press Up/Open to scroll the list of variables
o Press Enter and see the value
POSITION%: it shows the % of opening of the valve. Check that the value is according to
real valve position
POSITION DEMAND%: if the positioning function is on, this variable shows the valve
requested position.
POSITION ERROR%: if the positioning function is on, this variable shows the difference
between POSITION DEMAND% and POSITION%. It is used to calculate the output signal
(by the parameters GAIN K1 and K2), visible in AO1 OUT %
IN-POS DEMAND%: if the positioning function is on, this variable shows the input signal
of the valve requested position. The values of IN-POS DEMAND% and POSITION
DEMAND% are equals if the Input Characterization function is off
TEMPERATURE °C: it shows the temperature inside the ECU1000 cabinet
HUMIDITY %: it shows the humidity inside the ECU1000 cabinet
ACCELERATION-g: it shows the acceleration level
AO1 OUT %: if the positioning function is on and the hydraulic valve is analogue, this
variable shows the output control signal %
OIL PRESSURE bar: if the actuator is provided with integral HPU controlled by the
ECU1000, this variable shows the HPU oil pressure
NEXT PST: if PST function is on, this variable shows the date of the next PST cycle
PUMPS SWITCH: if the actuator is provided with integral HPU, dual pump, controlled by
the ECU1000, this variable shows the time before the next pump switch
• Return to HOME VIEW

•
6 DECOMMISSIONING
Disposal and recycling
At the end of the life the ECU1000 cabinet must be disassembled.
Warning: Do not dump non-biodegradable products, lubricants and non-ferrous (rubber,

PVC, resins, etc.) into the environment. Dispose of all such materials as indicated
in the following table:
Subject Hazardous Recyclable Disposal

Electrical and electronic equipment Yes Yes Use specialist recyclers.
Glass No Yes Use specialist recyclers.
Metals No Yes Use licensed recyclers.
Plastics No Yes Use specialist recyclers.
Rubber (seals and o-rings) Yes No May require special treatment before disposal,
use specialist waste disposal companies
Battery Yes No May require special treatment before disposal,
use specialist waste disposal companies.
Warning: Do not re-use parts or components which appear to be in good condition after they
have been checked or replaced by qualified personnel and declared unsuitable for
use.
Important:
In all cases check local authority regulation before disposal

7 TROUBLE SHOOTING
7.1 Local Operator Interface of ECU1000 off
Warning: • Switch off the main power from ECU1000 cabinet by the breaker in the
marshalling cabinet of control room
• Switch off any control voltage from ECU1000 cabinet
generate electrical spark and cause explosion.
Open the ECU1000 cabinet door.

With reference to the dedicated electrical diagram of the ECU1000 cabinet 193AR000xxx
• Perform the visual inspection of electronics, cables and terminals. No component should be damaged, no wires
should be disconnected from terminal and the screws of terminals should be well tightened.
• Check the fuses and the main switch of the ECU1000 cabinet
• Check that the surge arresters are not damaged, by a multimeter measure the continuity between the input and
output terminals
• If none of the above test solve the problem it needs to check the power supply module and then the ECU1000
cards
7.2 Local Operator Interface of ECU1000 available
7.2.1 Trouble-shooting by Local Operator Interface
The manuals DTDE327 and DTDE328 provide detailed instructions on the Local Operator Interface of ECU1000 and
on the Actuator malfunctions. Here below is described only the procedure to see the list of alarm and failure.
7.2.1.1 Failure, Alarm and Maintenance Request

See the display in the HOME VIEW.
• If it signals Failure
o Press Up/Open until the display shows Failure
o Press Enter
o Press Up/Open and Down/Close to scroll the list of Failure
o See the manual DTDE327, Actuator Malfunction tables to find the description and the reset condition
• If it signals Alarm
o Press Up/Open until the display shows Alarm
o Press Enter
o Press Up/Open and Down/Close to scroll the list of Alarms
• If it signals Maintenance Request
o Enter in the menu of the Local Operator Interface
o Check the Current Date and the Next Maintenance Date
o If necessary enter new dates

7.2.1.2 I/O check
• From HOME VIEW

oPress Up/Open to wake up the display
oPress Up/Open until the display shows Out Relay
oPress Enter
oCheck that each output contact is according to the required application (see electrical and mechanical
diagrams). If an output is in wrong state check the condition associated to relay in the parameter table
o Return to HOME VIEW
• From HOME VIEW
o Press Up/Open until the display shows Digital Inputs
o Press Enter
o Check that each digital input is according to the required application and change status when the
connected hardware input changes (see electrical and mechanical diagrams). If an input does not
change check the hardware connected to the input
• From HOME VIEW
o Press Up/Open until the display shows Analog Inputs
o Press Enter
o Check that each analog input is according to the required application and changes when the connected
hardware 4-20mA changes. The value of each input is shown in bits, from 0 to 4096 (see electrical
and mechanical diagrams). If an input does not change check the hardware connected to the input
7.2.2 Trouble-shooting by BIFFI-Assistant SW tool
The manuals DTDE330, DTDE327 and DTDE328 provide detailed instructions on the BIFFI-Assistant SW tool of
ECU1000.
Here below is described only the procedure to see the list of alarm and failure.
• Connect BIFFI-Assistant to actuator
• Select DEVICE COMMANDS
See the manual DTDE327, Actuator Malfunction
• Select LOG and GRAPH
tables to find the description and the reset condition.
• Select LOGGER
Remove Failures and Alarms.
• Select FAILURE and see the list of failure
• Select ALARM and see the list of alarms

8 ECU1000 cabinet code

The ECU1000 cabinet is identified by an eleven characters code “1 9 3 A R 0 0 0 x x x”. The final 3 characters identify
the options of each cabinet. Refer to the dedicated electrical wiring of cabinet to see the installed options
The electrical wiring of cabinet “1 9 3 A R 0 0 0 x x x” includes the bill of main components inside the cabinet. Below
is an example of bill of material. Refer to this document to require spare parts.
9 Routine test of ECU1000 cabinet

The factory performs a routine insulation test on the ECU1000 cabinet before shipping it. The complete test procedure
is described in the document “Factory test procedure of cabinet with ECU1000 device code 193AR000xxx”; it includes
insulation, functional, communication and PEarth continuity test. Here below are described only the insulation and PE
continuity tests. Refer to the dedicated electrical wiring of cabinet“1 9 3 A R 0 0 0 x x x” to identify the cabinet
terminals.
PEarth continuity test: the test checks the resistance between the earth stud and metallic parts of the cabinet (on the
screw). The resistance should be less than 0.1 ohm.
Insulation test of MAINS: test voltage= 840Vac (MAINS< 150V) or 1400Vac (MAINS >150V and <300V)
between the terminals with MAINS and Earth
Insulation test of IEarth: test voltage= 500 Vac between the IEarth (Instrumentation/Functional Earth) and PEarth
(Protection Earth). (to perform the test it needs to remove the jumper J1, see par. Earth connection)
Insulation test of signal I/O’s: test voltage= 500Vac between each I/O signal and PEarth.
To avoid damaging the Electronics the connectors of ECU1000 cards are disconnected (except CN39, CN40 and
CN41), the surge arresters device mounted on socket are removed or disconnected, the external loads are disconnected.
The test is done on the following terminals:
• Main supply terminals and PEarth
• Terminals connected to connectors CN39, CN40, CN41 and PEarth
• IEarth and PEarth
• Each analogue or digital input and output and PEarth
No flashover shall occur; no failure of Electronics shall be detected.

BIFFI ITALIA srl

Loc.. Caselle S. Pietro n. 420, 29017 Fiorenzuola d’Arda (PC) ITALY

ECU 1000 Control functions and Local Operator Interface
DTDE 327
ECU 1000
Control functions
and
Local Operator Interface
ECU1000 cards
ECU1000 cabinets
ITALIA.. All right riserved

Copyright by BIFFI ITALIA DTDE327-e5 Pag. i
INDEX
1 INTRODUCTION 1
ECU1000 FEATURES 1
1.1 Main characteristics of ECU1000 2
1.2 Inputs and Outputs of ECU1000 3
1.3 Status signalling 3
1.4 ECU1000 Electronic cards 4
1.5 ECU1000 terminals 5
2 POSITIONING FUNCTION FOR CONTINUOUS MODULATING ACTUATOR 6

2.2 Control of servovalves and proportional valves 6
2.3 Parameters of positioning function 7
2.4 Output of positioning function 8
2.5 Switch to auto mode 8
3 POSITIONING FUNCTION FOR STEPPING MODULATING ACTUATOR 8

3.2 Control of Solenoid Operated Valves 9
3.3 Parameters of positioning function 10
3.4 Output of positioning function 10
3.5 Switch to auto mode 10
4 SPEED SOV’S 10
5 ESD FUNCTION 11
6 FAILSAFE 12
7 INTERLOCK 12
8 STAY IN POSITION BY SOV 13
9 PRIORITY OF COMMANDS 13
10 OUTPUT 4-20MA 13
11 DATE 14
12 MISCELLANEOUS 14
13 OUTPUT RELAY 14
13.1 Status relay table 15
14 TRAVEL LIMIT SETTING 16
Copyright by BIFFI ITALIA. All right reserved DTDE327-e5 Pag. ii

14.1 Mechanical stops 16
14.2 4-20mA position transmitter 16
14.3 Electronic setting of travel limits 17
14.3.1 Travel limit on reaching the configured position 17
14.3.2 Travel limit on reaching the mechanical stop 18
14.4 Change open /close limit function 19
14.5 Bias adjustment of driver and valve purge 20
15 ACTUATOR MALFUNCTION TABLES 21

15.1 Failure table (NAMUR NE107: FAILURE) 21
15.2 Alarm table (NAMUR NE107: OUT of SPEC) 22
15.3 Additional Alarm table (NAMUR NE107: OUT of SPEC) 23
15.4 Remote not available table (NAMUR NE107: FUNCTION CHECK) 24
15.5 Maintenance required table (NAMUR NE107: MAINTENANCE REQUIRED) 24
16 LOGGERS 25
17 GRAPHS AND RECORDER 25
18 EXAMPLES OF MODULATING ACTUATORS 26

18.1 Actuator for heavy modulating service 26
18.2 Actuator for heavy modulating service and low oil drain 27
18.3 Actuator for stepping modulating service 28
19 LOCAL OPERATOR INTERFACE 29

19.1 Description 29
19.2 Pushbuttons UP, DOWN, ENTER 31
19.3 Push-buttons UP, DOWN , ENTER and two-position selector 32
19.4 ECU1000 menu 33
19.5 Parameter table 37
19.6 ECU cmd table 40
19.7 Status and variables table 40
20 EXAMPLES OF MENU OPERATIONS 41

20.1 Username and password 41
20.2 Parameter change 41
20.3 Parameter visualization 42
20.4 Execution of an ECU cmd 42
20.5 Visualization of “Status and variables” 43
20.5.1 Visualization of “HPU oil pressure” 43
20.5.2 Visualization of “Failure” and “Alarm” 44
20.5.3 Visualization of “Function summary” 44
20.5.4 Command “Clear Failure and Alarm” 44

Copyright by BIFFI ITALIA. All right reserved DTDE327-e5 Pag. iv

rule.
Warning:
Refer to DTDE326 for the installation and maintenance instruction manual of the
ECU1000 cabinet

1 14/03/2012 M. Giuliani A. Affaticati Mod. ESD par.
2 08/05/2013 M. Giuliani A. Affaticati Mod. Pos. stepping
3 28/08/2013 M. Giuliani A. Affaticati Mod. Alarm / Introd.
4 19/12/2013 M. Giuliani A. Affaticati Interlock/speed SOV
5 28/03/2014 M. Giuliani A. Affaticati Hand-pump alarm
Copyright by BIFFI ITALIA. All right reserved DTDE327-e5 Pag. v

1 Introduction
The DTDE326 “Installation and Maintenance” provides the instructions for the installation and maintenance of cabinet
with ECU1000. The DTDE327 Control functions and Local Operator Interface”, in the paragraphs 1 and 2 provides the
general characteristics of ECU1000, in the paragraphs 3,…,17 provides the instructions to use the Positioner and the
additional functions to control and monitor the actuator, in the paragraphs 19 and 20 provides the instructions of the
Local Operator Interface. The DTDE328 “Input characterization-Recorder-Graph-Logger-PST-HPU-On/Off control-
Optional local lamps” provides detailed instructions relevant to further ECU1000 functions (Input characterization-
Recorder-Graph-Logger-PST-HPU-On/Off control-Optional local lamps). The manuals DTDE 326, DTE327 and
DTDE328 provide the instructions relevant to complete set of ECU1000 functions. Only functions requested by the
application and needed to allow the correct actuator control and operation will be activated in the factory setting.
ECU1000 features
The ECU1000 is a new electronic unit to control an electro-hydraulic actuator for process valves. The main functions
are:
• To acquire the feedbacks from sensors of HA (Hydraulic Actuator), HCU (Hydraulic Control Unit), HPU
(Hydraulic Power Unit)
• To acquire the setpoints from control room
• To process the acquired data and send operational commands to HA, HCU and integral HPU
• To monitor the HA, HCU and HPU complete system
• To send to control room signals relevant to status and alarms of complete system
• To log events, alarms and failures
The next figures show the block diagram of the electro-hydraulic actuator with ECU1000.
Block diagram of an Electro-Hydraulic Actuator with ECU1000

Hardwired or BUS
remote control Valve position
Control ECU1000
Electronic Control Unit
room HPU controls
Hydraulic Optional Position Transmitter
Hydraulic Valves Transmitters
Accumulator Control
Electric supply
HPU Integral HCU Hydraulic Control HA

Hydraulic Power Unit Unit Hydraulic Actuator
Separated Hydraulic
Power
Process Valve
Block diagram of the ECU1000

Main voltage
ECU1000 I/O’s to control room
BUS control
HA, HCU, HPU Optional BUS card
12Vdc I/O’s to
Main power 24Vdc Base card Control card control room
supply HA, HCU,
I/O HPU
Optional driver I/O’s to Display card Local operator

card with PWM HCU interface
Copyright by BIFFI ITALIA. All right reserved DTDE327-e5 Pag. 1

The base version of the ECU1000 consists in 3 electronic boards, Base card, Control card and Display card. Optional
cards can be added to drive proportional valves by PWM signals or for bus control. The ECU1000 electronics is
supplied at 24VDC power supply. A power supply module should be provided in the cabinet to generate the requested
24VDC.
1.1 Main characteristics of ECU1000
• Control of any BIFFI hydraulic actuator (OLGA-H, OLGAS-H, HLA, HLA-S, single acting spring return and
double acting, modulating and on-off service)
• Standard control functions:
o Positioning of modulating actuator (heavy duty, low drain-heavy duty, stepping)
o Control of integral HPU with single or dual pump. Automatic switch of electrical pumps
o Control of on-off actuator
o Partial Stroke Test
o Input characterization
o Failsafe function
o ESD function
o Interlock function
o Stay in position by dedicated SOV
o Outputs to control Servovalves, Proportional Valves, on-off Solenoid Operated Valves (SOV’s),
Electrical Motor of hydraulic pumps
o Inputs to read 4-20mA transmitters and switches
o Optional module to drive proportional valves by PWM signals
• Hardwired and BUS remote control
• Local control
• Local Operator Interface with graphic OLED display and pushbuttons, visible at very low temperature (-40°C)
• User friendly navigation in the menu. English language menu.
• Diagnostic function
• Full local parameterization.
• Access to parameters protected by four levels of password
• Configuration data saved in 3 separated permanent memories
• 2 Watch-dog timer working in parallel
• Real Time Clock and battery to maintain date and time
• CRC function to validate communication messages and memory content
• Bluetooth wireless communication
• Temperature, humidity and acceleration sensors of electronic cards
• Electronic NAME PLATE of electronic cards
• Failure, Alarm, Event, Connection loggers
• Graph, Recorder and Signatures
• BIFFI-Assistant, SW tool for PC for connection to actuator via Bluetooth or RS232
• Operating temperature from -40 °C to +75 °C
• Electronics suitable to “On-field” operation inside an IP65 or Ex-d cabinet containing:
o ECU1000 electronic cards
o Power supply module
o Line filter, fuses, surge arrester, optional magnetothermal switch
o DIN RAIL terminals for connection with control room, HA, HPU and HCU
o Optional Heater
Local operator Examples of

interface cabinets with
ECU1000

Even if the ECU1000 can work without LOCAL OPERATOR INTERFACE (it means without Display card), it is
suggested to use the ECU1000 with its Local Operator Interface. The LOCAL OPERATOR INTERFACE is useful for
the following reasons:
• In the commissioning of actuator it allows executing calibration, setting and local control
• In operation it allows viewing maintenance and diagnostic data
• The display works and is visible also at very low temperature (from -40°C)
• No additional tools are required
• On request it can be placed in a separate cabinet
• It provides the wireless Bluetooth option for downloading curves, signatures, logger by PC and BIFFI-
Assistant from ECU1000 memory
1.2 Inputs and Outputs of ECU1000
The DTDE326 gives more detailed information relevant to the ECU1000 I/O’s.
• Analogue inputs
4 x 4-20mA isolated analogue inputs, max voltage drop at 20mA = 9V
1 x 4-20mA isolated analogue input, max input resistance 250 ohm
• Analogue output
1 x 4-20mA isolated analogue output, max load resistance 250ohm
• Servovalve / proportional valve control

1 x isolated analogue output, configurable by jumpers
o +-10V, +-10mA, +-15mA, +-50mA, +-100mA
1 x digital output, optocoupled
o enable control to servovalve / proportional valve or general output
1 x digital input, optocoupled
o fault status of servovalve / proportional valve or general input
• Digital inputs
10 x digital inputs, optocoupled, max voltage 30Vdc
• Digital output
1 x digital outputs, optocoupled
• Output relays
4 x single side stable, SPDT contact, voltage free
5 x single side stable, SPST NO contact, voltage free
2 x single side stable, SPST NO contact, voltage free (on request latching relays can be provided)
Each input and output is configurable and can be associated either to signals to/from control room or to signals to/from
HA, HCU, HPU.
1.3 Status signalling
According to NAMUR NE107 the ECU1000 provides the following outputs:

• FAILURE
• ALARM (OUT OF SPEC)
• REMOTE NOT AVAILABLE (FUNCTION CHECK)
• MAINTENANCE REQUIRED
The above statuses are available to the control room by output relays and locally by the ECU1000 Local Operator
Interface. By the configuration options the conditions associated to the output relays can be changed.

1.4 ECU1000 Electronic cards
CONTROL CARD
and
BASE CARD
DISPLAY CARD

1.5 ECU1000 terminals
Output relays Output relays Output relays Actuator Analogue Digital Digital Digital Service Actuator Analog Proportional valve
position inputs I/O’s inputs inputs voltage position inputs or servovalve
retransmission output input control
Power
Surge Supply
arresters and 230Vac/
Main switch
line filter 24Vdc
PE Protection PE Protection
230Vac Earth Earth

2 Positioning function for continuous modulating actuator

In the actuators for continuous modulating service the ECU1000 controls the hydraulic servovalve or proportional
valve. The ECU1000 output is an analogue or PWM signal which drives the servovalve or the proportional valve.
The Positioning function controls the actuator position by means of a 4-20mA Position Demand signal or a Bus signal
coming from Process Control System (DCS, PLC, etc.).

This paragraph lists the inputs and outputs used by the Positioning function.
Inputs from control room:
• 4-20mA Position Demand input signal
Inputs and outputs to HCU Hydraulic Control Unit:
• Analogue output: +-10V, +-10mA, +-15mA, +-50mA, +-100mA, configurable by hardware
• Digital input: Fault of proportional valve driver (in case of proportional valve)
• Digital output: Enable of proportional valve driver (in case of proportional valve)
• PWM, 2 channel with additional driver card (to drive PSOV’s or proportional valves)
Input and output to HA Hydraulic Actuator:
• 4-20mA Actuator Position.
• 24Vdc output to supply the actuator position transmitter
Positioning data:
• Position resolution: 0.1%
• Control algorithm: PI
2.2 Control of servovalves and proportional valves
The figure below shows the block diagram of positioning function of ECU1000.
Local control Open loop control

ECU1000
HPU
ESD Hydraulic Power Unit
Positioning Optional
function Diagnostic and
Manual OP Driver card
output control
Manual CL
Automatic/ Manual Output
selectorl Position error module HCU
Positioner output Hydraulic Control Unit
Position (analogue or PWM)
Demand out%
Internal position
Input demand% Optional Speed SOV’s
Characterization
Position Demand Position transmission 4-20mA 4-20mA position HA

4-20mA
transmitter Hydraulic Actuator

The ECU1000 sets different operating modes on the base of the input signals and actuator status. Below it is the
description of the operating modes.
• Regular operation
It is the normal operating mode of positioning function. In AUTOMATIC mode the Position Demand signal is
continuously compared with the Position transmission signal. The ECU1000 calculates the difference between
Position Demand and Position Transmission (called Position error) and drives the actuator in open or close direction
until the demanded position is achieved. In MANUAL mode the actuator moves in opening or closing according to
command Manual OP and Manual CL and when the command stops the actuator maintains the last position. In LOCAL
the local controls UP/OPEN and DOWN/CLOSE drive the valve in opening and closing.
• Stay in position
It is automatically set by the ECU1000. The conditions to have “stay in position” mode are shown in the paragraph
“Actuator malfunction” tables. In the above mode the ECU1000 maintains the actuator in the last position,
memorized before switching from “regular operation” to “stay in position” mode.
• Tracking
It is automatically set by the ECU1000. The conditions to have “tracking” mode are listed in the paragraph “Actuator
malfunction” tables. In the above mode the positioning function sets its output to 0, and no output is generated to drive
the actuator. The actuator stays in position or moves depending on the drain of the hydraulic valves (servovalve,
proportional valve, solenoid valve).
• Open loop control
The Local Operator Interface, by the function “Open Loop cmd” in “ECU cmd, Travel limit setting” menu, allows
moving the actuator without any constraint due to position signal (for instance during calibration of analogue inputs /
outputs, travel limit setting, etc.). The positioning function works in tracking mode and the actuator can be moved by
the local pushbuttons UP/OPEN and DOWN/CLOSE.
2.3 Parameters of positioning function

The following parameters can be set by the Local Operator Interface:
Dead band: it is the percentage of position error with output equal to 0. If the position error is greater than dead band
the positioning function drives the actuator until the position error is smaller than the dead band. The value is small
(from 0 to 0.3) in the actuator with standard servovalves and proportional valves. It can be greater in case of SOV or
PSOV’s with low drain.
Error band OP-K1OP: band of small position error in opening, it is the percentage of error where the positioning
function output is proportional to position error with gain K1OP
Gain K1OP: gain used in the band of small position error in opening to calculate the output and drive the HCU
Gain K2OP: gain used in the band of large position error in opening (if position error is larger than error band OP-
K1OP). In general K2OP is smaller than K1OP and it is used to increase the actuator speed when position error is great.
Error band CL-K1CL: band of small position error in closing, it is the percentage of position error where the
positioning function output is proportional to position error with gain K1CL
Gain K1CL: gain used in the band of small position error in closing to calculate the output and drive the HCU
Gain K2CL: gain used in the band of large position error in closing, (if position error is larger than error band CL-
K1CL). In general K2CL is smaller than K1CL and it is used to increase the actuator speed when position error is great.
Integral time Ti: it is the integral time of the Integral function. Normally it is not used (set to 0)
Switch to auto time: time to switch from manual to automatic mode. The actuator moves from the last position% to the
Position Demand% by a ramp, according to configured “Switch-to-Auto” time.
Demand source: it allows selecting the source of Position Demand signal (4-20mA, bus, internal set value). The option
“Internal” is used for test.
Internal position demand: value in % of internal Position Demand
Dither: 200 Hz frequency, configurable from 0 to 10% of output to quickly move the cursor of proportional valve /
servovalve
The following parameter can be set only by the customer
Damping factor K1: reduction % of K1OP or K1CL when position demand is >98% or <2%
It allows damping the speed near 0% and 100% and if the Position Demand requires to close or open the valve

The following figure shows the relationship between the above parameters and the actuator speed.
Band with gain K1CL Speed Band with gain K1OP
max. speed CL
max. speed OP
Speed / position error

relationship
0
position error %
Band of large error Band of small Dead Band of small Band of large error
in CL with gain error in CL band error in OP in OP with gain
K2CL K2OP
2.4 Output of positioning function

The output of “Positioning function” depends on the HCU. Different outputs are provided to control various types of
servovalves and proportional valves. The paragraph 3.1. lists the available outputs.
2.5 Switch to auto mode

If the ECU1000 switches in AUTOMATIC mode, the time needed to reach the Position Demand signal can be
configured by the parameter “Switch to auto time”, to avoid bump of valve.
Position Demand %
%
The time t1 is equal to parameter

Position% of actuator “Switch-to-Auto time”
Switch to AUTOMATIC
time
t1 t2
If Position Demand signal is not constant, the time to switch t1: configurable time to switch to AUTOMATIC mode
to AUTO is the time requested by the Position signal to
t2: normal operation in AUTOMATIC
cross the Position Demand.
3 Positioning function for stepping modulating actuator

In the hydraulic actuators for stepping modulating service the ECU1000 controls Solenoid Operated Valves (SOV’s).
The SOV’s are driven by the output relays of the ECU1000. The max number of starts per hours is 600. The Positioning
function controls the actuator position by means of a 4-20mA Position Demand signal or a Bus signal coming from
Process Control System (DCS, PLC, etc.). Two SOV’s drive the actuator in opening and closing direction, a third
optional SOV (Speed SOV) can be used to reduce the actuator speed when the actuator is close the position to reach
(see paragraph 4)

This paragraph lists the inputs and outputs used by the Positioning function.
Inputs from control room:
• 4-20mA Position Demand input signal
Outputs to HCU Hydraulic Control Unit:
• relay: open, voltage free, max 30Vdc/230Vac/1A (110Vdc/0.15A)
• relay: close, voltage free, max 30Vdc/230Vac/1A (110Vdc/0.15A)

Input and output to HA Hydraulic Actuator:

• 4-20mA Actuator Position
• 24Vdc output to supply the actuator position transmitter
Positioning data:
• Position resolution: 0.1%
• Control algorithm: P
3.2 Control of Solenoid Operated Valves
The figure below shows the block diagram of positioning function of ECU 1000.
Local control Open loop control

ECU1000 HPU
Hydraulic Power Unit
ESD
Positioning
function Diagnostic and
Manual OP output control
Manual CL Open
Automatic/ Manual HCU
Output Close Hydraulic Control Unit
selectorl Position error
relays
Optional by 2 or 3 SOV’s
Position
Demand out% Internal position Speed SOV’s
demand%
Input
Characterization
Position transmission 4-20mA 4-20mA position HA
Position Demand
4-20mA
transmitter Hydraulic Actuator
The ECU1000 sets different operating modes of positioning function on the base of the input signals and actuator status.
Below it is the description of the operating modes.
• Regular operation
It is the normal operating mode of positioning function. In AUTOMATIC mode the Position Demand signal is
continuously compared with the Position transmission signal. The ECU1000 calculates the difference between
Position Demand and Position Transmission (called Position error) and drives the actuator in open or close direction
until it reaches the demanded position. If the actuator is provided with “Speed SOV”, when the position error is smaller
than the “Speed SOV %”, the “Speed SOV” reduces the actuator speed to improve the accuracy in the positioning. In
MANUAL mode the actuator moves in opening or closing according to command Manual OP and Manual CL and
when the command stops the actuator maintains the last position. In LOCAL the local controls UP/OPEN and
DOWN/CLOSE drive the valve in opening and closing.
• Stay in position
It is automatically set by the ECU1000. The conditions to have “stay in position” mode are shown in the paragraph
“Actuator malfunction” tables. In the above mode the positioning function maintains the actuator in last position,
memorized before switching from “regular operation” to “stay in position” mode.
• Tracking
It is automatically set by the ECU1000. The conditions to have “tracking” mode are shown in the paragraph “Actuator
malfunction” tables. In the above mode the positioning function sets its output to 0, it updates the position value but
no output is generated to control the actuator. The actuator is free to move depending on the drain of the hydraulic
valves of HCU.
• Open loop control
The Local Operator Interface, by the function “Open Loop cmd” in the “ECU cmd, Travel limit setting” menu,
allows moving the actuator without any constraint due to position signal (for instance during calibration of analogue
inputs / outputs, travel limit setting, etc.). The positioning function works in tracking mode and the actuator can be
moved by the local pushbuttons UP/OPEN and DOWN/CLOSE.

3.3 Parameters of positioning function

The following parameters are available in the local menu:
Dead band: it is the percentage of position error with output 0. If the position error is greater than the dead band, the
positioning function drives the actuator until the position error is smaller than the dead band.
Motion inhibit time: the parameter sets the minimum time between two commands to the open/close SOV’s.
Switch to auto time: time to switch from manual to automatic mode. The actuator moves from the last position% to the
Position Demand% by a ramp, according to configured “Switch-to-Auto” time.
Demand source: it allows selecting the source of Position Demand signal (4-20mA, bus, internal set value). The option
“Internal” is used for test.
Internal position demand: value in % of internal Position Demand
The following figure shows the relationship between the above parameters and the actuator speed. The figure is relevant
to an actuator provided with SPEED SOV (see paragraph Speed SOV)
speed
High speed SOV
High speed SOV
Low speed
Low speed
position error %
SpeedSOV % SpeedSOV %
Dead
(see Speed SOV’s) (see Speed SOV’s)
band
3.4 Output of positioning function
The paragraph 4.1 lists the available outputs.
3.5 Switch to auto mode
The function works as in the actuator for continuous modulating service. The paragraph 2.5 describes the characteristics
of the function
4 Speed SOV’s
This function allows increasing/decreasing the speed of the actuator when the following conditions occur:
• position error % is greater than the configurable reference value “Speed SOV %”
• the position is > 10%
• the position is < 90%
Two options are available:
• 1 output relay of ECU1000 to drive 1 only SOV
• 2 output relays of ECU1000 to drive 2 SOV’s, one for each direction OP and CL
As further option, 1 SOV can be controlled by a solid state switch on the optional PWM driver card (see DTDE328
instruction manual). The Speed SOV’s are used when the actuator is requested to be precise in the positioning but also
to have a high travelling speed. The function can be activated only by the manufacturer and depends on the hydraulics
of actuator and end user request. It can be activated both in “Positioning function for continuous modulating actuators“
and “Positioning function for stepping modulating actuators”. The Speed SOV’s are always off in Local control,
Manual control, PST, Failsafe, Configuration and Stay in position by SOV.
Outputs to SOV features:
• relay: voltage free contact, max 30Vdc/230Vac/1A (110Vdc/0.15A)
• solid state driver: 24Vdc /1A, present on the PWM module
Parameter of “Speed SOV:
• Speed SOV %: position error % to energize/de-energize the Speed SOV’s (hysteresis 1%, min1%, max 50%)
The parameter is available in the POSITIONER menu with username “OPERATOR”.

5 ESD function
The ESD command overrides any other command and allows executing an emergency action. The ESD action is
active until the command is present. The end user can set the ESD action to be active when the signal is present or
absent. ESD function is off in LOCAL control mode. More ESD inputs can be configured, according to the end user
request. Both inputs can be set to work as wired OR or AND. The local display shows the message “ESD” if the
ESD” is on”. The following parameters can be used to modify the response to ESD command:
ESD action:
• Off : ESD command not used
• Tracking: the ESD command is executed by a dedicated SOV. The positioning function does not generates
any output to control the actuator
• Stay in position: the positioner maintains the last position
• Go to position%: in presence of an ESD command the positioning function drives the actuator to the
configured position
ESD position: position % if the option selected is “go to position %”
ESD logical operator: the available options are OR and AND. The parameter is used in case of multiple ESD input
signals.
ESD delay: duration of signal before initiating ESD action (see “t1” in the drawing below)
Min ESD duration: min duration of ESD action even if the ESD command is a pulse
ESD signal type: it selects the type of ESD command signal (present, absent)
ESD command on ESD command off
t1 t2 t3 time
Regular operation ESD active Regular operation
t1: configurable time before than ESD action takes place t2: configurable minimum duration of ESD action t3: normal operation
The time “t1” is the minimum duration of the ESD signal to initiate the ESD action. It is obtained by the sum of
“ESD delay” + “min ESD cmd (>0.7 sec).
The maximum speed in ESD is configured by the customer.
Note: the ESD command can be executed by the modulating hydraulic control valve (proportional valve /
servovalve, etc.), but in general, the HCU has a dedicated SOV to execute ESD action. The ESD command must be
connected to the ECU1000 according to the below figure and the ESD action should be “Tracking”.
HCU (hydraulic HA
ECU1000 control unit) Hydraulic
Actuator
ESD SOV
ESD cmd
Example of application of parameter “ESD logical operator”

If parameter “ESD logical operator” is configured
ECU1000 “OR”, the ESD action takes place according to
relationship “ESD cmd1 OR ESD cmd2”
If parameter “ESD logical operator” is configured

“AND”, the ESD action takes place according to
relationship “ESD cmd1 AND ESD cmd2”
ESD ESD
Cmd1 Cmd2

6 Failsafe
The FAILSAFE function allows the actuator performing a configured action if one of FAILSAFE conditions occurs.
The configurable conditions to initiate the FAILSAFE are
• Position Demand: failure of 4-20mA Position Demand if the actuator is controlled by an analogue signal
• BUS control: failure of bus signal if the actuator is controlled by bus
• Fail to position: alarm due to position error >4% (see Alarm table par 15.2)
• HPU failure: failure due to HPU. The failure exits only if
o The actuator is provided with integral HPU
o HPU is configured to generate a failure (see Failure table par 15.1 and manual DTDE 328)
The paragraph “Actuator malfunction tables” reports the Failure and Alarm conditions. To control the actuator by
local pushbuttons UP/OPEN, DOWN/CLOSE is available. The configurable actuator actions are: off, tracking,
stayput, go to position. The following options can be set:
Action delay: delay in second before executing the configured action. The actuator stays in position in the delay
time.
Action of actuator: action of actuator
• Off : function not active
• Tracking: The positioner does not generates any output to control the actuator (positioner out=0)
• Stay in position : the positioner maintains the last position
• Go to position%: the positioner drives the actuator to the configured position
• Position %: position % if the option selected is “go to position %”
Condition to initiate Condition to end

Failsafe=on Failsafe=off
t1 t2 time
Regular operation “Failsafe” active
Regular operation
t1: configurable time in “Stay in position” mode before than “Failsafe” action takes place t2: normal operation
The “Failsafe” function is activated by the manufacturer on the base of actuator type and user request. The
manufacturer also sets the maximum speed in “Failsafe”. When “Failsafe” is on , the local display shows the
message “Failsafe”
7 Interlock
The Interlock function is used to inhibit the actuator controls in one or both directions according to the setting done
by the manufacturer. The Interlock control can be generated by
1. digital inputs: an electrical signal connected to the ECU1000 digital inputs and coming from control room
or from on-off sensors (pressure, temperature, level, etc.) can be configured to inhibit open or close or both
open/close commands from remote or local. Interlock action can be configured to be active when digital
signal is on or off.
2. 4-20mA analog input: an electrical 4-20mA signal connected to the ECU1000 analogue inputs and coming
from control room or from 4-20mA transmitter (pressure, temperature, level, etc.) can be configured to
inhibit open or close or both open/close commands from remote or local if the value of 4-20mA input is
greater or less than the reference “AI-Ref.” Interlock action can be configured to be active when the
analogue signal is “greater than” or “less than” the configurable reference “AI-Ref.”
3. digital commands from BUS: the Interlock commands from bus can inhibit open or close or both
open/close commands from remote or local. See the relevant instruction manual of bus.
4. 4-20mA oil pressure transmitter of HPU: if the actuator is provided with integral HPU and 4-20mA to
control the HPU pressure, the Interlock function can be used to inhibit both open and close commands
from remote or local when the HPU pressure is “less than“ the configurable reference “Int-HPU-Pres”
The alarm “Fail to position” is not active in the direction of Interlock. Configuration of Interlock function can be
done only with username “Specialist” or “Guest2”. Change of reference values can be done also with username
“Service”. When “Interlock” is on, the local display shows the message “Interl”

8 Stay in position by SOV

The function can be activated by the manufacturer and requires an optional SOV connected to an output relay of the
ECU1000. The ECU1000 energizes / de-energizes the dedicated Solenoid Operated Valve SOV (SOV1) when a
configurable set of events occurs. The action of the SOV depends on the hydraulic connections in the HCU (Hydraulic
Control Unit). In general the SOV keeps the actuator in POSITION, but it could be also used to force the actuator in
open or close position according to the hydraulic connections. The configurable events to activate the “Stay in position
by SOV” are:
• failure of Actuator Position signal
• failure of Position Demand signal
• Temperature out of range
• Power Supply out of range
• SW error0
• Fail to position
• Failure of Bus control signal
• HPU failure. The action is performed only if
o The actuator is provided with integral HPU
o HPU is configured to generate a failure (see Failure table par 15.1 and manual DTDE328)
The output to SOV is cleared only if the condition that causes the SOV to be active disappears. When the function is
active the positioner switches in “Tracking” mode.
The conditions of the “HPU failure” are described in the paragraph 15 “Actuator malfunction tables” and DTDE328.
The following additional parameters can be set only by the manufacturer: Optional SOV1 conditions, Optional SOV1
relay logic operator (default OR), optional SOV1 start delay (default 0 sec), Optional SOV1 stop delay (default 6 sec),
Optional SOV1 relay coil (default energized).
When “Stay in position by SOV” is on, the ECU1000 signals “FAILURE” (due to “STAYPUT by SOV”) and the
local display shows the message “SOV1”
9 Priority of commands
The following diagram shows the priority of commands when actuator works in remote control mode. The “Stay in
position by optional SOV” has the highest priority and overrides any existing commands (if enabled). Automatic and
manual remote controls have the lowest priority.
Stay in position by optional SOV In Local control mode only local controls by pushbuttons UP/OPEN and
DOWN/CLOSE are available.
ESD In configuration mode the actuator stays in position. It can be moved only by
the commands of the menu “ECU commands, Travel limit setting” (and
Interlock
“PWM control” if PWM card is present).
Failsafe
The hydraulic connection in HCU could modify the priority of “ESD” and
“Stay in position” commands
Automatic and manual remote control
10 Output 4-20mA
The output 4-20mA can be configured by the user according to the following options:
• Out. 4-20mA: position retransmission or position demand
• Polarity 4-20mA out: it allows reversing the polarity of output 4-20mA signal.

11 Date
The function is used to set the following parameters
Date and Time: it sets the present date and time.
Start-up date: it is a maintenance parameter. The user can set the working start date of the actuator in the plant
Maintenance request date: it is a maintenance parameter. The user can set the date of the next planned maintenance. It
generates the “maintenance required” information (see paragraph “Actuator malfunction tables, Maintenance required
table”).
12 Miscellaneous
The function includes various types of parameters.
Time to reach posit: it is used to generate the alarm “Fail to position” (described in the paragraph “Actuator
malfunction tables”, “Alarm table”) if the position error complies with the following conditions
• In automatic mode : the maximum time with position error > 4% is greater than “Time to position” in
seconds
• In manual mode : actuator is not moving
User password: it allows changing the password level 1 (corresponding to username USER)
Service password: it allows changing the password level 2 (corresponding to username OPERATOR)
Bluetooth name: it selects the Bluetotooth name (cabinet serial number, actuator serial number, valve tag)
DL1 close colour: it selects the colour of DL1 LED CLOSE of Local Operator Interface (green or red)
DL2 alarm colour: it selects the colour of DL2 LED ALARM of Local Operator Interface (yellow or red)
DL3 open colour: it selects the colour of DL3 LED OPEN of Local Operator Interface (green or red)
13 Output relay
The standard configuration provides 4 output relays to signal “FAILURE, ALARM, REMOTE NOT AVAILABLE,
FAIL to POSITION” to control room. The configuration of each relay can be changed by the end user. The
manufacturer can change the number of available relays on request of end user.
The list of options available for each relay is shown in the below “Status relay table”.
The following parameters are available:
RLx condition: it allows selecting one or more conditions of “Status relay table” to trip the relay contacts
RLx pos<%: it allows to set the position% if the condition is “Position < xx%”
RLx pos>%: it allows to set the position% if the condition is “Position > xx%”
RLx logic operator: in case of selection of more conditions it allows to put them in OR or AND
RLx coil: it allow selecting to energize the coil when conditions occur and viceversa
Example: to set the relay RLx to switch when the actuator position is <10% or >90% by the ECU1000 local operator
interface.
In the menu “Actuator setup, Out relay”, select the relay RLx. Select “RLx condition”, enable the 2 conditions
“Position<xx” and “Position>xx”. The enabled status is shown by the symbol “>”. Select “RLx POS<% and enter the
value “10%”. Select “RLx POS>%” and enter “90%”. Select “RLx Logical Operator” and set “OR”. Select “RLx coil”
and set “Energized or de-energized”.

13.1 Status relay table

Name Description
Actuator status summary
Failure It collects the failures of table 15.1 (See “Failure” table)
Alarm (Out of spec.) It collects the alarms of tables 15.2 and 15.3 (See “Alarm” tables)
REMOTE not available (Function check) It collects the conditions of table 15.4 (See “Remote not available” table)
Maintenance required It collects the conditions of table 15.5(See “Maintenance required” table)
Nu Not available
Actuator status
Open limit Actuator fully open
Close limit Actuator fully closed
Position < xx% Actuator position < xx%
Position > xx% Actuator position > xx%
Intermed. position Actuator in intermediate position
Opening Actuator opening
Closing Actuator closing
Configuration Configuration mode
Local Actuator in local control
Remote Actuator in remote control
ESD ESD control active
Interlock Interlock active
Nu Not available
PST PST function active (available only if PST function is enabled)
PST failed PST result “failed/aborted” (available only if PST function is enabled)
Nu Not available
Actuator failure and alarm
Position demand Position Demand signal out of range
Actuator position Actuator position signal out of range
Failure to position Time to have error < 4% greater than parameter “Time to position”
Proportional valve Available only if proportional valve or its drive have the failure feedback signal
Power supply Power supply out of range
PWM Utilization % Only if PWM module is active. It signals strong use of the PWM controlled hyd. valve
Electronic failure It collects the “electronic failures” of table 15.1 (See “Failure” table)
Electronic alarm It collects the “electronic alarms” of table 15.2 (See “Alarm” tables)
Nu Not available
Nu Not available
HPU signals (Available only if HPU control is active)
HPU status summary
Pump1 alarm It collects all alarms of HPU and pump1 (See table 15.3)
Pump 2 alarm It collects all alarms of HPU and pump2 (See table 15.3)
HPU status
Pump 1 motor on Motor of pump1 on
Discharge SOV on (DSOV) Discharge SOV on
HPU malfunction / Out of spec
HPU pres. transm. Pressure transmitter of HPU out of range
High oil pressure Oil pressure > reference
Low oil pressure Oil pressure < reference
Oil temperature (high) High oil temperature
Oil level (low level) Low oil level
HPU gener. sens. General on-off sensor of HPU
Hand-pump Hand-pump operation
HPU sign sw HPU signalling on-off sensor (for instance “ HPU oil filter”)
Pump1 power sup. Failure of electrical power supply of pump1 motor

Pump1 mot. TH (motor temperature) High temperature of pump1 motor
Pump1 filter Clogged filter of pump1
Gener. sens. pump1 General sensor of pump1
Max time pump1 Time to reach the working pressure > reference time “Max time to pressure”
Pump2 mot. Sup. (electrical power supply) Failure of electrical power supply of pump2 motor

14 Travel limit setting

The procedure consists in the following steps
• Setting of actuator mechanical stops
• Calibration of zero and span of 4-20mA position transmitter
• Setting of electronic travel limits
Setting of travel limits is done by the Local Operator Interface. The instructions to use the Local Operator Interface
are in the paragraphs 19 and 20.
Setting of mechanical stops and 4-20mA position transmitter must be done before initiating the setting of
electronic travel limit.
The below instructions allow setting the mechanical stops and the 4-20mA position transmitter by means of the
command “OPEN LOOP CMD”, function block “ECU cmd”, function TAB “Travel limit setting” in the Local
Operator Interface. The command is available with password level 2. The command “Speed”, in “ECUcmd, Travel
limit setting” allows selecting the output/speed of actuator in the limit setting operations. The default value is 10%.
The above commands allow moving the actuator by the UP/OPEN and DOWN/CLOSE pushbuttons at low speed and
ignoring the value of position transmitter and the existing travel limits.
14.1 Mechanical stops

If mechanical stops are not in the correct position it needs to adjust them. Refer to mechanical setting instruction book
of actuator.
From HOME VIEW of local display, by ENTER select username and password and then “ECU cmd”, “Travel limit
setting”, “OPEN LOOP CMD”. Press ENTER. By UP/OPEN and DOWN/CLOSE move the actuator and adjust the
open and close mechanical stops to obtain the desired maximum travel of actuator and process valve.
Mechanical stop Mechanical maximum travel Mechanical stop
If mechanical stops are not present or not used only calibration of 4-20mA position transmitter is required.
14.2 4-20mA position transmitter

Connect the multimeter in series to the 4-20mA position transmitter signal according to the following diagram.
+24Vdc Actuator
ECU 1000 Position
transmitter
Multimeter Position 4-20mA

Zero and span
Terminals
adjustement
From HOME VIEW of local display, by ENTER select username and password and then “ECU cmd”, “Travel limit
setting”, “OPEN LOOP CMD”. Move the actuator in fully closed position and set the zero of transmitter to 3.9mA.
Move the actuator in fully open position and set the span of transmitter to 20,1mA. The 4-20mA range must be smaller
than the mechanical maximum travel.

14.3 Electronic setting of travel limits

After having set the mechanical stop and the 4-20mA position transmitter it is necessary to set the electronic limits by
means of the Local Operator Interface.
Setting of electronic limits depends on the parameters in “Restricted, Travel limit, Open limit mode and Close limit
mode”. Two options are available:
• Travel limit on reaching the configured position in bit (mode: position)
• Travel limit on reaching the mechanical stops (modes: continuous, position change, cycle)
Each option is configurable separately for open and close with password level 2.
By the commands “Open/Close limit manual set”, “Open/closed limit autocalibration”, “Change open/close limit”,
in the “ECU cmd, Device cmd, Travel limit setting” menu of the Local Operator Interface, the ECU1000
memorizes the values in bit corresponding to positions 0% and 100%.
The next paragraphs provide the instructions to set the electronic travel limits in case of “Travel limit on reaching the
configured position” or “Travel limit on reaching the mechanical stop”.
Before executing the procedure relevant to “setting of travel limits”, it is mandatory to set the mechanical stop of
actuator and the calibration of 4-20mA position transmitter
14.3.1 Travel limit on reaching the configured position

The above option is available if the parameter “Restricted, Travel limit, open limit mode or closed limit mode” is set
to “position”
The actuator stops when it reaches the configured open or close limit position. Positioning function keeps the actuator in
the travel limit position. The Open / Close LED in the Local Operator Interface is ON. The hysteresis on signalling by
LED’s and relays is 0.5%. Mechanical stops should be positioned externally to the desired actuator travel as shown in
the below figure.
Mechanical stop Actuator travel Mechanical stop
Close Open
Limit (0%) Limit (100%)
The procedure to set travel limits by position is the following:
Open limit:
• Enter in the menu “View param ”.
• In “Restricted, Travel limit” check that “open limit mode” is “position”.
• Exit and return to HOME VIEW.
• Enter in the menu “ECU cmd, Travel limit setting”.
• Set a low operation speed, by the parameter SPEED (10-70%)
• Select the option “Op limit manual set”. By UP/OPEN and DOWN/CLOSE move the actuator to the desired
open position. By ENTER save the open position limit.
Close limit:
• Enter in the menu “View param”.
• In “Restricted, Travel limit” check that “close limit mode” is “position”.
• Select the option “Cl limit manual set”. By UP/OPEN and DOWN/CLOSE move the actuator to the desired
close position. By ENTER save the close position limit.
• Exit and return to HOME VIEW
The option “Open and Close limit autocalibration” CANNOT BE USED.

14.3.2 Travel limit on reaching the mechanical stop

The above option is available only if the parameter “Restricted, Travel limit, open limit mode or closed limit mode”
is set either “continuous or position change or cycle”
The actuator stops when it reaches the mechanical stops. Every time the actuator reaches the mechanical limit, the
corresponding actuator position% of actuator could be slightly different, due to different operating conditions (pressure,
temperature, etc).
Stop Stop
zone %) zone %)
Close Open
Limit (0%) Limit (100%)
The options “continuous”, “position change” and “cycle” allow changing the actuator control while it is on the travel
limit. The most used option is “continuous”.
Continuous: when the actuator is close the end of travel (in general few %), the output of positioning function is set to
a constant value. If the position is stable, the ECU1000 assumes the reached position as “end of travel” but the output is
maintained on and the actuator constantly pushes against the mechanical stop. Local LED’s and relays signal
“open/closed end of travel”. Command in opposite direction is generated only if Position Demand is > 2% (<98%) or by
manual command.
Position change: when the actuator is close the end of travel (in general few %), the output of positioning function is
set to a constant value. If the position is stable, the ECU1000 assumes the reached position as “end of travel” and the
output of positioning function goes to zero. Local LED’s and relays signal “open/closed end of travel”. If the actuator
moves few% from the end of travel position”, it is driven to return to previous position with constant speed and duration
of command. Command in opposite direction is generated only if Position Demand is > 2% (<98%) or by manual
command.
Cycle: when the actuator is close the end of travel (in general few %), the output of positioning function is set to a
constant value. If the position is stable, the ECU1000 assumes the reached position as “end of travel” and the output of
positioning function goes to zero. Local LED’s and relays signal “open/closed end of travel”. Cyclically an output
command is generated to maintain the actuator in the end of travel position. Maximum speed, time between pulses and
duration of command are constant. Command in opposite direction is generated only if Position Demand is > 2% (98%)
or by manual command.
Interval time Output in cycle mode

Out speed duration
time
Before executing the procedure “Setting of travel limits on reaching the mechanical stop”, it is mandatory to set
the mechanical stop of actuator.
If the actuator is not provided of mechanical stops the above option CANNOT BE USED.

The procedure to set travel limits on mechanical stops is the following:

Open limit:
• In “Restricted, Travel limit” check that “open limit mode” is “continuous or position change or cycle” (the
choice depends on the type of process valve and actuator).
Automatic setting of open limit:
• Check that mechanical open stop is correctly set
• Select the option “Open limit autocalibration”.
• At the end of autocalibration procedure exit and return to HOME VIEW.
Close limit:
• In “Restricted, Travel limit” check that “close limit mode” is “continuous or position change or cycle”
(this choice depends on the type of process valve and actuator).
Automatic setting of close limit:
• Check that mechanical close stop is correctly set
• Select the option “Close limit autocalibration”.
• At the end of autocalibration procedure, exit and return to HOME VIEW
14.4 Change open /close limit function

This function allows modifying the existing travel limit without repeating the complete procedure. The option can be
used only in case of “travel limit on reaching the configured position” (described in the paragraph 14.3.1)
The procedure is the following:
Open limit:
• Select the option “Change open limit”. By UP and DOWN enter the desired value. By ENTER save the new
value of position.
Close limit:
• Select the option “Change open limit”. By UP and DOWN enter the desired value. By ENTER save the new
value of position.
Stop New open
zone %) limit (100 %)
Change limit function not Close Open

applicable Limit (0%) Limit
(100%)

14.5 Bias adjustment of driver and valve purge
BIAS adjustement
The adjustment of BIAS of ATOS driver card is performed in factory in the test
operation. If the ATOS driver card must be replaced, it is necessary to adjust the
BIAS of the new card. The procedure is the following:
• Select the option SPEED. The default value is 10%. Press ENTER if it is
OK or change the value by UP and DOWN
• Select the option “Open loop cmd”. By UP and DOWN move the valve to
about 50%.
• By a screwdriver rotate the screw of BIAS until the actuator position in bit
on the ECU1000 display is stable
Purge
The purge operation is used to exhaust the air that could be present into the hydraulic circuit, immediately after the
hydraulic supply connection, or after proportional valve re-installation. (See the documentation relevant to ATOS
Proportional Valve).
• Enter in the menu “ECU cmd, Travel limit setting”. Select the option SPEED. The default value is 10%.
Press ENTER if it is OK or change the value by UP and DOWN.
• Select the option “Open loop cmd”. By UP and DOWN move the valve to about 50%.
• Unloose carefully the purge screw (see ATOS documentation) and then press alternatively the OPEN / CLOSE
push-buttons until the oil flows out without air.
• Re-tight the purge screws and cleans the proportional valve from the oil.

15 Actuator malfunction tables

15.1 Failure table (NAMUR NE107: FAILURE)
Name Description Actuator operation Failure Failure reset
status
General failure
Position demand (1) Position demand signal out of range Configured “FAILSAFE” action (8) (10) x Position Demand in the correct range
Bus control (9) Bus control is off Configured “FAILSAFE” action (8) (10) Bus signal is correct
Actuator position Actuator position signal out of range Tracking (no out) (3) x Actuator position in the correct range
Proportional valve (2) Proportional valve driver malfunction Tracking (no out) (3) x Feedback from proport. valve driver correct
Power supply Power supply <20Vdc or >30Vdc Tracking (no out) (3) x Power supply in the correct range
Failsafe (6) Failsafe mode active due to configured conditions Configured “FAILSAFE” action x Failsafe condition removed
Stayput by SOV (5) Stay in position by optional SOV active due to configured conditions Stay in position x Stay in position condition removed
Electronic failure
Temperature Temperature of electronics <-45°C >90°C Tracking (no out) (3) x Electronics repaired
SW error 0 The 3 memories containing the working parameters are damaged Tracking (no out) (3) x Electronics repaired
Hardware 0 Hardware failure Tracking (no out) (3) x Electronics repaired
HPU failure
HPU failure (4) Fault of integral HPU (if present) No change of actuator operation (7) (10) x HPU repaired
(1) Position Demand: local control, configuration and manual operations are available. The failure is not generated in the on-off actuator
(2) Proportional valve: available only if the ECU1000
• controls the “driver card” of the proportional valve and this driver card has the FAULT output signal connected to an ECU1000 digital input (Atos proportional valve type)
• controls a “proportional valve with integrated electronic driver” and the valve has a monitoring 4-20mA output signal connected to an ECU1000 analogue input (Moog proportional valve type)
• controls the optional “Biffi PWM driver card” and the power supply is out of range (18-30Vdc) (see DTDE328) (in case of standard proportional valves without transducer, 1 or 2 coil)
• controls the optional “Biffi PWM driver card”, the power supply is out of range (18-30Vdc) (see DTDE328) or the position of PSOV’s cursor is 0 (in case of Biffi PSOV’s proportional valves)
• the failure is not generated in the actuators with servovalves controlled by current (+-10,…,+-100mA) without feedback signal and in the on-off actuators
(3) Tracking: electrical signal to drive the proportional valve/servovalve/SOV is set to 0 (output of positioning function = 0).
(4) HPU failure: in the default configuration the HPU malfunctions generate only alarms (see ADDITIONAL ALARM TABLE) and only if the actuator is with integral HPU. On request the ECU1000 can be set to
generate an HPU failure
(5) Stayput by SOV: it exits only if the “Stay in position by optional SOV” function is on
(6) Failsafe: it exits only if Failsafe function was configured “on"
(7) In the default configuration the “HPU failure” does not change the actuator operating mode. On request ECU1000 can be set to initiate the Failsafe or the “Stay in position by optional SOV” functions
(8) In the default configuration the “Position Demand” and “Bus control” failures initiate the configured Failsafe action. On request the ECU1000 can be set to “No change actuator operation” or “Stay in position by
optional SOV”
(9) Bus control: the Failure exits only if the actuator is controlled by Bus
(10) In general if the function “Stay in position by optional SOV” is enabled the “Failsafe” function is disabled and viceversa

15.2 Alarm table (NAMUR NE107: OUT of SPEC)

Name Description Actuator operation Alarm Alarm reset Time is set by
the parameter
General alarm “Time to reach
Hyd. Valve Leak (4) Valve leakage (only ON-OFF actuator) Regular operation x Check PSOV/autocal./check SOV (4) posit.” in the
Fail to position (2) Posit error >4% after configurable time or no position change in manual Regular operation ( 3) x Position error < 4% (2) “Function block
Stroke limit (1) Travel limit not correct Regular operation x See note below Actuator setup,
PWM Utilization % (5) PWM utilization rate greater than reference (PWM % <Reference) Regular operation x See note below Function TAB,
Miscellaneous”
Electronic alarm
High temperature Temperature of Electronics > reference value Regular operation x Temperature correct
Low temperature Temperature of Electronics < reference value Regular operation x Temperature correct
Humidity Humidity of Electronics > reference value Regular operation x Humidity correct
Acceleration-x Acceleration-x of Electronics > reference value Regular operation x Acceleration correct
Acceleration-y Acceleration-x of Electronics > reference value Regular operation x Acceleration correct
Acceleration-z Acceleration-y of Electronics > reference value Regular operation x Acceleration correct
Memory-FL Failure in writing the flash memory of ECU1000 Regular operation x Check of memory OK
Memory-NVR Failure in writing the non-volatile ram of ECU1000 Regular operation x Check of memory OK
Characterization Input characterization data wrong (n° points, incr/dec, monotonic) Regular operation x Characterization data correct
Display card The communication line between Base and Display cards is damaged Regular operation x Communication correct
(1) Stroke limit: the Alarm exits if the Actuator Position % is % < “-STOP ZONE%” or > “100+STOP ZONE%”. The actuator moves according to “position demand”, it does not indicates “end of travel” and when
position % is within the “STOP ZONE%” or “100+STOP ZONE%” the alarm disappears.
(2) Fail to position: the Alarm exits if:
• The ECU1000 works in remote control (auto or manual) or in ESD
• The position error is > 4% for a time greater than parameter “time to position”
• The actuator is not closed and the command is “close” or the actuator is not open and the command is “open”.
• Reset of alarm “Fail to position”:
in remote auto : position error < 4%
in remote manual by a new open/close manual command or if position % is less than 4% from open and close limit
in ESD by removing ESD command or position % within 4% of ESD position
The maximum out of positioning function is 50%
The alarm is not generated in local control and configuration mode.
(3) On request ECU1000 can be set to initiate the Failsafe action or to activate the “Stay in position by optional SOV” function in case of “Fail to position”
(4) Hyd. Valve Leak: The alarm is available only in the “on-off actuator”.
(5) PWM Utilization %: the alarm exits only if the ECU1000 is provided with PWM driver and the actuator is controlled by PSOV’s or modulating proportional valve without spool feedback. When alarm is active the
maximum duty of PWM signal is lowered until the alarm disappears. It is a protection of proportional valve /PSOV from over-heating in case of heavy service (see description of alarm in the DTDE328)

15.3 Additional Alarm table (NAMUR NE107: OUT of SPEC)

The following table includes the alarms present only if the relevant function is active. See DTDE328 for the instruction of PST and HPU.
Name Description Actuator operation Pump control Alarm Alarm reset
Alarm of PST
PST T-PST T-PST time % greater than T-PST of signature Regular operation x New PST or Clear Failure/Alarm
PST OV-TR OV-TR % greater than configured value Regular operation x New PST or Clear Failure/Alarm
PST T-RET T-RET time % greater that T-RET of signature Regular operation x New PST or Clear Failure/Alarm
PST Reset PST cycle aborted Regular operation x New PST or Clear Failure/Alarm
Alarm of HPU (with 2 pumps)

HPU pres. transm. Oil pressure transmitter out of range Regular operation (1) Pump1 and 2 off x Correct range of signal
High oil pressure Oil pressure > high pressure limit Regular operation (1) Pump1 and 2 off x Pressure < limit
Low oil pressure Oil pressure < low pressure limit Regular operation (1) Regular operation x Pressure > limit
Oil level (low) Oil level sensor = on Regular operation (1) Pump1 and 2 off x Level switch off
Oil temper. (high temperature) Oil thermostat = on Regular operation (1) Pump1 and 2 off x Thermostat off
HPU gener. sens. General on-off sensor of HPU = on Regular operation (1) Pump1 and 2 off x General on-off sensor in off
Hand-pump Hand-pump engaged Tracking (1) Regular operation x Hand-pump disengaged
Max start D-SOV Starts of Discharge SOV (D-SOV) > reference Regular operation Regular operation x Clear counter command
HPU sign sw HPU signalling on-off sensor Regular operation Regular operation x HPU on-off sensor in off
Alarm of PUMP1
Pump1 power sup (electrical power) Loss of power supply of pump1 motor Regular operation (1) Pump1 off , switch to pump2 (2) x Electrical power of pump1 correct
Pump1 mot. TH Motor thermostat of pump1=on Regular operation (1) Pump1 off , switch to pump2 (2) x Motor thermostat of pump1 off
Pump1 filter Oil filter sensor=on Regular operation (1) Regular operation x Oil filter sensor of pump1 off
Gener. sens. pump1 General on-off sensor of pump1=on Regular operation (1) Pump1 off, switch to pump2 (2) x General sensor of pump1 off
Max time pump1 Max time to reach the pressure (pump1) Regular operation (1) Pump1 off, switch to pump2 (3) x Clear alarm cmd or pressure is correct
Max start pump1 Starts of motor of pump1 > reference Regular operation Pump1 off , switch to pump2 (4) x Clear counter command
Alarm of PUMP2
Pump2 power sup. (electrical power) Loss of power supply of pump2 motor Regular operation (1) Pump2 off , switch to pump1 (2) x Electrical power of pump2 correct
Pump2 mot. TH Motor thermostat of pump2=on Regular operation (1) Pump2 off , switch to pump1 (2) x Motor thermostat of pump2 off
Gener. sens. pump2 General on-off sensor of pump2=on Regular operation (1) Pump2 off, switch to pump1 (2) x General sensor of pump2 off
Max time pump2 Max time to reach the pressure (pump2) Regular operation (1) Pump2 off, switch to pump1 (3) x Clear alarm cmd or pressure is correct
Max start pump2 Starts of motor of pump2 > reference Regular operation Pump2 off , switch to pump2 (4) x Clear counter command
The HPU and pump alarms exit only if the pump is provided with the relevant sensors (for instance if the HPU is without oil level sensor, the “Oil level” alarm cannot exit)
(1) In the default configuration the ECU1000 signals ALARM. On request ECU1000 can be set to signal “FAILURE” due to “HPU failure” (see “Failure table” in DTDE327 and “HPU control” in DTDE328).
(2) If both pumps are in Alarm both Pumps are off.
(3) If the alarm occurs the running pump switches to off and the second pump starts. If the alarm occurs also with the second pump, “the motor stops” or “the motor runs” according to the configuration of the ECU1000.
(4) If both pumps are in “Max start alarm” the running pump continues to work.

Name Description Actuator operation Pump control Alarm Alarm reset
Alarm of HPU (with 1 pump)

HPU pres. transm. Pressure transmitter of HPU signal out of range Regular operation (1) Pump1 off x Correct range of signal
High oil pressure Oil pressure > high pressure limit Regular operation (1) Pump1 off x Pressure < limit
Low oil pressure Oil pressure < low pressure limit Regular operation (1) Regular operation x Pressure > limit
Oil level (low) Oil level sensor = on Regular operation (1) Pump1 off x Level switch off
Oil temper. (high temperature) Oil thermostat = on Regular operation (1) Pump1 off x Thermostat off
HPU gener. sens. General on-off sensor of HPU = on Regular operation (1) Pump1 off x General on-off sensor in off
Hand-pump Hand-pump engaged Tracking (1) Regular operation x Hand-pump disengaged
Max start D-SOV Starts of Discharge SOV (D-SOV) > reference Regular operation Regular operation x Clear counter command
HPU sign sw HPU signalling on-off sensor Regular operation Regular operation x HPU on-off sensor in off
Alarm of PUMP1
Pump1 power sup (electrical power) Loss of power supply of pump1 motor Regular operation (1) Pump1 off x Electrical power of pump1 correct
Pump1 mot. TH Motor thermostat of pump1=on Regular operation (1) Pump1 off x Motor thermostat of pump1 off
Gener. sens. Pump1 General on-off sensor of pump1=on Regular operation (1) Pump1 off x General sensor of pump1 off
Max time pump1 Max time to reach the pressure (pump1) Regular operation (1) Pump1 off or run (2) x Clear alarm cmd or pressure is correct
Max start pump1 Starts of motor of pump1 > reference Regular operation Regular operation x Clear counter command
The HPU and pump alarms exit only if the pump is provided with the relevant sensors (for instance if the HPU is without oil level sensor, the “Oil level” alarm cannot exit)
(1) In the default configuration the ECU1000 signals ALARM. On request ECU1000 can be set to signal “FAILURE” due to “HPU failure” (see “Failure table” in DTDE327 and “HPU control” in DTDE328).
(2) The pump control can be configured to “the motor stops” or “the motor runs” when the alarm occurs.
15.4 Remote not available table (NAMUR NE107: FUNCTION CHECK)

Name Description Actuator status Remote control not available
Configuration Configuration mode Stay in position x

Local Actuator in local control Regular operation by local manual control x
Hand-pump Hand-pump engaged Tracking x
15.5 Maintenance required table (NAMUR NE107: MAINTENANCE REQUIRED)

Name Description Actuator operation Maintenance
Requir. status
Expired maintenance date Present date > reference date ( maintenance request date) Regular operation x

16 Loggers
The manual DTDE328 provides the instructions to use the Logger feature. The present paragraph gives only a brief
description of the main features of logger function. The ECU1000 has the following separated logger:
• Event logger: it contains the list of the last 256 events. Each event is described by type, date and action
• Failure logger: it contains the list of the last 256 failures. Each failure is described by type and date
• Alarm logger: it contains the list of the last 256 alarms. Each alarm is described by type and date
• Statistic log: it contains statistic data and counters
The tables with the list of Failures and Alarms are reported in the paragraph “Actuator malfunction tables”. The
following tables show the list of Event and Statistic logger:
Event Description The data of loggers are saved in

Power on Main voltage on and external watch-dog OK
the permanent memory of
Remote-man Remote manual cmd
Local-cmd Local manual cmd (from display card or serial) ECU1000, and maintained in
Bus-man Manual cmd from bus the memory even if the
ESD ESD cmd electrical power fails. When the
Limit calib. Limit calibration memory is full and a new
Failsafe Failsafe function active event, failure or alarm occurs
Demand<5>95%-hw Demand >95% or <5%, from remote hw, hysteresis 10%
Demand<5>95%-bus Demand >95% or <5%, from bus, hysteresis 10%
the oldest one is deleted and the
Demand<5>95%-loc Demand >95% or <5%, from local, hysteresis 10% (from display card or serial) new one is entered.
PST PST cmd
Configuration Configuration status The loggers can be viewed only
Interlock Interlock function active by BIFFI-Assistant SW tool
Restore config. Restore configuration cmd
since the view area of local
Full default Full default cmd
Tracking Tracking status display is small.
CRC Memory-EE Check of memory-EE
CRC Memory-FL Check of memory-FL The short logger allows
CRC Memory-NVR Check of memory-NVR viewing only the last 10 events,
Pump1-2 switch Switch of pumps (pump1-2 or pump2-1) failures or alarms to speed-up
the read operation from
ECU1000.
Statistics Description
Max temperature Highest temperature of ECU1000 in °C Statistic log is not available in
Min temperature Lowest temperature of ECU1000 in °C the short logger
Pump1 start Number of starts of pump1 (only with HPU and pump1)
Pump1 run time Run time of pump1 in hours (only with HPU and pump1)
Pump2 start Number of starts of pump2 (only with HPU and pump2)
Pump2 run time Run time of pump2 in hours (only with HPU and pump2)
HPU D.SOV start Number of starts of DSOV of HPU (only with HPU and DSOV)
EV1 max utilization% Highest value of EV1 PWM utilization% (only with PWM module)
EV2 max utilization% Highest value of EV2 PWM utilization % (only with PWM module)
17 Graphs and Recorder

The manual DTDE328 gives the instructions to use the Graph and Recorder functions. The present paragraph gives
only a brief description of the main features of graph and recorder. By the Recorder function, the ECU1000 can save
in its permanent memory the last 5 curves and 1 signature for each one of the following options:
• Opening curve (OP-stroke)
• Closing curve (CL-stroke)
• Record curve
• PST curve (if the function is active)
The data are maintained in the memory even if the electrical power fails. When the memory is full and a new curve is
available the oldest one is deleted and the new one is entered. Each curve can save up to 4 variables. Each curve
consists in 200 samples of each selected variables. The curves can be viewed and exported only by BIFFI-Assistant
SW tool.

18 Examples of modulating actuators
18.1 Actuator for heavy modulating service
The figures below show the operating principle.
Double acting actuator for heavy modulating

service
ECU1000
Single acting spring return actuator for heavy

modulating service and additional SOV for
emergency command
ECU1000

18.2 Actuator for heavy modulating service and low oil drain
The figures below show the operating principle.
Double acting actuator for heavy modulating

service, stay in position in case of loss of
electrical power
ECU1000
Single acting spring return actuator for

heavy modulating service, stay in position in
case of loss of electrical power
ECU1000

18.3 Actuator for stepping modulating service
The figures below show the operating principle
Single acting spring return actuator for modulating

service, 2 SOV’s to open/close the actuator, one
fast/slow speed SOV, manual pump with selector.
ECU1000
Double acting actuator for

modulating service, 4 SOV’s to ECU1000
open/close the actuator and
one fast/slow speed SOV,
integral HPU with dual motor
pump, manual pump

19 Local Operator Interface

19.1 Description
The Local Operator Interface allows

• Selection between LOCAL and REMOTE control
• Local control of actuator to drive the valve in opening and closing direction
• Navigation in the menu to
o view the working parameters
o modify the working parameters
o send commands to electronics and actuator to execute calibration procedures and operations on data
stored in the memory
o to view the value of the working variables (position, temperature, pressure, status, etc)
o to view the present “Failure” and “Alarm”
o to view the “Function summary”
o to clear the Failure and Alarm
It consists in:
• Two bi-coloured green/red LED’s to indicate the following status: open / opening, closed / closing, stop in
intermediate position.
o The LED indicating open/opening is green and the one indicating closed/closing is red. The colour
can be changed to red and green by the setting operation in the menu
o If one LED flashes, the actuator moves in the direction of flashing LED
o If both LED’s are on the actuator is not moving
o If one LED is on and the second one is off , the actuator is fully open or fully closed
• One bi-coloured yellow/red LED to indicate the following status: failure, alarm (out of specification). The
standard configuration is yellow. The colour can be changed to red by the setting operation in the menu
o Failure = LED on
o Alarm = LED flashing
• One blue LED to indicate connection to PC via Bluetooth
• 1 graphic OLED display, 64x128 dots. When actuator is powered the display shows the “HOME VIEW” that
collects the most important data relevant to actuator (position, status, etc.) in one only view.
• 3 push-buttons UP/OPEN, DOWN/CLOSE, ENTER with double function
o In MENU operation: UP and DOWN move the cursor and increase / decrease the value of selected
variable
o In LOCAL control mode: OPEN and CLOSE drive the actuator in opening and closing direction
• 1 optional two position LOCAL/REMOTE selector
• On demand the Local Operator Interface can be provided with 8 additional LED’s. The conditions to switch-on
the LED’s are configurable by the menu options.
REMOTE, LOCAL, CONFIGURATION operations:

• LOCAL: the actuator can be moved by means of pushbuttons UP/OPEN, DOWN/CLOSE
• REMOTE: the actuator is under control of signals coming from control room
• CONFIGURATION: the actuator stays in position. It is possible to modify the working parameters and send
commands to Electronics of ECU1000
Dislay of Local Operator

Interface

Navigation in the menu:

It is allowed only in REMOTE by means of the local pushbuttons ENTER, UP/OPEN, DOWN/CLOSE
• ENTER: it allows switching to the next level of menu of the selected line. It HOME VIEW
allows to return to previous level of menu if the cursor is on “..” line. The same Opening/closing
operation can be done by pushing simultaneously UP and DOWN.
UP or DOWN: they allow moving the cursor and select the lines of menu. The
•
selected line is shown in reversed mode. 100.0%
100.0%
• DOWN: if the display shows the HOME VIEW, it allows viewing data and status Auto-rem
of actuator
The next paragraphs describe the procedures to navigate in the menu and to switch in local control with the options:
• only pushbuttons UP/OPEN, DOWN/CLOSE, ENTER
• pushbuttons UP/OPEN, DOWN/CLOSE, ENTER and optional selector LOCAL/ REMOTE
When ECU 1000 is powered, the microcontroller executes the initialization routine to check the memory, set I/O’s, read
data, etc. The display shows the message “ > Connection…”. When the initialization procedure ends the display
switches to the HOME VIEW.
DISPLAY of ECU 1000 -Opening, closing, no-out
-ESD, Failsafe, Travel limit, Stayput

HOME VIEW Operation and functions
-PST, PSOV autocal, Interl, SOV1
-<R>
FAILURE
Position %
ALARM Status
-Auto-rem, Manual-rem, Auto-bus,
MAINT. REQUEST Manual-bus, Local, Local-auto
<c> Demand %
-Control, Configuration, Tracking,
<c> is present only if
the Input Control mode Stay in posit, Switch to auto
Characterization
function is on
Example of HOME VIEW
Actuator closing
CLOSING, ESD, <R> ESD active
Recorder active
Position 100.0%
FAILURE
ALARM 100.0% Position Demand 90.0% (no Input Characterization)
FAILURE
ALARM
MAINTENANCE REQUIRED
MAINT. REQ. 90.0% Automatic remote control
Switch to Auto function active
AUTO-REM, SWITCH TO AUTO
The ECU 1000 automatically returns to HOME VIEW if no local pushbutton is used in 10 min.
If the actuator is for on-off service the “Demand%” is not present on the local display.

19.2 Pushbuttons UP, DOWN, ENTER
The figure below shows the menu chart. To enter in LOCAL control mode, press UP and then ENTER, maintaining UP
pressed. Then enter the password (at least level 1, User). In local control mode the navigation in the menu is not
allowed since UP and DOWN pushbuttons work as OPEN and CLOSE commands to open and close the valve. The
LOCAL control status is saved in the permanent memory of the Electronics. If the actuator is switched off, it will restart
in LOCAL. To exit from LOCAL it needs to press ENTER.
HOME VIEW
closing
Enter = exit from local control
Local control of actuator
100.0%
100.0%
Up and Enter + PSW = enter in local control by Up=Open and
Down=Close
REMOTE
View actuator status and variables

Enter Enter
Enter Enter
.. ..
List of data …………… Up /
Down ………….. Enter …………… Down Name of variable
.. ………….. Up / Data……....
User Down Enter
………….. …………… Enter Value
Operator
Service Up /
Down
Specialist
Guest 0/1/2 User selection
Enter Enter
.. ..
View ……………
Up /
Setup Enter …………… Down
..
Up /
ECU cmd Down + Funct.block ……………
Enter Up /
PSW …………… …………… Down
Funct. TAB Name of parameter
View parameters …………… Enter
Enter
Value
Enter Enter
.. ..
Enter Up /
Setup …………… Down
..
Up / +
ECU cmd Down
Funct.block ……………
Enter Up /
PSW …………… …………… Down
…………… Enter
Set parameters
Value Up / Enter
Down
Enter Enter
.. ..
Enter Up /
..
ECU cmd Up / + Funct.block ……………
Enter Up /
Down PSW …………… …………… Down
3322 Funct. TAB Name of command
Commands of ECU1000 Enter
Value Up /
Down
In menu operation the UP/DOWN/ENTER pushbuttons allow moving in the menu.
In View mode the working parameters of ECU1000 can be viewed but not changed
In Setup mode the working parameters of actuator can be viewed and changed
In ECU cmd mode it is possible to activate commands to calibrate analogue inputs and outputs, set travel limits, set
memory, save configuration data, view variables, etc.
Note: it needs to press one time UP or DOWN or ENTER to wake up the display before initiating menu operation. This
is due to the display function “auto or save”.

19.3 Push-buttons UP, DOWN , ENTER and two-position selector
On demand the local operator interface can be provided with a local two-position selector LOCAL, REMOTE
o Switch from LOCAL to REMOTE control mode is done by selector, password is not required
o Navigation in the menu is not allowed if selector is in LOCAL
o In LOCAL the actuator can be moved by means of pushbuttons UP/OPEN, DOWN/CLOSE.
o In REMOTE the actuator is under control of signals of control room
HOME VIEW
Remote Local
closing
Local control of actuator
100.0%
xxx.x% LOCAL
by Up=Open and
Down=Close
REMOTE SELECTOR
View actuator status and variables

Enter Enter
Enter Enter
.. ..
List of data …………… Up /
Down ………….. Enter …………… Down Name of variable
………….. Up / Data……....
Down Enter
.. ………….. …………… Enter Value
User
Operator
Service Up /
Specialist
Down User selection
Guest 0/1/2
Enter
.. ..
View …………… Enter
Up /
Setup Enter …………… Down
..
Up /
ECU cmd Down + Funct.block ……………
Up /
PSW …………… Enter …………… Down
View parameters …………… Enter Enter
Value
Enter
.. ..
Enter Up /
..
Up / +
ECU cmd Down
Funct.block ……………
Enter Up /
PSW …………… …………… Down
Set parameters
Value Up / Enter
Down
Enter
.. ..
Enter Up /
..
ECU cmd Up / + Funct.block ……………
Up /
Down PSW …………… Enter …………… Down
Funct. TAB Name of command
Commands of ECU1000 Enter
Value Up /
Down
In menu operation the UP/DOWN/ENTER pushbuttons allow moving in the menu.
In View mode the working parameters of ECU1000 can be viewed but not changed
In Setup mode the working parameters of actuator can be viewed and changed
In ECU cmd mode it is possible to activate commands to calibrate analogue inputs and outputs, set travel limits, set
memory, save configuration data, view variables, etc.
Note: it needs to press one time UP or DOWN or ENTER to wake up the display before initiating menu operation. This
is due to the display function “auto or save”.

19.4 ECU1000 menu

Username Mode Enter password Function Function TAB View /change parameters,
HOME VIEW selection selection BLOCK selection selection send commands
Enter Enter Enter Enter Enter
closing
.. .. .. ..
View Actuator setup ESD
Enter Enter Enter
USER Enter Setup Name plate Positioner View
Enter password Enter ………….
100.0% ECU cmd …………... parameters
Enter
xxx.x% OPERATOR
REMOTE
SERVICE
Down Enter Enter Enter
SPECIALIST Enter Enter
.. .. ..
GUEST0/1/2 View Actuator setup ESD
.. Setup Enter Enter Name plate Positioner Enter
Enter Modify
Actuator status ECU cmd password …………... Enter …………. parameters
Enter
Actuator variables
Use UP / …………..
DOWN
to CONFIGURATION STATUS
position Enter Enter
the Enter ..
Enter .. ..
cursor in View Enter Enter
Device cmd Travel limit
the Enter Setup
View status and Enter Enter Log and graph …………. Execute ECU
desired ECU cmd ………….. Enter
variables password commands
line Enter Enter
To view/modify a parameter or send an ECU command from the HOME VIEW it needs: to select the username, to select the mode, to enter the password, to select the Function Block, to select the
Function TAB, to select the parameter or ECU command.

HOME VIEW
USERNAME MODE PASSWORD
ENTER
FUNCTION BLOCKS FUNCTION TAB’s TAB POSITIONER PARAM. DEAD BAND

DOWN/
CLOSE
VIEW
Press DOWN/
CLOSE and
FUNCTION BLOCKS FUNCTION TAB’s TAB POSITIONER PARAM. DEAD BAND CHANGE DEAD BAND
UP/OPEN to move up
and down the cursor
of display.
SETUP
Press ENTER to
select the line. Press
ENTER on “..” to
FUNCTION BLOCKS FUNCTION TAB’s TAB TRAVEL LIMIT SET. OPEN LOOP CMD CMD Execution
switch back to
previous screen
ECU
command

HOME VIEW
FAILURE FAILURE LIST Press DOWN/ CLOSE
and UP/OPEN to
move up and down the
cursor of display.
Press ENTER to
select the line. Press
ALARM ALARM LIST ENTER on “..” to
switch back to
DOWN/ previous screen
CLOSE
LIST of VIEW DATA
ACTUAT. VARIABLES LIST ACTUAT. VAR. OIL PRESSURE POSITION ERROR TEMPERATURE
CLEAR FAIL-ALARM CMD Execution

In View mode the working parameters of ECU1000 can be viewed but not changed. In Setup mode the working
parameters of actuator can be viewed and changed. In ECU cmd mode it is possible to send commands to ECU1000
(to calibrate analogue inputs and outputs, set travel limits, set memory, save configuration data, view variables, etc.).
The access to View, Setup and ECU cmd menus depends on the username and password level. 4 password levels are
available; each password is 6 char long (number or capital letters). Three additional passwords allow special operations.
Username and password work as described below:
• Username USER: only parameters of active functions with password level 1 can be viewed and modified; only ECU
cmd’s of active functions with password level 1 can be executed. The default password is “100000”. It is
configurable and allows modifying few parameters (Dead band, Recorder, output relay, etc.). Disabled functions and
ECU cmd’s cannot be viewed.
• Username OPERATOR: only parameters of active functions with password levels 1 and 2 can be viewed and
modified; only ECU cmd’s of active functions with password level 1 and 2 can be executed. The default password is
“200000”. It is configurable and allows commissioning the actuator (positioner, ESD, status relay, travel limit
calibration, etc.). Disabled functions and ECU cmd’s cannot be viewed.
• Username SERVICE: only parameters of active functions with password levels 1, 2 and 3 can be viewed and
modified; only ECU cmd?s of active functions with password level 1, 2 and 3 can be executed. Disabled functions
and ECU cmd’s cannot be viewed.
• Username SPECIALIST: this password (level 4) allows viewing/modifying any parameter of active functions and
executing any ECU cmd of active functions. Disabled functions and ECU cmd’s cannot be viewed.
• Username GUEST0: it allows viewing the full set of parameters and ECU commands, including the parameters
and ECU commands of the non-active functions. No write operation is allowed. The GUEST0 password is “10000A”.
• Username GUEST1: it allows only viewing the NAME PLATE function block. No write operation is allowed. The
GUEST0 password is “A0000A”.
• Username GUEST2: it has the same permits of the SPECIALIST, but the number of access to ECU1000 menu is
limited to 10. After 10 accesses the password is no longer valid.
Passwords of SERVICE, SPECIALIST, and GUEST2 are reserved to product specialist.
The menu is organized in “Function block”, “Function TAB”, “Parameter and Command”.
Each “Function TAB” collects a group of “Parameters or ECU Commands”, each “Function block” collects a group
of “Function TAB’s”. Only the parameters and commands with username levels lower or equal to entered username
level can be viewed and modified. Parameters and functions not enabled will not be shown (except username GUEST0)
The paragraph “Parameter table” shows the table of the FUNCTION BLOCKS, FUNCTION TAB’s and
PARAMETERS, the description of each PARAMETER and the PSW level required.
The paragraph “ECU cmd table” shows the table of the FUNCTION BLOCKS, the FUNCTION TAB’s and
COMMANDS, the description of each “ECU command” and the PSW level required.
The paragraph “Status and variables table” shows the list of the status and variables visible on the display and useful
for commissioning and diagnostic operations.
To access to parameters and ECU cmd’s the following steps are required:
• Verify the PSW level required in the “Parameter and ECU cmd” tables
• Enter username and password
• Select the Function Block
• Select the Function TAB
• Select the parameter or ECU cmd
• View / change the parameter or execute the ECU cmd
• Exit from menu

19.5 Parameter table

The following table shows the parameters of ECU 1000 visible and changeable with password level 1 and 2, the
Function TAB and Function BLOCK to which the parameters belong and the password level required. The option
“View.” allows viewing their value, the option “Setup” allows changing their value.
Function block Function TAB Parameter Psw

Actuator Setup level
ESD
ESD action (off, tracking, stayput, go to position %) 2
ESD position % (0-100) 2
ESD logical operator (OR-AND) 2
ESD delay (0.1-10 sec) 1
Min ESD duration (1-100 sec) 1
ESD signal type (present, absent) 2
Positioner
The TAB contains the Dead band (0-10.0 %) 1
parameters of Error band OP-K1OP (0.5-20.0 %) 2
positioning function Gain K1OP (0.01-99.99) 2
for continuous Error band CL-K1CL (0.5-20.0 %) 2
modulating actuator. Gain K1CL (0.01-99.99) 2
The TAB is not visible Gain K2OP (0.01-99.99) 2
in stepping modulating Gain K2CL (0.01-99.99) 2
actuator. Integral time Ti (0-99.9 sec) 2
Switch to Auto time (0-255 sec) 1
Demand source (4-20mA, bus, internal) 2
Internal position demand (0.0-100.0%) 2
Dither % (0-10%) 2
Speed SOV reference (% of position error, 1-20.0) (if SPEED SOV’s function ison) 1
Positioner
The TAB contains the Dead band (0-10.0 %) 1
parameters of Speed SOV reference (% of position error, 1-20.0) (if SPEED SOV’s function ison) 1
positioning function Motion inhibit time (1-20 sec) 2
for stepping Switch to Auto time (0-255 sec) 1
modulating actuator. Demand source (4-20mA, bus, internal) 2
The TAB is not visible Internal position demand (0.0-100.0%) 2
in continuous
modulating actuator.
Out. 4-20mA
Out. 4-20mA (position, demand) 1
Polarity 4-20mA OUT (4mA=cl, 4mA=op) 1
Out relay
Rl0 condition (see Status relay table) 2
In the standard Rl0 pos <% (1-100 %) 1
configuration Rl0 pos >% (0-99 %) 1
only 4 relays Rl0, Rl0 logic operator (OR-AND) 2
Rl1, Rl2, RL3 are Rl0 coil (de-energized, energized) 2
available to signal
status and
malfunctions to
control room.
On request the
manufacturer can
activate additional Rl3 pos <% (1-100 %) 1
relays, from Rl4 to Rl3 pos >% (0-99 %) 1
Rl10. Rl3 logic operator (OR-AND) 2
Rl3 coil (de-energized, energized) 2

Rl10 pos <% (1-100 %) 1
Rl10 pos >% (0-99 %) 1
Rl10 logic operator (OR-AND) 2
Rl10 coil (de-energized, energized) 2


Failsafe
Function visible only Action delay (0-100 sec) 1
if activated by the Action of actuator (off, tracking, stayput, go to position%) 2
manufacturer Position% (0-100 %) 2
Miscellaneous
Max time to position (1-255 sec) 1
Bluetooth name (actuator serial number, valve tag, cabinet serial number) 1
Value not visible User password 1
Value not visible Operator password 2
DL1 close colour (green, red) 1
DL2 alarm colour (yellow, red) 1
DL3 open colour (green, red) 1
Date
Date and time (2010.01.01 to 2099.12.31) 1
Start-up date (2010.01.01 to 2099.12.31) 1
Maintenance request date (2010.01.01 to 2099.12.31) 1
Pump control
Function visible only Pump1 mode (auto, off) 2
if activated by the Pump stop delay (0-255 sec) 1
manufacturer Act ctrl delay (0-255sec) (after ECU1000 power on) 2
Maximum time to pressure (0-255 min) (0= disable check of time) 2
Pump2 mode (auto, off) 2
Pump cycle (0-10000 h) 1
Recorder
Recorder time (2,4,10,20,50,…,1000) (used to calculate sampling time) 1
Stop condition (failure, alarm, position <5%, position >95%) 1
Y-axis (position demand, position, HPU pressure, position error,etc.) 1
Recorder mode (off, record, pst, op-curve, cl-curve) 1
Input characterization
Input characteristic (off, linear 100-0, custom increase, custom decrease) 2
Function visible only Custom point (from 2 to 21) 2
if activated in the Input #0 2
Restricted menu, Output #0 2
Function selector. Input #1 2
Only a number of Output #1 2
points equal to Input #2 2
“Custom point” is Output #2 2
shown on the local Input #3 2
display.
Output #3 2
Input #4 2
Output #4 2
Input #5 2
Output #5 2
Input #6 2
Output #6 2
Input #7 2
Output #7 2
Input #8 2
Output #8 2
Input #9 2
Output #9 2
Input #10 2
Output #10 2
Input #11 2
Output #11 2
Input #12 2
Output #12 2
Input #13 2
Output #13 2
Input #14 2
Output #14 2


Input #15 2
Output #15 2
Input #16 2
Output #16 2
Input #17 2
Output #17 2
Input #18 2
Output #18 2
Input #19 2
Output #19 2
Input #20 2
Output #20 2
PST setup ID 1800

PST selector (disable, position, pressure1, pressure2, hpu oil pressure, temperature 2
Function visible only PST start (manual, auto, auto-manual) 2
if activated by the PST period (in auto or auto-manual) 2
manufacturer PST time (in auto or auto-manual) 2
PST travel 2
PST pause 2
Max T-PST (% of signature) 2
Max T-RET (% of signature) 2
Max OV-TRAV (% of position) 2
Max PST duration (sec) 2
Name Plate
ECU1000 cabinet data
FW version display card (12 char) 1

FW version control card (12 char) 1
Valve data
Valve data
Valve manufacturer (16 char) 1
Valve serial number (16 char) 1
Valve tag name (16 char) 1
Restricted
Function selector
In characteriz (on/off) 2
Optional SOV1
Function activated by Optional-SOV1 relay condition 2
the manufacturer
Travel limit
Open limit mode (position, continuous, position change, cycle) 2
Close limit mode (position, continuous, position change, cycle) 2

19.6 ECU cmd table

The following table shows the commands of ECU 1000 available with password level 1 and 2, the Function TAB and
Function BLOCK to which the commands belong and the password level required. The option “ECU cmd” allows
executing the commands. Event logger, Failure logger, Alarm logger and curves are visible only by BIFFI-Assistant
SW tool.
Function block Function TAB Command Psw

level
Device cmd
Travel limit setting
Speed (output/speed % in travel limit setting, default 10%) 2
Open loop command 2
Op limit manual set (off, on) 2
Cl limit manual set (off, on) 2
Open limit autocalibration (on, off) 2
Close limit autocalibration (off, on) 2
Change open limit (0.0-5.0 %) 2
Change close limit (0.0-5.0) 2
SOV’s control
Function visible only PSOV’s autocalibration (off, on) 2
if activated by the PSOV manual PWM (0-100 %) 2
manufacturer Drive PSOV (by UP and DOWN) 2
PST command
Visible only if PST start (off-on) 2
activated
Log and graph
Curves
PST signature is Select opening signature 1
available only if PST Select closing signature 1
function is activate Select recorder signature 1
Select PST signature 1
19.7 Status and variables table

The following table shows the list of data visible from the HOME VIEW by pressing DOWN. No PSW is requested.
Note: it needs to press one time UP or DOWN or ENTER to wake up the display before initiating menu operation.
Description of data Content
Actuator status: Output Opening, closing, no-out

Position Open, closed, intermediate
Status Normal, failure, alarm, maintenance required
Operating mode Control, configuration, tracking, stay in position, switch to auto
Control type Auto-rem, manual-rem, auto-bus, manual-bus, local, local auto
Control function ESD, Failsafe, travel limit, stayput, PST, PSOV autocal, Interl, SOV1
Actuator variables: Position %, Position demand % , Position error %, In-pos demand %, Temperature °C,
Humidity %, Acceleration-Xg-Yg- Zg, AO1 out %, Oil pressure bar, EV1 PWM%, EV2
PWM%, Next PST, Next pump switch, EV1-2 monitor, EV1-2 rate
Failure: See list of failure in the paragraph “ Actuator malfunction tables”
Alarm: See list of alarms in the paragraph “ Actuator malfunction tables”
Variables and counter: Not used
Out relay status: Rl0,….RL10, off, on
Digital input (bit): DI0,….DI10, EVPWR, 0, 1
Digital output (bit): DO0 signal, DO1 signal, EV3 signal, 0, 1
Analogue input (bit): AI0, AI1, AI2, AI3, AI4, HW-rev-ctrl, Temperature, Humidity, Acceleration-X-Y-Z, HW-rev-
base, AI5 EV1 lift, AI6 EV2 lift
Analogue output (bit): AO0, AO1
Bus status Not available
Clear Failure / Alarm It clears the list of failures and alarm. It can be used only for test operation since if a
failure/alarm is present it will still appear in the list.
Function summary The ECU1000 functions are enabled by the manufacturer according to the actuator/HPU/HCU
to control. The end user can only change the parameters of each function to optimize the
features of system. The command “Function summary” allows viewing the status
(enabled/disabled) of the functions and their main characteristics.

20 Examples of menu operations

The following paragraph shows some example of operation with the ECU1000 menu.
Use UP and DOWN to select the line of display or to change the value of parameter. Use ENTER to confirm the value
of parameter and to move to next menu. Select the line “..” and press ENTER to return to previous menu. The selected
line of display is shown in reversed mode.
Press UP or DOWN or ENTER to wake up the ECU1000 display before initiating menu operation.
20.1 Username and password

The following example shows the procedure to enter username and password, to view / change parameter or execute an
ECU cmd, to exit from menu operation and return to HOME VIEW.
• Press ENTER
• By UP and DOWN select the username and then press ENTER. The option available are “User”, “Operator”
“Service”, “Specialist”, “Guest 0/1/2”
• By UP and DOWN select “View” or “Setup” or “ECU cmd”, then press ENTER.
• Enter the password. By UP and DOWN select the first character of password, then press ENTER to confirm.
• Repeat the above procedure and enter further 5 characters one at a time. Use number or capital letter.
• If password is not according to username the access to menu is not allowed. The display shows the previous
option (selection of username). If password is correct the menu shows the list of Function Block available,
according to password level and username.
• By UP and DOWN select the Function Block and then press ENTER.
• By UP and DOWN select the Function TAB and then press ENTER.
• By UP and DOWN select the parameter or the ECUcmd, then press ENTER.
• By UP and DOWN view / change the parameter or execute the ECUcmd, then press ENTER.
• By UP and DOWN select “..” and then press ENTER, to return to previous level of menu. Alternatively press
simultaneously UP and DOWN.
• Repeat the above step until the HOME VIEW appears.
20.2 Parameter change

The example shows the procedure to change the value of DEAD BAND. Check the parameter table. The parameter
DEAD BAND is in the Function Block “Actuator Setup” and in the Function TAB “Positioner”. The minimum
password level requested is 1, associated to username “USER”.
• Press ENTER
• By UP and DOWN select “Setup” and then press ENTER.
• By UP and DOWN select the Function Block “Actuator Setup” and then press ENTER.
• By UP and DOWN select the Function TAB “Positioner” and then press ENTER.
• By UP and DOWN select the parameter “DEAD BAND” and then press ENTER. Select “Help” to have
additional information about the parameter. Press ENTER to exit from “Help”.
• By UP and DOWN increase / decrease the value and then press ENTER to set the new value.
• The cursor of display is on the line “..”. Press ENTER to return to the previous level of menu.
• By UP and DOWN select “..” and then press ENTER to return to previous level of menu. Alternatively press

20.3 Parameter visualization

The example shows the procedure to view the value of DEAD BAND. Check the parameter table. The parameter
DEAD BAND is in the Function Block “Actuator Setup” and in the Function TAB “Positioner”. The minimum
password level requested is 1, associated to username “USER”.
• Press ENTER
• By UP and DOWN select “View” and then press ENTER.
• By UP and DOWN select the Function Block “Actuator Setup” and then press ENTER.
• By UP and DOWN select the Function TAB “Positioner” and then press ENTER.
• By UP and DOWN select the parameter “DEAD BAND” and then press ENTER.
• The display shows the value of the Dead Band. Select “Help” to have additional information about the
parameter. Press ENTER to exit from “Help”.
• By UP and DOWN move the cursor of display to the line “..”. Press ENTER to return to the previous level of
menu.
20.4 Execution of an ECU cmd

The example shows the procedure to execute the command “Select opening signature”. Check the ECU cmd table. The
command “Select opening signature” is in the Function Block “Log and Graph” and in the Function TAB “Curves”.
The minimum password level requested is 1, associated to username “USER”.
• Press ENTER
• By UP and DOWN select “ECU cmd” and then press ENTER.
• By UP and DOWN select the Function Block “Log and Graph” and then press ENTER.
• By UP and DOWN select the Function TAB “Curves”, then press ENTER.
• By UP and DOWN select the command “Select opening signature”, then press ENTER.
• The display shows the present value. Select “Help” to have additional information about the parameter. Press
ENTER to exit from “Help”.
• By UP and DOWN select the number of the new opening signature curve and then press ENTER to set the
new value.
• The cursor of display is on the line “..”. Press ENTER to return to the previous level of menu.
menu.

20.5 Visualization of “Status and variables”
HOME VIEW
closing
Note: press one time UP or DOWN or ENTER to wake up
100.0%
100.0%
the display before initiating menu operation.
REMOTE
Enter Enter
.. ..
List of data ……………
Down …………… Up / Enter Name of variable
………….. Enter Enter
Down
………….. Up / Data……....
Down
………….. …………… Value
With reference to the “status and variables table” in par 19.7

• Press DOWN
• By UP and DOWN select the type of data to view
• Press ENTER.
• By UP and DOWN select the data to view
• Press ENTER to view the value
• Press ENTER to return to previous level menu
menu.
• By UP and DOWN move the cursor of display to the line “..”. Press ENTER to return to HOME VIEW
Alternatively the switch to previous level of menu can be done by pressing simultaneously UP and DOWN
The following examples show the procedure to view “HPU oil pressure”, “Failure”, “Alarm”, and “Function summary”
20.5.1 Visualization of “HPU oil pressure”
The procedure allows viewing the value of the variable “HPU oil pressure”. The variable is measured only if the
actuator is provided with HPU.
• Press DOWN
• By UP and DOWN select “ACTUATOR VARIABLES”
• Press ENTER
• By UP and DOWN move the cursor to select “”OIL PRESSURE bar”.
• Press ENTER to view the value
• Press ENTER to return to the previous level of menu.
menu.
• By UP and DOWN move the cursor of display to the line “..”. Press ENTER to return to HOME VIEW

20.5.2 Visualization of “Failure” and “Alarm”
The procedure allows viewing the list of Failures and Alarms

• Press ENTER
• By UP and DOWN select “FAILURE”
• Press ENTER to view the list of failures. Use UP and DOWN to scroll the list of failures
menu.
• By DOWN select “Alarm”
• Press ENTER to view the list of alarms. Use UP and DOWN to scroll the list of alarms
menu.
• By UP and DOWN move the cursor of display to the line “..”. Press ENTER to return to the HOME VIEW.
20.5.3 Visualization of “Function summary”
The procedure allows viewing the list of function enabled to work in the ECU1000 and their main parameters
• Press ENTER
• By UP and DOWN select “Function summary”
• Press ENTER to view the list of function. Use UP and DOWN to scroll the list.
• Press Enter to view if the function is enabled.
• Press Enter to return to the list of functions
menu.
Example of function summary:

Positioner MO-2PSOV positioner in modulating mode, 2PSOV
Interlock enable Interlock enabled
Opt-SOV1 enable Stayput SOV control enabled
PST manual PST available in Manual
PWM enable PWM module enabled
Open limit mode position Open limit by position
Close limit mode continuous Close limit continuous
ESD go to position% ESD set in “go to position”
Only the function present in the list work.
20.5.4 Command “Clear Failure and Alarm”
The procedure allows clearing the Failures and Alarms present in the ECU1000. If a Failure or Alarm is still detected by
the ECU1000 it will appear again.
• Press ENTER
• By UP and DOWN select “Clear Fail-Alarm”
• Press ENTER. Use DOWN to select “Clear Fail-Alarm”.
• Press Enter. By UP and DOWN set the value “1”.
• Press Enter. The cursor of display return on “..”
• Press ENTER to return to the previous level of menu.
• By UP and DOWN move the cursor of display on the line “..”
• Press Enter to return to HOME VIEW

BIFFI ITALIA srl


ECU 1000 Functions description
DTDE 328
ECU 1000
Input Characterization,Recorder,
Graph, Logger,PST, HPU control,
On-off control, Optional local lamps,
PWM driver, RS485 Modbus RTU
Display card
Base and logic cards

card
ECU1000 with
PWM driver card
Modbus RTU card

INDEX
1 INTRODUCTION 1
2 INPUT CHARACTERIZATION 1
2.1 Option: Off 2
2.2 Option: Linear 100-0 2
2.3 Configuration of 2 valves in Split range 3
2.4 Option: Custom increase 3
2.5 Option: Custom decrease 4
2.6 Control of 3 valves by 1 only 4-20mA signal 4
2.7 Input characterization parameters 5
2.8 Status and variables table 6
2.9 ESD and Failsafe 6
2.10 Configuration by Local Operator Interface 6
2.11 Configuration by BIFFI-Assistant 7
3 RECORDER 8
3.1 Recorder mode 8
3.2 Start condition 8
3.3 Stop condition 8
3.4 Recording duration 9
3.5 Max recording time 9
3.6 Y-axis: 9
3.7 OP-stroke curve 9
3.7.1 OP-stroke signature 10
3.8 CL-stroke curve 10
3.8.1 CL-stroke signature 10
3.9 PST curve 10
3.9.1 PST signature 10
3.10 Record curve 10
3.10.1 Record signature 10
3.11 Parameters and ECU cmd of Recorder 11
3.12 Configuration of Recorder 11
3.13 Configuration by Local Operator Interface 11
3.13.1 Recorder function 11
3.13.2 Curve signature 12
3.14 Configuration by BIFFI-Assistant 12
4 GRAPH 13
4.1 Curves 14
5 LOGGER 17
5.1 Event, Failure and Alarm logger 17
5.2 Short Event, Failure and Alarm logger 18
6 PST PARTIAL STROKE TEST 19
6.2 Parameters of Partial Stroke Test 20
6.3 Command to initiate the PST cycle 20
6.4 Reset of PST cycle 21
6.5 PST reports 21

6.6 Remote signalling 21
6.7 PST curves and PST signature 22
6.8 Procedure to initiate PST by local command 23
6.9 Procedure to select the PST SIGNATURE 23
7 HPU CONTROL 24
7.2 Function description 24
7.3 HPU in heavy service for modulating actuators 25
7.3.1 1 pump, intermittent service, 4-20mA pressure transmitter, discharge D-SOV 25
7.3.2 2 pumps, intermittent service, 4-20mA pressure transmitter, Discharge D-SOV, cycle mode 27
7.3.3 2 pumps, intermittent service, 4-20mA pressure transmitter, Discharge D-SOV, master-slave mode 29
7.3.4 1 pump, continuous service, 4-20mA pressure transmitter, discharge D-SOV 31
7.3.5 2 pumps, continuous service, 4-20mA pressure transmitter, Discharge D-SOV, cycle mode 32
7.3.6 2 pumps, continuous service, 4-20mA pressure transmitter, Discharge D-SOV, master-slave mode 34
7.4 HPU for modulating and ON-OFF actuators 36
7.4.1 1 pump, intermittent service, 4-20mA pressure transmitter 36
7.4.2 2 pumps, intermittent mode, 4-20mA pressure transmitter, cycle mode 37
7.4.3 2 pumps, intermittent mode, 4-20mA pressure transmitter, master-slave mode 39
7.5 Simple HPU, 1 pump, intermittent service, pressure switch 41
7.6 HPU with 4-20mA pressure transmitter and hot-backup pressure switch 42
7.7 HPU with hydraulic unloading relief valve 42
7.8 HPU with D-SOV to reduce the start current of motor pump 42
7.9 Examples of HPU 43
8 ON-OFF ACTUATOR CONTROL 44
8.1 Control options 44
8.1.1 2 inputs/2outputs 44
8.2 ESD function 45
8.3 PST function 45
8.4 Alarms 45
9 PWM DRIVER 46
9.1 PWM driver for Biffi PSOV’s 47
9.2 PWM driver for proportional valve without spool feedback 49
10 OPTIONAL LOCAL LAMPS 51
11 RS 485 MODBUS RTU INTERFACE 51

rule.
Warning:
Refer to DTDE326 for the installation and maintenance instruction manual of the
ECU1000 cabinet.

1 14/03/2013 M. Giuliani A. Affaticati Changed HPUctrl
2 08/05/2013 M. Giuliani A. Affaticati Changed ON-OFF
3 28/08/2013 M. Giuliani A. Affaticati Introd. and Pushbut.
4 20/12/2013 M.Giuliani A. Affaticati PWM and Modbus
Copyright by BIFFI ITALIA. All right reserved DTDE328-e5 Pag. iv

1 Introduction
The DTDE326 “Installation and Maintenance” provides the instructions for the installation and maintenance of cabinet
with ECU1000. The DTDE327 “Control functions and Local Operator Interface” provides the instructions to use the
Local Operator Interface, the Positioner and the additional functions to control and monitor the actuator. The manual
DTDE328 “Functions description” provides the instructions relevant to the following ECU1000 functions:
• Input Characterization
• Recorder, Graph and Logger
• PST Partial Stroke Test
• HPU (Hydraulic Power Unit) control
• On-Off actuator control
• Optional local lamps
• PWM module
• RS485 Modbus RTU interface
The manuals DTDE 326, DTE327 and DTDE328 provide the instructions relevant to complete set of ECU1000
functions. Only functions requested by the application and needed to allow the correct actuator control and operation
will be activated in the factory setting.
Warning: It is assumed that the installation, the setting, the commissioning, the maintenance
and repair works are carried out by qualified personnel and checked by
responsible Specialists. Operating the unit or working on the Electronics with the
cabinet door open could cause personal injury.
2 Input characterization
The Input Characterization function allows modifying the profile of the 4-20mA input signal “Position Demand” in a
custom defined curve. The function is active only if the parameter “In. Characteriz., on-off” in the menu “Restricted,
Function Selector” is set to ON.
If the above parameter is OFF the input 4mA = corresponds to Position Demand 0% and 20mA = corresponds to
Position Demand 100%.
If the above parameter is ON, 4 options are available: off, linear 100-0, custom increase and custom decrease.
• off: the input signal 4mA corresponds to Position Demand 0% and 20mA corresponds to 100%.
• Linear 100-0: the input signal 4mA corresponds to Position Demand out 100% and 20mA corresponds to 0%.
No additional parameters are required.
• Custom increase: the user sets the relationship between the 4-20mA Position Demand input signal and the
Position Demand out %. The user should enter from 2 to 21 X-Y points according to the configurable
parameter “Custom point number” in the menu “Actuator setup, Input Characterization”. The entered
data should be X>X-1, Y>=Y-1. If number of data is not according to “Custom point number” or their value is
not according to the above constraints, the ECU1000 issues the ALARM “Characterization” and works in
“off” mode.
• Custom decrease: the user sets the relationship between the 4-20mA Position Demand input signal and the
Position Demand out %. The user should enter from 2 to 21 X-Y points according to the configurable
parameter “Custom point number” in the menu “Actuator setup, Input Characterization”. The entered
data should be X>X-1, Y<=Y-1. If number of data is not according to “Custom point number” or their value is
not according to the above constraints, the ECU1000 issues the ALARM “Characterization” and works in
“off” mode.
Position Demand out %
Position Demand in 4-20mA Input characterization Positioning function
If the Input Characterization function is on, the display of the Local Operator Interface shows the letter <c>before the
value of the Position Demand %. The <c> indicates that the value shown on the display is the Position Demand out %.

The following parameters are available:

• Input characteristic (off, linear 100-0, custom increase, custom decrease)
• Custom point number (from 2 to 21), default 21
• Input #0 (X)
• Output #0 (Y)
• -----
• -----
• Input #20
• Output #20
The local display of ECU1000 does not show the X,Y points that exceed the “Custom point number”. The BIFFI-
Assistant shows all 21 points even if “Custom point number” is less than 21.
The figures below shows the relationship between the Position Demand 4-20mA input and Position Demand out %
2.1 Option: Off
Position demand out %

Option: Off
Input 0% = 4mA Output = 0%
100% Input 100% = 20mA Output = 100%
75%
50% Custom point number: not used
25% Input#n = not used output# n = not used
0%
0% 25% 50% 75% 100% Input Position Demand %

4mA 8mA 12mA 16mA 20ma Input Position Demand 4-20 mA
2.2 Option: Linear 100-0

Option: linear 100-0
100% Input 0% = 4mA Output = 100%
Input 100% = 20mA Output = 0%
75%
50% Custom point number: not used
Input#n = not used output#n = not used
25%
0%

4mA 8mA 12mA 16mA 20ma Input Position Demand 4-20mA

2.3 Configuration of 2 valves in Split range

100% Option: Custom increase
Custom point number: 2
Input#0=0, output#=0
Input#2=50 output#2=100
50% Actuator #1
0%


Option: Custom decrease
Input#0=0, output#=100
100% Input#2=50 output#2=0
Actuator #2
50%
0%

The ECU1000 controls one only actuator. Two valves in split range can be controlled by 2 ECU1000 and one only 4-
20mA input demand signal (see paragraph 2.6, Control of more valves by one only 4-20mA signal).
2.4 Option: Custom increase

Option: CUSTOM increase
100% Input#0=0, output#0=0
85%
0%


2.5 Option: Custom decrease
Position demand out % Option: CUSTOM decrease

Input#0=0, output#0=100
100% 85%
0%

2.6 Control of 3 valves by 1 only 4-20mA signal

Even if the 4-20mA analogue inputs are optocoupled, each input has a maximum voltage drop of 9V at 20mA, so one 4-
20mA input signal can drive one only ECU1000. Control of more valves by one only 4-20mA input signal (Position
Demand) can be done by an additional 4-20mA analogue separator/repeater with low voltage drop characteristic,
according to the following diagram.
4-20mA + Additional 4- 4-20mA ECU1000

20mA separator
24V
Example of separator:
PHOENIX type
MINI –MCR-SL-I-I
Additional 4- ECU1000
4-20mA
20mA separator
24V
Additional 4- ECU1000
4-20mA
4-20mA - 20mA separator
24V

2.7 Input characterization parameters

The following table shows the parameters of the Input Characterization function, the Function TAB, the Function
BLOCK to which the parameters belong and the password level required. The option “View param.” allows viewing
their value, the option “Setup param.” allows changing their value.

ESD
Input characteristic (off, linear 100-0, custom increase, custom decrease) 2
Custom points (from 2 to 21) 2
Input #0 2
Output #0 2
Input #1 2
Output #1 2
Input #2 2
Output #2 2
Input #3 2
Output #3 2
Input #4 2
Output #4 2
Input #5 2
Output #5 2
Input #6 2
Output #6 2
Input #7 2
Output #7 2
Input #8 2
Output #8 2
Input #9 2
Output #9 2
Input #10 2
Output #10 2
Input #11 2
Output #11 2
Input #12 2
Output #12 2
Input #13 2
Output #13 2
Input #14 2
Output #14 2
Input #15 2
Output #15 2
Input #16 2
Output #16 2
Input #17 2
Output #17 2
Input #18 2
Output #18 2
Input #19 2
Output #19 2
Input #20 2
Output #20 2
Restricted
General
Function selector
In characteriz (on/off) 2

2.8 Status and variables table
The following table shows the data visible from the HOME VIEW of local display by pressing DOWN and relevant to
Input Characterization function. No PSW is requested.
Note: it needs to press one time one of the Local Operator Interface pushbuttons to wake up the display before
initiating the menu operations.
Description of data Content
Actuator status:
Actuator variables: -
Position demand % (Position Demand out % to positioning function)
Position error %
In-pos demand % (Position Demand input %)
-
-
Next PST
Next pump switch
Failure:
Alarm: See list of alarms (Characterization, in case of wrong data)
2.9 ESD and Failsafe
Input Characterization function works only on the 4-20mA Position Demand input. ESD function and Failsafe functions
are not affected by the Input Characterization.
2.10 Configuration by Local Operator Interface
Note: it needs to press one time UP or DOWN or ENTER to wake up the display before initiating the menu operations
(due to display function “auto or save”).
of parameter and to move to next menu. Select the line “..” and press ENTER to return to previous menu. The access to
“Actuator setup, Input Characterization” menu and to “Restricted, Function selector, In characteriz” parameter
requires at least password level 2 and username “Operator”. The procedure to set the parameter of the function is the
following:
• Press ENTER
• By UP and DOWN select the username, then press ENTER
• By UP and DOWN select View or Setup, then press ENTER.
Enter the password. By UP and DOWN select each character and then press ENTER to confirm.
If the function Input Characterization is disabled it need to enable it by the instruction below. If the function is
already enabled the next step is not required.
• By UP and DOWN select “Restricted”, then press ENTER
• By UP and DOWN select “Function selector”, then press ENTER. By UP, DOWN select the parameter “In
characteriz” , and then press ENTER.
• By UP, DOWN set it to “ON” and then press ENTER.
• By UP, DOWN select “..” and then press ENTER, to return to previous menu.
• Repeat the procedure until the menu is “.., Actuator setup, …. , Restricted” appears.

Setting of the “Input characterization“ function:

• By UP and DOWN select “Actuator Setup” and then press ENTER. By UP and DOWN select “Input
Characterization” and then press ENTER.
• By UP and DOWN select “Input characteristic”, then press ENTER. By UP and DOWN select the desired
characteristic, then press ENTER.
• By UP and DOWN select “Custom points”, then press ENTER. By UP and DOWN select the desired number
of X-Y points, then press ENTER.
• By UP and DOWN select “IN#0 (X0)”, then press ENTER. By UP and DOWN set the IN#0 (X0) , then press
ENTER.
• By UP and DOWN select “OUT#0 (Y0)”, then press ENTER. By UP and DOWN set the OUT#0 (Y0) , then
press ENTER.
• Repeat the above steps and enter the number of points IN#n (Xn) and OUT#n (Yn) set by the parameter
“Custom points”
• By UP and DOWN select “..”, then press ENTER.
2.11 Configuration by BIFFI-Assistant

The “Input Characterization” function can be configured by BIFFI-Assistant. The Instruction Manual of BIFFI-
Assistant gives all the instructions to operate with it.
The figure shows the parameter

Inp Characteriz to activate the
Input Characterization function.
The figure shows the

parameters of Input
Characterization function

3 Recorder
The Recorder function allows sampling the variables selected by “Y-axis” in function of the time “t” and saving them
in the permanent memory of the ECU1000. The data can be recovered, viewed and exported as Y/t graphs by the
BIFFI-Assistant SW tool. The data cannot be viewed by the Local Operator Interface of ECU1000. Up to 5 curves of
each “Recorder mode” option can be saved in the memory. When the memory is full and a new curve is saved, the
oldest one is deleted. Each curve can have up to 4 Y-axis variables. One of the curves can be saved in a separate
memory and used as “Signature”. It can be compared with the last saved curves to obtain data relevant to the behavior
of the actuator and process valve.
Sampling of data starts 5 sec. after the selection of Recorder mode. When it is on, the HOME VIEW of the local
display shows <R>. If Recorder mode is changed while “sampling” of data is on, the collected data will be lost.
Collected data are saved in the permanent memory of ECU1000 only if one of the “STOP condition” described below
occurs.
The below tables show the parameters to set the Recorder function.
3.1 Recorder mode

Mode Description
Off Off (Recorder not active)
Record to save the last 200 sample of “Y-axis” variables before than selected “Stop condition” occurs
PST: to save the “Y-axis” variables sampled in the time “Recording Duration”, in the PST cycle
OP-stroke: • to save the “Y-axis” variables in the time “Recording Duration”, in the full opening stroke
• to save the “Y-axis” variables in the time “Recording Duration”, during the actuator travel
CL-stroke: • to save the “Y-axis” variables in the time “Recording Duration”, in the full closing stroke
• to save the “Y-axis” variables in the time “Recording Duration”, during the actuator travel
3.2 Start condition

Mode Description
Record Data sampling starts 5 sec. after than the “Record” option is entered.
PST Data sampling starts when command to perform PST (partial stroke test) is detected
OP-Stroke • Recorder enabled 5 sec. after than the “OP-mode” option is entered
• Modulating actuator: data sampling starts if position demand is >1%
• On-Off actuator: data sampling starts when ECU1000 receives a command to open
CL-Stroke • Recorder enabled 5 sec. after than the “CL-stroke” option is entered
• Modulating actuator: data sampling starts if position demand is <99%
• On-Off actuator: data sampling starts when ECU1000 receives a command to close
3.3 Stop condition

Mode Description
Record One of the following condition occurs:
• FAILURE
• ALARM
• POSITION < 5%
• POSITION > 95%
• Recording time > Max recording time
Op- stroke The selected “Recording Duration” has passed (measured from time of “Start condition”)
Cl-stroke The selected “Recording Duration” has passed (measured from time of “Start condition”)
PST mode The selected “Recording Duration” has passed (measured from time of “Start condition”)
Only one Recorder mode at a time is active. In Record / Op-stroke / Cl-stroke modes the recorder switches off when
the stop condition occurs. It can restart by a new setting of the “Recorder mode”. In “PST mode” the recorder switches
off when the stop condition occurs, but it restarts automatically when a new PST initiates.

3.4 Recording duration

Recording Sampling
Duration Time
2s 10 ms The table shows the relationship between
4s 20 ms the selected “Recording Duration” and
10 s 50 ms the “Sampling Time” of Recorder.
20 s 100 ms
50 s 250 ms
100 s 500 ms
200 s 1.0 s
500 s 2.5 s
1000 s 5.0 s
3.5 Max recording time

Recording Max recording Max recording Max recording Max recording
duration time, 4 variables time, 3 variables time, 2 variables time, 1 variable The table shows
hh:mm:ss hh:mm:ss hh:mm:ss hh:mm:ss the relationship
2s 1m 42.4s 2m 33.6s 3m 24.8s 6m 49.6s between the
4s 3m 24.8s 5m 7.2s 6m 49.6s 13m 39.2s selected
10 s 8m 32s 12m 48s 17m 04s 34m 08s “Recording
20 s 17m 04s 25m 36s 34m 08s 1h 08m 16s Duration” and the
50 s 42m 40s 1h 04s 1h 25m 20s 2h 50m 40s “Max Recording
100 s 1h 25m 20s 2h 08s 2h 50m 40s 5h 41m 20s Time” in
200 s 2h 50m 40s 4h 16s 5h 41m 20s 11h 21m 40s “Record” mode
500 s 7h 6m 40s 10h 40m 14h 13m 20s 28h 26m 40s
1000 s 14h 13m 20s 21h 20m 28h 26m 40s 56h 53m 20s
3.6 Y-axis:
Y-Axis variable Descritption
Position demand Position Demand %
Actuator Position Actuator Position % The parameter “Y-axis” allows
HPU oil pressure Available only if the HPU control is active selecting the variables of Y-Axis to
Position error Position Error % sample. Up to 4 variables can be
AO1 % Analogue Output of positioner % selected. Each saved curve is made
Interlock Interlock variable of 200 samples of each variable
Pressure cylinder1 Available only if the transmitter is present
Pressure cylinder2 Available only if the transmitter is present
PST trigger Start and stop marker of PST
3.7 OP-stroke curve

Mode Start condition Stop condition Y-axis Recording duration
OP-stroke Modulating actuator: Recording duration Position demand%, Position%, >Estimated full
Position demand >1% passed max 4 variables opening time
OP-stroke On-Off actuator: Recording duration Position%, Pressure, max 4 >Estimated full
Command to open passed variables opening time
The above option can be used to record the full opening stroke of actuator. If the Position Demand is 0% and 5 sec. after
“OP-stroke” mode selection, the recorder enters in the “wait for trigger” status. When Position Demand signal
becomes >1% the sampling of data starts and ends when the “Recording duration” time has passed.
This option can be used also to record a partial actuator travel in both directions for the “Recording duration” time.

3.7.1 OP-stroke signature

By the ECU commands, LOG and GRAPH, RECORDER COMMANDS in the Local Operator Interface or by BIFFI-
Assistant, one OP-stroke curve of the ECU1000 memory, can be saved in a separated memory area and used as “OP-
stroke signature” for comparison with the new curves to see changes in the actuator operation.
3.8 CL-stroke curve

CL-stroke Modulating actuator: Recording duration Position demand%, Position%, >Estimated full
Position demand <99% passed max 4 variables closing time
CL-stroke On-Off actuator: Recording duration Position%, Pressure, max 4 >Estimated full
Command to close passed variables closing time
The above options can be used to record the full closing stroke of actuator.
If the Position Demand is100% and 5 sec. after “CL-stroke” mode selection, the recorder enters in the “wait for
trigger” status. When Position Demand signal becomes <99% the sampling of data starts and ends when the
“Recording duration” time has passed.
This option can be used also to record a partial actuator travel in both directions for the “Recording duration” time.
3.8.1 CL-stroke signature

By the ECU commands, LOG and GRAPH, RECORDER COMMANDS in the Local Operator Interface or by BIFFI-
Assistant, one CL-stroke curve of the ECU1000 memory, can be saved in a separated memory area and used as “CL-
stroke signature” for comparison with the new curves to see changes in the actuator operation
3.9 PST curve
The paragraph “PST Partial Stroke test” describes the PST Partial Stroke test and provides the detailed information
relevant to PST function. Here are reported only the information to set the Recorder in the PST function

PST Rem-Auto, modulating Recording duration Position%, Pressure 1, >Estimated max PST
Rem-Man, on-off passed Pressure2, max 4 variables time
3.9.1 PST signature

By the ECU commands, LOG and GRAPH, RECORDER COMMANDS, in the Local Operator Interface or by BIFFI-
Assistant, one PST curve of the ECU1000 memory, can be selected and saved in a separated memory area and used as
“PST signature” for comparison with the new curves to see changes in the actuator operation. An Alarm is generated
if PST cycle aborts or if the comparison with the signature fails.
3.10 Record curve

Record When Record mode is Failure, Alarm, position Position demand%, >Estimated full
selected <5%, position >95% Position%, max 4 variables closing time
This option can be used to sample the selected variables and save the last 200 samples in the ECU1000 memory when
the condition to stop occurs. The record operation ends if the stop condition does not occur in “Max recording time”.
3.10.1 Record signature

By the ECU commands, LOG and GRAPH, RECORDER COMMANDS, in the Local Operator Interface or by BIFFI-
Assistant one Record curve of the ECU1000 memory, can be saved in a separated memory area and used as “Record
signature” for comparison with the new curves to see changes in the actuator operation.

3.11 Parameters and ECU cmd of Recorder

The following table shows the parameters of the Recorder function, the Function TAB, the Function BLOCK to which
the parameters belong and the password level required. The option “View param.” allows viewing their value, the
option “Setup param.” allows changing their value.

ESD
Recorder
Recording duration (from 2 to 1000 sec) 1
Stop condition (in Record mode, Failure, Alarm, Position<5%, Position >95%) 1
Y-axis (Position%, Position Demand%, AO1, etc) 1
Recorder mode (off, OP-stroke, CL-stroke, PST, Record) 1
The following table shows the ECU cmd necessary to set the “Signature” in the Recorder function.

Log and graph level
Logger
Curves
Select OP-stroke signature 1
Select CL-stroke signature 1
Select Record signature 1
3.12 Configuration of Recorder

Warning: the correct configuration of Recorder can be done only in accordance to the below conditions:
• Change of the recorder settings is allowed only if the parameter “Recorder mode” is OFF
• If the parameter “Recorder mode is ON, no change of recorder settings is accepted by the ECU1000
• To change the parameter “Recorder mode” it needs to set it to OFF and then enter the new mode
3.13 Configuration by Local Operator Interface
Before initiating menu operations, it needs to press one time UP or DOWN or ENTER to wake up the display.
of parameter and to move to the next menu. Select the line “..” and press ENTER to return to previous menu. The
manual DTDE327 “Actuator control and Local Operator Interface” provides detailed instructions to use the Local
Operator Interface. Here are reported only the information to set the Recorder by the Local Operator Interface.
3.13.1 Recorder function

• Select the username, enter the password. Select View or Setup mode
• By UP and DOWN select “Actuator Setup” and then press ENTER. By UP and DOWN select “Recorder” and then
press ENTER.
• By UP and DOWN select the parameter “Recorder mode” and then press ENTER. By UP and DOWN select the
option “OFF”, then press ENTER.
• By UP and DOWN select the parameter “Recording time” and then press ENTER. By UP and DOWN select the
desired time and then press ENTER.

• By UP and DOWN select “Stop condition” and then press ENTER. By UP and DOWN select the desired stop
condition and then press ENTER. Configure this parameter only if the Recorder mode will be “Record”.
• By UP and DOWN select “Y-Axis, then press ENTER. By UP and DOWN set the variable to sample and then press
ENTER.
• By UP and DOWN select the parameter “Recorder mode” and then press ENTER. By UP and DOWN select the
desired option (“OP-stroke, CL-stroke, PST, Record”) and then press ENTER.
• By UP and DOWN select the line “..” and then press ENTER. Repeat the procedure to return to HOME VIEW.
Now the Recorder is active. The sampling of data starts when the trigger condition occurs. To modify the setting it
needs to set again the Recorder mode in OFF.
3.13.2 Curve signature

• Select the username, enter the password. Select ECU cmd mode
• By UP and DOWN select “Log and Graph” and then press ENTER.
• By UP and DOWN select “Curves” and then press ENTER.
• By UP and DOWN select the type of signature and then press ENTER.
• By UP and DOWN select the number of the curve to save as signature and then press ENTER.
• By UP and DOWN select the line “..” and then press ENTER. Repeat the procedure to return to HOME VIEW
3.14 Configuration by BIFFI-Assistant

The “Recorder” function can be configured by BIFFI-Assistant. The Instruction Manual of BIFFI-Assistant gives all the
instruction to operate with it.

parameters of Recorder
function
The figure shows the ECU cmd

of signature selection

4 Graph
The function is available only by BIFFI-Assistant. The Recorder function saves the curves and the signatures in the
ECU1000 permanent memory according to instructions of previous paragraphs. The saved data can be viewed as graph
or table and exported only by BIFFI-Assistant SW tool. The Graphs are not visible on the local Operator Interface due
to small visible area of the display. This paragraph reports only the instructions of BIFFI-Assistant relevant to the
Graph. Detailed instructions about the installation and operation of the BIFFI-Assistant are reported in the “BIFFI-
Assistant Instruction Manual”. Use the left key of mouse to select the line, use right key of mouse to read / write the
selected BLOCK, TAB, data. Each graph can be individually or with other data exported and saved in the PC memory.
Connection by RS232 (wired) or Bluetooth (wireless)

ECU1000
Select the line by the

left key of mouse.
Use the right key of
mouse to read the
complete function
BLOCK or function
TAB
Select the line by the

left key of mouse.
Use the right key of
mouse to read the
data of the selected
function

4.1 Curves

list of “Opening
curves” (OP-stroke)
available in the
ECU1000 memory.
The signature is
identified by the
number 0 and the “*”
in the column
“signature”. The
curve number 5 is the
oldest one.

Y-t “Closing “ curve
0 (signature)
available in the
ECU1000 memory
(CL-stroke).
The curve is viewed
by selecting the
option “Chart view”.
Use the left key of
mouse to select the
variable and to
activate the “Track
points”. By the
option “X axis”
change to Y-X graph

“Opening “ curve 0
(signature) available
in the ECU1000
memory (OP-stroke).
The point of the curve
can be viewed by
selecting the option
“Grid view”.

Only 2 curves at a
time can be viewed.
Each curve can have
maximum 4
variables.
“Opening “ curve 0
(signature) and
curve 2, 2 variables
for each curve

“Closing“curve 4, 4
variables

“Record “ curve 0
(signature), 2
variables


“PST “ curve 0.
4 variables are
shown: actuator
position, HPU
pressure, AO1% and
Pressure P1 of
cylinder
Full screen view of

PST curve in Y-X, X
mode “reversed”. Y=
Pressure inside the
cylinder in bar, X=
actuator position %

5 Logger
The function is available only by BIFFI-Assistant. The ECU1000 saves the Event logger, the Failure logger and the
Alarm logger in the ECU1000 permanent memory. The saved data can be viewed as tables and exported only by
BIFFI-Assistant SW tool. The loggers are not visible on the local Operator Interface due to small visible area of the
display. This paragraph reports only the instruction of BIFFI-Assistant relevant to the Logger. Detailed instructions
about the installation and operation of the BIFFI-Assistant are reported in the “BIFFI-Assistant Instruction Manual”.
Use the left key of mouse to select the line, use the right key of mouse to read / write the selected BLOCK, TAB, data.
Each logger can be individually or with other data exported and saved in the PC memory. The list of Events, Failure and
Alarms is reported in the manual DTDE327 “Actuator control and Local Operator Interface”. The figures in the
previous paragraph show how to use the BIFFI-Assistant SW tool.
5.1 Event, Failure and Alarm logger

Event logger saved
in the ECU1000
memory. It may
contain up to 256
events. When the
memory is full and a
new event occurs the
oldest one is deleted.
The table shows the
name of event, the
date of event and the
action done by
ECU1000 due to
event.

Failure logger saved
in the ECU1000
memory. It may
contain up to 256
failures. When the
new failure occurs the


Alarm logger saved
in the ECU1000
memory. It may
contain up to 256
alarms. When the
new alarm occurs the
5.2 Short Event, Failure and Alarm logger

short Event logger
saved in the
ECU1000 memory. It
contains the last 10
events. It is faster to
read than the
complete event
logger.
The short Failure
logger and the short
Alarm logger have
the same
characteristics.

6 PST Partial Stroke Test

The function Partial Stroke Test (PST) of ECU1000 is used to check the actuator and valve operation while they are in
service in the pipeline. It is performed only if
• PST function was enabled (by manufacturer)
• the actuator is fully open or closed
• the actuator is not fully open or closed but the position is >98% or < 2%
• the actuator is not in local control mode (by Local Operator Interface)
• ESD command is off
• No FAILURE is present
• the actuator is
o modulating under control of 4-20mA (AUTO-REM mode) and Position Demand is <2% or >100%
o modulating and in manual mode (MAN-REM)
o the actuator is on-off
The PST cycle (Partial Stroke Test) consists in the following steps:
• To drive the actuator to move the valve to the configured position (PST travel)
• To measure the time to reach the configured position (T-PST)
• To stop the actuator when the configured position is reached and measure the over-travel % (OV-TR)
• To stay in position for the configured PAUSE time
• To drive the actuator to move the valve to the initial position
• To measure the time to return to the initial position (T-RET)
The following figures show the actuator position% versus time in case of PST in closing and opening direction.
Max PST duration
100 100
Position %
PST travel%
Overtravel % (OV-TR)
PST in closing
T-RET direction
T-PST Stay in
Command position
to initiate (PAUSE)
PST Time sec
0
Position % Max PST duration
T-RET PST in opening

direction
T-PST Stay in
position
Cmd to (PAUSE)
initiate
PST Overtravel % (OV-TR)
PST travel%
0 Time sec

6.2 Parameters of Partial Stroke Test
The following parameters are available in the menu options “ACTUATOR SETUP, PST SETUP” of ECU1000 to set
PST function:
a. PST START mode: OFF, MANUAL, AUTO, AUTO-MANUAL
• OFF: the PST function is disabled
• MANUAL: the PST cycle starts if one of the conditions 1 and 2 occurs
1. ECU1000 receives a remote hardwired PST command (min duration 1 sec)
2. ECU1000 receives the PST command from the Local Operator Interface in the menu option
“ECU cmd, Device command”
• AUTO: the PST cycle starts automatically if both the conditions 3 and 4 occur
3. The time from the last PST cycle is equal to the parameter PST PERIOD
4. The time of the day is equal to the parameter PST TIME (hh:mm:ss)
• MAN-AUTO: the PST cycle starts if one of the condition 5 and 6 occurs
5. Conditions 1. and 2. of MANUAL mode are satisfied
6. Conditions 3. and 4. of AUTO mode are satisfied
b. PST PERIOD: time interval between PST’s in days, configurable from 1 to 1000, in PST START=“AUTO”
c. PST TIME: hour, minute and second to start the PST, in PST START=“AUTO”.
d. PST TRAVEL: position travel during PST cycle, in % of position, configurable from 1 to 40. If actuator is
fully open it moves from 100% to “100-PST TRAVEL %”, if actuator is fully closed it moves from 0% to
“PST TRAVEL %”
e. MAX T-PST: max time to carry out the PST TRAVEL, measured in % of T-PST time of SIGNATURE,
configurable from 0 to 1000%.
f. MAX PST T-RET: max time allowed to return to initial position, measured in % of T-RET time of
SIGNATURE, configurable from 0 to 1000%
g. PAUSE: time of staying in position of actuator, in sec, configurable from 0 to 60 sec.
h. MAX PST OV-TR: max position over-travel during PST cycle, in percentage of position, configurable from 0
to 100.
i. MAX PST DURATION: max time to complete the PST cycle, configurable from 2 to 1000 sec.

PST setup
PST start (off, manual, auto, auto-manual) 2
PST period (only in auto or auto-manual) 2
PST time (only in auto or auto-manual) 2
PST travel 2
PST pause 2
Max T-PST (% of signature) 2
Max T-RET (% of signature) 2
Max OV-TRAV (% of position) 2
Max PST duration (sec) 2
6.3 Command to initiate the PST cycle
PST cycle initiates if the following conditions are satisfied:

• The conditions described in the par. 6.1 are satisfied
• The PST START mode is “MANUAL” and the ECU1000 receives the PST command
• The PST START mode is “AUTO” and the time to start automatically the cycle has arrived
• The PST START mode is “MAN-AUTO” and the ECU1000 receives the PST command or the time to start
automatically the cycle has arrived

6.4 Reset of PST cycle
PST cycle is aborted or not completed in the following conditions:

• FAILURE during the PST execution
• The time to complete the PST cycle is greater than the parameter “MAX PST DURATION”
• ESD command during the PST execution
6.5 PST reports
When the PST cycle is in progress the display of the Local Operator Interface shows the message “PST”. The start of
the PST cycle is saved in the Event logger as “PST”
When PST cycle ends, the ECU1000 compares the collected data with the configured setpoints “MAX T-PST, MAX
PST T-RET, MAX PST, OV-TR. The following alarms are available:
Status Description Alarm Note

Passed Test OK No message on the ECU1000 display
Reset test aborted or not completed PST See reset conditions
T-PST failed time T-PST T-PST See parameter MAX T-PST
T-RET failed time T-RET T-RET See parameter MAX PST T-RET
OV-TR PST over-travel OV-TR See parameter MAX PST OV-TR
Failed at least two of T-PST, T-RET, OV-TR, Reset Failed
The Alarm can be viewed by the Local Operator Interface of ECU1000 or by a PC connected via Bluetooth interface.
The Alarms are also recorded in the Alarm log.
6.6 Remote signalling
The following conditions can be individually configured to switch the output relays.
• PST: PST cycle in progress
• PST failed: it summarizes T-PST, T-RET, OV-TR and Reset. The status of relay “PST failed” can be reset by a
new PST command or by a manual reset of alarm via actuator Local Operator Interface (see manual DTDE327,
paragraphs 19 and 20).
The manual DTDE327 in the paragraphs “Local Operator Interface” and “Output relay” provides the instructions to set
the ECU1000 output relays.
Status relay table

Name Description
Actuator status
PST PST function active

PST failed PST result “failed/aborted”

6.7 PST curves and PST signature
The Recorder function can save the profile of the PST cycle in the ECU1000 memory. It needs to configure Recorder
mode “PST”. The Recording duration should be greater than the estimated duration of PST cycle. The paragraph
“Recorder”, supplies the information to set the Recorder function.
During the PST cycle the ECU1000 samples and saves the Actuator Position%, the Time and the PST trigger. If the
actuator is provided with transmitters of cylinder pressure (P1 and P2), the recorder saves also the profiles of the above
pressures. The ECU1000 memory contains up to 5 PST profiles. When the memory is full and a new set of data is
available the oldest profile is deleted and the new one is stored.
By the command “SELECT PST SIGNATURE”, in the local operator interface, one “PST curve” can be copied in the
“PST SIGNATURE” memory. The “PST SIGNATURE” cannot be modified; it can be updated only by a new
“SELECT PST SIGNATURE” command.
By the comparison between the PST SIGNATURE and the PST curves, the ECU1000 can produce status and warning
useful in maintenance operation.
By PC and BIFFI-Assistant software tool, the curves can be read from ECU1000 and then viewed and compared in a
graph.
PST curve details
Example of PST in
opening (Y-t)

Example of PST in
opening (Y-X),
“Pressure in bar”
versus “Actuator
Position in %”
6.8 Procedure to initiate PST by local command

• Select the username, enter the password. Select ECU cmd
• By UP and DOWN select “Device cmd” and then press ENTER. By UP and DOWN select “PST command” and
then press ENTER.
• By UP and DOWN select “PST start” and then press ENTER.
• By UP and DOWN move the cursor to “PST start” and then press ENTER.
• By UP and DOWN set “ON” and then press ENTER.

level
Device cmd
PST command
PST start (off-on) 2
6.9 Procedure to select the PST SIGNATURE

• Select the username, enter the password. Select ECU cmd
• By UP and DOWN select “Log and Graph” and then press ENTER. By UP and DOWN select “Curves” and then
press ENTER.
• By UP and DOWN select the parameter “Select PST signature” and then press ENTER. By UP and DOWN select
the number of the curve to be saved as signature, then press ENTER.

level
Device cmd
Log and graph

Curves
1
1
1

7 HPU control
Input to control the HPU:
• 4-20mA HPU oil pressure input signal
• Digital inputs,to set optocoupled, max 30Vdc, available for optional HPU on-off sensors
Output to HPU Hydraulic Power Unit:
• Output by relay: SPST voltage free contacts, max 30Vdc/230Vac/1A (110Vdc/0.15A) to drive the contactor of
pump1 motor
• Output by relay: SPST voltage free contacts, max 30Vdc/230Vac/1A (110Vdc/0.15A) to drive the contactor of
pump2 motor (in case of dual pump)
• Output by relay: SPST voltage free contacts, max 30Vdc/230Vac/1A (110Vdc/0.15A) to drive the discharge
SOV ( in case of modulating actuator)
HPU type:
• HPU with 1 or 1 electrical pumps, Discharge SOV, 4-20mA pressure transmitter, optional pressure switch
• HPU with 1 or 2 electrical pumps and 4-20mA pressure transmitter, optional pressure switch
• HPU with 1 electrical pump and pressure switch
• HPU with 1 or 2 electrical pump, 4-20mA pressure transmitter, optional pressure switch, unloading relief valve
7.2 Function description

The HPU control function can be activated only by the manufacture. The type of control depends on the hydraulics of
HPU. By the Local Operator Interface the end user can set the parameters to manage the HPU operations. The
following figure shows the block diagram of HPU function.
ECU 1000
Out relay Discharge D-SOV
Configurable
On-off sensors reference values
(temperature, level, Out relay
power supply, filter, HPU Electrical motor of
hand-pump, etc.) function pump1
Pressure switch Out relay

Electrical motor of
Diagnostic pump2
4-20mA oil pressure
function
transmitter
Depending on the HPU hydraulics, the ECU1000 can control the HPU pressure
• By a 4-20mA analogue pressure transmitter or
• By a pressure switch or
• By 4-20mA analogue pressure transmitter and pressure switch
o in case of failure of 4-20mA transmitter the ECU1000 works with the pressure switch
If redundancy of pumps is requested the ECU1000 can control two electrical pumps in two modes:
o cyclic: one pump at a time works, the ECU1000 switches from the running pump to the other one in
case of malfunction or at the end of the configured cycle time
o master-slave: one pump at a time works, the ECU1000 switches from the master pump to the slave
one in case of malfunction. A selector switch is needed to choose the master pump.
The Discharge D-SOV is present only in the HPU’s in heavy working service with low drain proportional/PSOV
valves and allows to by-pass the pump when the oil pressure reaches the working pressure. The SOV is released when
the pressure is lower than the preset low limit to allow the pump charging the accumulator. The minimum on time of the
pump is 2 sec. Optional on-off sensors can be added to monitor the HPU status and generate “alarm (out of spec)”
conditions. The list of the optional on-off sensors is below
• Oil Level • High motor temperature
• High oil temperature • General on-off sensors
• Oil filter • Hand-pump
• Loss of main power supply

The max number of sensors, transmitters and commands is limited by the hardware characteristics of ECU1000,
described in the document DTDE326 and DTDE 327 (11 digital inputs, 11 output relays, 5 analogue inputs, etc.).
Configuration and diagnostic operations of HPU are available by the Local Operator Interface of ECU1000. Upon
request, the ECU1000 cabinet can be provided with 8 additional LED’s to show HPU status. The complete list of the
available conditions is in the paragraph “Output relay, Status Relay table” of manual DTDE327. The table below lists
only the conditions related to HPU.
Status relay table

Name Description
HPU status summary

Pump1 alarm It collects all alarms of HPU and pump1 (See table 15.3)
Pump 2 alarm It collects all alarms of HPU and pump2 (See table 15.3)
HPU status
Discharge SOV on (DSOV) Discharge SOV on
HPU malfunction / Out of spec
HPU pres. transm. Pressure transmitter of HPU out of range
High oil pressure Oil pressure > reference
Low oil pressure Oil pressure < reference
Oil temperature (high) High oil temperature
Oil level (low level) Low oil level
HPU gener. sens. General on-off sensor of HPU
Hand-pump Hand-pump operation
HPU sign sw HPU signalling on-off sensor (for instance “ HPU oil filter”)
Pump1 power sup. Failure of electrical power supply of pump1 motor

Pump2 mot. Sup. (electrical power supply) Failure of electrical power supply of pump2 motor
The next paragraphs describe the operation of the available HPU controls.
7.3 HPU in heavy service for modulating actuators
7.3.1 1 pump, intermittent service, 4-20mA pressure transmitter, discharge D-SOV

The following parameters are available in the menu “Actuator setup, Pump control”
Pump1 mode: it allows selecting the operating mode of Pump
• Off: the pump does not work
• Auto: the pump works
Pump stop delay: it is the time without any command or with actuator position error < 3%. After the above time the
pump is stopped. It can be configured from 0 to 255 sec, but the value should be great enough to avoid frequent restarts
of pump (for instance 30 sec).
Actuator control delay: delay to initiate the actuator control after the ECU1000 power on. It can be set from 0 to 255
sec.
Max time to pressure: it is the maximum allowed time to reach the working pressure. The parameter can be set from 0
to 255 min. If the working pressure is not reached in the above time the ECU1000 generates the alarm “Max time
pump1”. The alarm is cleared when the pressure is correct or by the ECU commands “Clear Failure / Alarm”. If the
parameter is set to 0 the alarm is not generated.
Pump2 mode and Pump cycle are not used.


Pump control
Pump stop delay (0-255 sec) 1
Actuator ctrl delay (0-255 sec) 2
Max time to pressure (0-255 min) 2
Other not used parameters
The following figure shows the working cycle of the HPU pump, in AUTO mode. The motor pump starts by pressure
and command. The max pressure of HPU should be limited by a hydraulic safety valve limiting the HPU pressure
below the “Max allowable Pressure”.
Pump stop Pressure increase
4-20mA Pressure transmitter delay check Protection by
Max allowable Pressure hydraulic safety
Max time to pressure High pressure limit valve
Max working pressure

Working
area of Working
D-SOV area of
D-SOV low pressure limit pump
Stop of pump Start of pump (on command)
Motor start pressure
Start of pump
Low pressure limit
0 Time
When HPU pressure is equal to “Max working pressure” the Discharge SOV is activated. The pump still runs, but the
pressure stops increasing. The Discharge SOV is released when the HPU pressure becomes lower than “D-SOV low
pressure limit” and pressure can increase again up to “Max working pressure”. The pump stops if
• The Position error signal is less than 3% for the time “Pump stop delay”
• No command is sent to ECU100 (ESD, PST, etc.) for the time “Pump stop delay”
The pump restarts if
• The HPU pressure is lower than “Motor start pressure”
• The position error is>3% or a new command is sent to ECU1000 (ESD, PST, etc.) and the pressure is lower
than “Max working pressure”
If the HPU pressure rises over the “High pressure limit” the ECU1000 stops the motor of pump and generates an Alarm
If the HPU pressure gets down the “Low pressure limit” the ECU1000 generates an Alarm.
The following tables show the HPU/Pump malfunctions detected by the ECU1000.
The “HPU/Pump malfunctions” are listed in the “Additional Alarm table” of the instruction manual DTDE327
(paragraph “Actuator malfunction tables”) and can exit only if the HPU control is on. The column “Signalling relay”
shows the conditions that can be individually linked to the output relays of the ECU1000 by means of the menu options.
Malfunctions of HPU
Name of malfunction Description Pump control Pump Signalling
Alarm relay
HPU pres. transm. Pressure transmitter of HPU signal out of range Pump1 off x x
High oil pressure Oil pressure > high pressure limit Pump1 off x x
Low oil pressure Oil pressure < low pressure limit Regular operation x x
Oil level (low) Oil level sensor = on Pump1 off x x
Oil temper. (high temperature) Oil thermostat = on Pump1 off x x
HPU gener. sens. General on-off sensor of HPU = on Pump1 off x x
Hand-pump Hand-pump engaged Regular operation x x
Max start D-SOV Starts of Discharge SOV (D-SOV) > reference Regular operation x NO
HPU sign sw HPU signalling on-off sensor Regular operation x x

Malfunctions of pump
Alarm relay
Pump1 power sup (electrical power) Loss of power supply of pump1 motor Pump1 off x x
Pump1 mot. TH Motor thermostat of pump1=on Pump1 off x x
Pump1 filter Oil filter sensor of pump1=on Regular operation x x
Gener. sens. Pump1 General on-off sensor of pump1=on Pump1 off x x
Max time pump1 (1) Max time to reach the pressure (pump1) Pump1 off or run (2) x x
Max start pump1 Starts of motor of pump1 > reference Regular operation x NO
(1) Max time pump1: it exits if one of the following conditions occurs:
• the oil pressure is lower than the “Max working pressure” after the time “Max time to pressure” (set by the user)
• the “pressure increase” (bar/min) is less than the parameter “Min pressure increase” (set by the manufacturer). The function “pressure
increase” measures the pressure change only if the actuator is in stable position (position error within 3%), the pump is on and D-SOV off
In case of “HPU/Pump alarm” the actuator works regularly (see the paragraph “Actuator malfunction tables,
Additional alarm table” in DTDE327).
On request, the ECU1000 can be set (by the manufacturer) to signal “Failure” due to “HPU failure”. In case of “HPU
failure” the ECU1000 can be configured either to “regular actuator operation” or “failsafe” or “optional SOV1”
actions. The manual DTDE327 describes the functions “Failsafe” and “optional SOV1”.
The malfunctions to set in “HPU failure” are: “HPU pres. transm.”, “high oil pressure”, “low oil pressure”, “oil level”,
“oil temperature”, “HPU general sensor”, “hand-pump”, “pump blocked”.
“Pump blocked” summarizes the following alarms “pump1 power sup, pump1 mot. TH, Gener. Sens. Pump1”. The
alarm “Max time pump1 is included in the “Pump blocked” if it is configured “the motor stops”. On the contrary it is
not included in the “Pump blocked” if it is configured “the motor runs”.
7.3.2 2 pumps, intermittent service, 4-20mA pressure transmitter, Discharge D-

SOV, cycle mode
One pump at a time works. The following parameters are available in the menu “Actuator setup, Pump control”.
Pump1 mode: it allows selecting the operating mode of Pump1
• Off: the pump1 does not work
• Auto: the pump1 works
Pump stop delay: it is the interval of time without any command or with actuator position error < 3%. After the above
time the pump is stopped. It can be configured from 0 to 255 sec, but the value should be great enough to avoid frequent
restarts of pump (for instance 20 sec). The parameter works only if the Pump1 mode is “Auto”.
sec.
pump1 and Max time pump2”. The alarm is cleared when the pressure is correct or by the ECU commands “Clear
Failure / Alarm”. If the parameter is set to 0 the alarm is not generated.
Pump2 mode:
Pump cycle: it sets the working time of each pump, from 1 to 10000 h. If both pumps are in AUTO, after the “Pump
cycle” the running pump stops and after 4 sec the second pump starts.

Pump control

The switch from one pump to the other one can be

• Manual: the working pump is selected by setting the parameter Pump1 mode and Pump2 mode (for instance
Pump1 mode=off and Pump2 mode=Auto and viceversa)
• Automatic: in case of malfunction of one pump or at the end of the configured “Pump cycle”
Each pump works as described in the paragraph 7.3.1. The ECU1000 controls the D-SOV and two pumps instead of
only one. The 4-20mA pressure transmitter, oil level sensor, oil temperature sensor are common in both pumps.
The following tables show the HPU/Pumps malfunctions detected by the ECU1000. They are also listed in the
“Additional Alarm table” of the instruction manual DTDE327 (paragraph Actuator malfunction tables). The column
“Signalling relay” shows the conditions that can be individually linked to the output relays of the ECU1000 by means of
the menu options.
Malfunctions of HPU
Name Description Pump control Pump Signalling
Alarm relay
HPU pres. transm. Oil pressure transmitter out of range Pump1 and 2 off x x
High oil pressure Oil pressure > high pressure limit Pump1 and 2 off x x
Oil level (low) Oil level switch = on Pump1 and 2 off x x
Oil temper. (high temperature) Oil thermostat = on Pump1 and 2 off x x
HPU gener. sens. General on-off sensor of HPU = on Pump1 and 2 off x x
Max start D-SOV Starts of Discharge SOV > reference Regular operation x NO
Malfunctions of pumps
Alarm relay
Pump1 power sup (electrical power) Loss of power supply of pump1 motor Pump1 off , switch to pump2 (2) x x
Pump1 mot. TH Motor thermostat of pump1=on Pump1 off , switch to pump2 (2) x x
Pump1 filter Oil filter sensor=on Regular operation x x
Gener. sens. pump1 General on-off sensor of pump1=on Pump1 off, switch to pump2 (2) x x
Max time pump1 (1) Max time to reach the pressure (pump1) Pump1 off, switch to pump2 (3) x x
Max start pump1 Starts of motor of pump1 > reference Pump1 off , switch to pump2 (4) x NO
Pump2 power sup. (electrical power) Loss of power supply of pump2 motor Pump2 off , switch to pump1 (2) x x
(1) Max time pump1 and 2: they are due to one of the following conditions:
increase” measures the pressure change only if the actuator is in stable position (position error within 3%), the pump is on and D-SOV off.
(3) If the alarm occurs the running pump switches to off and the second pump starts. If the alarm occurs also with the second pump, “the motor
stops” or “the motor runs” according to the configuration of the ECU1000.
Additional alarm table” in the DTDE327. The above tables and notes describe the condition to switch the pumps due to
alarm
“Pump blocked” summarizes the following alarms “pump1/2 power sup, pump1/2 mot. TH, Gener. Sens.
Pump1/2”. The alarm “Max time pump1 is included in the “Pump blocked” if it is configured “the motor stops”. On
the contrary it is not included in the “Pump blocked” if it is configured “the motor runs”.

7.3.3 2 pumps, intermittent service, 4-20mA pressure transmitter, Discharge D-

SOV, master-slave mode
One pump at a time works. A 3-position “PUMP1/OFF/PUMP2” selector is requested to set the pump master.
In “OFF” both pumps are off.
In “PUMP1” the pump1 works. The pump2 starts in case of alarm of pump1. A further switch to pump1 is not allowed.
The following parameters are available in the menu “Actuator setup, Pump control” of ECU1000.
Pump stop delay: it is the interval of time without any command or with actuator position error < 3%. After the above
time the pump is stopped. It can be configured from 0 to 255 sec, but the value should be great enough to avoid frequent
restarts of pump (for instance 20 sec). The parameter works only if the Pump1 mode is “Auto”.
sec.
pump1and Max time pump2”. The alarm is cleared when the pressure is correct or by the ECU commands “Clear
Pump2 mode:
Pump cycle: not used

Pump control
The switch of pumps is

• Manual: by the selector “PUMP1/OFF/PUMP2”
• Automatic: in case of malfunction of one pump
the menu options.
Malfunctions of HPU
Alarm relay

Malfunctions of pumps with selector in PUMP1 (pump1 master)

Alarm relay
Pump2 power sup. (electrical power) Loss of power supply of pump2 motor Pump2 off (2) x x
Pump2 mot. TH Motor thermostat of pump2=on Pump2 off (2) x x
Gener. sens. pump2 General on-off sensor of pump2=on Pump2 off (2) x x
Max time pump2 (1) Max time to reach the pressure (pump2) Pump2 off (3) x x
Max start pump2 Starts of motor of pump2 > reference Pump2 off (4) x NO

Alarm relay
Gener. sens. Pump2 General on-off sensor of pump2=on Pump1 off, switch to pump2 (2) x x
Gener. sens. Pump1 General on-off sensor of pump1=on Pump2 off (2) x x
Max time pump1 Max time to reach the pressure (pump1) Pump2 off (3) x x
Max start pump1 (1) Starts of motor of pump1 > reference Pump2 off (4) x NO
alarm.

7.3.4 1 pump, continuous service, 4-20mA pressure transmitter, discharge D-SOV

sec.
Pump2 mode, Pump stop delay and Pump cycle are not used.

Pump control
Not used Pump stop delay (0-255 sec) 1
The following figure shows the working cycle of the HPU pump, in AUTO mode. The motor pump starts as it is
powered. The max pressure of HPU should be limited by a hydraulic safety valve limiting the HPU pressure below the
“Max allowable Pressure”.
4-20mA Pressure transmitter
Protection by
High pressure limit valve

Working
area of
D-SOV
D-SOV low pressure limit
Pressure increase
check
Low pressure limit
Start of electrical motor

0 Time
When the HPU pressure is equal to “Max working pressure” the Discharge D-SOV is activated. The pump still runs,
but the pressure stops increasing. The Discharge D-SOV is released when the HPU pressure becomes lower than “D-
SOV low pressure limit”. The pump does not stop.
shows the conditions that can be individually linked to the output relays of the ECU1000 by means of the menu options.

Malfunctions of HPU
Alarm relay
Max start D-SOV Starts of Discharge SOV (D-SOV) > reference Regular operation x NO
Alarm relay
increase” measures the pressure change only if the actuator is in stable position (position error within 3%), the pump is on and D-SOV is
off.
7.3.5 2 pumps, continuous service, 4-20mA pressure transmitter, Discharge D-SOV,

cycle mode
sec.
pump1and 2”. The alarm is cleared when the pressure is correct or by the ECU commands “Clear Failure / Alarm”. If
the parameter is set to 0 the alarm is not generated.
Pump2 mode:
Pump stop delay: not used


Pump control

the menu options.
Malfunctions of HPU
Alarm relay
Alarm relay
alarm

7.3.6 2 pumps, continuous service, 4-20mA pressure transmitter, Discharge D-SOV,

master-slave mode
sec.
pump1 and Max time pump2”. The alarm is cleared when the pressure is correct or by the ECU commands “Clear
Pump2 mode:
Pump cycle and Pump stop delay: not used

Pump control

the menu options.

Malfunctions of HPU
Alarm relay

Alarm relay

Alarm relay
alarm.

7.4 HPU for modulating and ON-OFF actuators
7.4.1 1 pump, intermittent service, 4-20mA pressure transmitter
sec.

Pump control
The following figure shows the working cycle of the HPU pump, in AUTO mode. The motor pump starts when it is
powered. The max pressure of HPU should be limited by a hydraulic safety valve limiting the HPU pressure below the
“Max allowable Pressure”.
When the HPU pressure is equal to “Max working pressure” the pump stops and the pressure stops increasing. The
pump restarts when the HPU pressure is lower than “Motor start pressure”.
4-20mA Pressure transmitter Pressure increase

check Protection by
valve
High pressure limit

Working area
of pump
Motor start pressure
Max time to pressure Start of pump
Low pressure limit
Time
0

shows the condition that can be individually linked to the output relays of the ECU1000 by means of the menu options.
Malfunctions of HPU
Alarm relay
Alarm relay
increase” measures the pressure change only if the actuator is in stable position (position error within 3%) and the pump is on.
7.4.2 2 pumps, intermittent mode, 4-20mA pressure transmitter, cycle mode
sec.
Pump2 mode:
Pump stop delay: not used


Pump control

Each pump works as described in the paragraph 7.4.1. The ECU1000 controls two pumps instead of only one. The 4-
20mA pressure transmitter, oil level sensor, oil temperature sensor are common in both pumps.
the menu options.
Malfunctions of HPU
Alarm relay
Alarm relay
Max time pump2 Max time to reach the pressure (pump2) Pump2 off, switch to pump1 (3) x x
Max start pump2 (1) Starts of motor of pump2 > reference Pump2 off , switch to pump2 (4) x NO
increase” measures the pressure change only if the actuator is in stable position (position error within 3%) and the pump is on
alarm

7.4.3 2 pumps, intermittent mode, 4-20mA pressure transmitter, master-slave mode
sec.
Pump2 mode:
Pump cycle and Pump stop delay: not used

Pump control

Each pump works as described in the paragraph 7.4.1. The ECU1000 controls two pumps instead of only one. The 4-
20mA pressure transmitter, oil level sensor, oil temperature sensor are common in both pumps.
the menu options.

Malfunctions of HPU
Alarm relay

Alarm relay

Alarm relay
increase” measures the pressure change only if the actuator is in stable position (position error within 3%) and the pump is on.
alarm.

7.5 Simple HPU, 1 pump, intermittent service, pressure switch
The control of HPU pressure is based on a pressure switch. Start and stop of motor pump depend on the pressure switch
hysteresis.
sec.

Pump control
The following figure shows the working cycle of the HPU pump, in AUTO mode. The max pressure of HPU should be
limited by a hydraulic safety valve limiting the HPU pressure below the “Max allowable Pressure”.
When the pressure switch is off (open contact) the pump stops and the pressure stops increasing. The pump restarts
when the pressure switch is on (contact closed). The two limits “pressure to stop the pump” and “pressure to start
the pump” are set by the hysteresis of the pressure switch.
HPU oil pressure (bar) Protection by
Max allowable pressure hydraulic safety
valve
Max time to pressure Pressure switch off
Pressure to stop the pump
Pressure switch hysteresis Working area
of pump
Pressure to start the pump
Pressure switch on
Time
0
The logic of pressure switch can be reversed on request: pressure switch off (closed contact)= the pump stops and
pressure switch on (open contact)= the pump starts.
shows the condition that can be individually linked to the output relays of the ECU1000 by means of the menu options.

Malfunctions of HPU
Alarm relay
Alarm relay
(1) Max time pump1: it exits if the HPU pressure is lower than the “Pressure to stop the pump” after the time “Max time to pressure” (set by the
user)
The malfunctions to set in “HPU failure” are: “oil level”, “oil temperature”, “HPU general sensor”, “hand-pump”,
“pump blocked”.
The options with 2pumps, master-slave or cycle, are available and each pump works as described above. The conditions
to switch from one pump to the other are described in the paragraphs 7.4.2 and 7.4.3.
7.6 HPU with 4-20mA pressure transmitter and hot-backup pressure switch
The option is available in the HPU configurations described in the previous paragraphs 7.3. and 7.4. It provides
redundancy in the pressure measure. Normal control is done by the 4-20mA pressure transmitter. In case of failure of 4-
20mA pressure transmitter, the ECU1000 switches to pressure switch mode, described in the paragraph 7.5. In the
above mode the start/stop of pumps depends only on the pressure switch hysteresis. When 4-20mA restores, the
pressure control returns to pressure transmitter. The switch from 4-20mA transmitter to pressure switch is done in 5 sec,
the restoration in > 30 sec.
7.7 HPU with hydraulic unloading relief valve
If the ECU1000 controls an HPU provided with unloading relief valve all options described in the previous paragraphs
are still available. The Discharge D-SOV is not necessary since the unloading relief valve performs in automatic the
same function. In fact the unloading relief valve allows automatic pump by-pass as the pressure reaches the setting
value. The valve closes when the pressure drops at 88% and pump can charge again the accumulator.
7.8 HPU with D-SOV to reduce the start current of motor pump
If it needs to reduce the start current of the electric motor it is possible to add a Discharge D-SOV in the HPU to allow
pump by-pass. The D-SOV is activated at each start of motor and after 5 sec is released to let the pump to charge the
accumulator. The D-SOV can be used with the options described in the previous paragraphs. In the HPU described in
the paragraph 7.3 the D-SOV is activated at the start of the pump and as the pressure reaches the “Max working
pressure”.

7.9 Examples of HPU
HPU with 2 pumps, 4-20mA pressure transmitter and Discharge D-SOV
HCU
and Electronic
HA Control
Unit D-SOV control
Hydraulic
Control Unit ECU
and 1000
Hydraulic
Actuator
HPU with 1 pump and 4-20mA pressure transmitter
HCU Electronic
and Control
HA Unit
Hydraulic ECU
Control Unit 1000
and
Hydraulic
Actuator

8 ON-OFF actuator control

The paragraph describes the ECU1000 functions to control an on-off Hydraulic Actuator with Solenoid Operated
Valves (SOV) and optional Hydraulic Power Unit (HPU). The “Positioning” and “Input Characterization” functions are
disabled or not working, while the remaining ECU1000 functions are still available. The “Position Demand” signal is
not present and not visible on the local display. The “Actuator position” signal is present and it is visualized on the local
display. The manuals DTDE326 and DTDE327 and the previous paragraphs of this document can be used as instruction
manual for the functions used by the ECU1000 with on-off actuator.
8.1 Control options

The ECU1000 receives the commands on the digital inputs and drives the SOV’s by the output relays. The following
types of controls are available:
8.1.1 2 inputs/2outputs
V+
SOV to
open
Control options:
Open Optocoupled • Open: push to run
Output
digital input V+
relay • Close: push to run
V- SOV to Travel limit options:
Close Optocoupled close • position
digital input
Control unit • Continuous
ESD Output ESD options:
Optocoupled relay
digital input V- • Off
Actuator position • Go to position 100%
PST Optocoupled
• Go to position 0%
digital input Optional cylinder • Tracking
4-20mA
ECU1000 pressure P1
Optional cylinder
Position retransmission pressure P1
V+
SOV to
open/close
Open/Close Control option 1:

Optocoupled Output
digital input relay
• Signal=on: opens
• Signal=off: closes
V-
Control option 2:
Control unit Actuator position • Signal=on: closes
• Signal=off: opens
ESD Optocoupled Travel limit options:
digital input
• Continuous
Optional cylinder ESD options:
PST Optocoupled pressure P1
• Off
digital input
ECU1000 Optional cylinder • Go to position 100%
pressure P2
4-20mA • Go to position 0%
Position retransmission

V+
SOV to
open Control option 1:
Open/Close Optocoupled Output
• Signal=on: opens
digital input relay V+ • Signal=off: closes
V- SOV to
Control option 2:
close • Signal=on: closes
Control unit • Signal=off: opens
ESD Output Travel limit options:
Optocoupled relay
digital input
• Continuous
V-
• Position
Actuator position ESD options:
PST Optocoupled
Optional cylinder • Off
digital input pressure P1
ECU1000 • Go to position 100%
4-20mA
Position retransmission Optional cylinder • Go to position 0%
pressure P2
• Tracking
8.2 ESD function

ESD function can be started by a command on the digital inputs and drives the SOV’s by the output relays as shown in
the previous figures. The DTDE327 “Actuator control and Local Operator Interface” provides the instruction of ESD
function.
8.3 PST function

PST function can be initiated by a command on the digital inputs and drives the SOV’s by the output relays as shown in
the previous figures. The paragraph 6 provides the instruction of PST function
8.4 Alarms
• Max time to position
• Hyd. Valve leak
See Alarm table in the manual DTDE 327, paragraph “Actuator malfunction tables”.

9 PWM driver
The optional card “ECU1000 PWM driver” is mounted above the control card of the ECU1000 assembly. It is
supplied at 24 VDC and it is connected to ECU1000 control card by a flat cable. It can drive standard proportional
valves without spool feedback with 1 or 2 solenoids or 2BIFFI Proportional SOlenoid Valves (PSOV’s) with spool
feedback. It has the following inputs/outputs
• Two PWM output channels (24V, max 5A)
• One optocoupled digital input (max input 30Vdc)
• One digital output (24V, max 2A)
• One digital output (24V, max 0.5A)
• Two analogue input channels
The parameters of PWM module are stored in the ECU1000 memory and can be set only by the manufacturer. They can
be modified with username “Service”, “Specialist” and “Guest2”.
PWM driver card
Base card Logic card

9.1 PWM driver for Biffi PSOV’s
The Biffi Proportional SOlenoid Valves (Biffi PSOV) are used to control an hydraulic modulating actuator when a very
low drain is requested. Each actuator is controlled by 2 PSOV’s, one PSOV to open and the other one to close. Each
PSOV is provided with contactless sensor of cursor position. The following diagram shows the operating principle.
EV1 PWM
ECU1000 Hydraulic
Solenoid 1
PSOV1
power
PWM driver Cursor1 position
card Cursor1
Manifold
position sensor Cylinders,
scotch yoke,
EV2 PWM spring,
Solenoid 2
PSOV2
ECU1000 cards Cursor2 position
Cursor2
position sensor Actuator
4-20mA Actuator position position
transmitter
ECU1000 controls
PWM utilization function: it calculates the average in the configurable “Max PWM time” of PWM duty of each
PSOV and allows to evaluate their utilization rate and to avoid overheating and damage of system. The value of the
“PWM utilization %” is visible in the display of the Local Operator Interface in the menu “Status and variables”,
“EV1-2 MONITOR” and “EV1-2 RATE” (see DTDE 327, paragraph Local Operator Interface, Status and variables
table).
Failures: the PWM driver generates the failure “Proportional valve” in the following conditions:
• Power supply voltage of card <18Vdc or > 30Vdc
• Cursor1 position or cursor2 position = 0V
Alarms: the PWM driver generates the alarm “PWM utilization” if the PWM utilization is higher than the
configurable reference “MAX PWM UTILIZATION%”. The ECU1000 restricts the maximum PWM duty to the
“MAX PWM UTILIZATION” until the alarm disappears.
See the instruction manual DTDE327 par. “Actuator malfunction tables” to view the complete list of ECU1000 Failure
and Alarm.
ECU1000 commands: the following table shows the list of commands available in the Local Operator Interface in the
menu “ECU command”

Device cmd level
PWM control
PSOV’s autocalibration (off, on) 2
Manual PWM (0-100 %) 2
Drive Hyd-Valve 2
The command “Manual PWM” allows setting the level of PWM for a manual drive of the PSOV. The command
“Drive Hyd-Valve” allows moving the actuator in opening or closing by the local Open and Close pushbuttons with the
PWM level set in “Manual PWM”. The command “PSOV’s autocalibration” allows initiating the calibration cycle of
PSOV’s. By this command the ECU1000 reads and memorizes the minimum and maximum cursor position of each
PSOV, to be used in the control operation. The above commands are available with username “OPERATOR”.

The following parameters are available in the Local Operator Interface with username “SERVICE” for the PSOV’s
position loop tuning:
Restricted level
PWM module
Kp EV1 3
Ti EV1 3
Td EV1 3
Min PWM EV1 3
Max PWM EV1 3
AI5 bit at 2.5V 3
AI5 bit at 4.5V 3
AI5 signal filter 3
Kp EV2 3
Ti EV2 3
Td EV2 3
Min PWM EV2 3
Max PWM EV2 3
AI6 bit at 2.5V 3
AI6 bit at 4.5V 3
AI6 signal filter 3
PWM Frequency (200,400, 1000Hz) 3
Max PWM Utilization % 3
Max PWM time 3
Test of the PSOV’s drain: On request the Local Operator Interface can be provided with an additional self-maintained
pushbutton on the cabinet door to test the drain of the PSOV’s. The option is available only if the Local Selector
(Local, Remote) is not requested (see DTDE327 par. Local Operator Interface, par. 19.2 and 19.3).
The procedure is the following:
• Switch ECU1000 to LOCAL control mode by the instruction in par. 19.2 and 19.3 of DTDE327
• Push the pushbutton “PSOV test” on the ECU1000 cabinet door
• Take note of the actuator position% and of HPU pressure
• Wait few hours
• Take note of the actuator position% change
• Release the “PSOV test”
• Switch to REMOTE control mode by the instruction in par. 19.2 and 19.3 of DTDE327

9.2 PWM driver for proportional valve without spool feedback
The following diagram shows the block diagram of ECU1000 e PWM driver card with
• 1 bidirectional proportional valve without spool feedback and with 2 solenoids
• 2 unidirectional proportional valves without spool feedback and with 1 solenoid for each valve
• 1 bidirectional proportional valve valves without spool feedback and with 1 solenoid
EV1 PWM
ECU1000 Hydraulic
Solenoid 1
Manifold
power
PWM driver
card EV2 PWM
Solenoid 2 Cylinders,
scotch yoke,
Proportional valve spring,
with 2 solenoids Actuator
ECU1000 cards 4-20mA Actuator position position
transmitter
ECU1000 controls
Unidirectional
Proportional valve
EV1 PWM
ECU1000 Hydraulic
Solenoid 1
Manifold
power
PWM driver
card EV2 PWM
Cylinders,
Solenoid 2
scotch yoke,
Unidirectional spring,
Proportional valve
Actuator
transmitter
ECU1000 controls
EV1 PWM
ECU1000 Hydraulic
Manifold
power
PWM driver Solenoid
card
Cylinders,
scotch yoke,
Proportional valve spring,
with 1 solenoid Actuator
transmitter
ECU1000 controls

PWM utilization function: it calculates the average in the configurable “Max PWM time” of PWM duty of
proportional valve and allows to evaluate their utilization rates and to avoid overheating and damage of system. The
value of the “PWM utilization %” is visible in the display of the Local Operator Interface in the menu “Status and
variables”, “EV1-2 MONITOR” and “EV1-2 RATE” (see DTDE 327, paragraph Local Operator Interface, Status and
variables table).
Failures: the PWM driver generates the failure “Proportional valve” in the following conditions:
• Power supply voltage of card <18Vdc or > 30Vdc
Alarms: the PWM driver generates the alarm “PWM utilization” if the PWM utilization is higher than the
configurable reference “MAX PWM UTILIZATION%”. The ECU1000 restricts the maximum PWM duty to the
“MAX PWM UTILIZATION” until the alarm disappears.
ECU1000 commands: the following table shows the list of commands available in the Local Operator Interface in the
menu “ECU command”

Device cmd level
PWM control
Manual PWM (0-100 %) 2
Drive Hyd-Valve 2
The command “Manual PWM” allows setting the level of PWM for a manual drive of the proportional valve. The
command “Drive Hyd-Valve” allows moving the actuator in opening or closing by the local Open and Close
pushbuttons with the PWM level set in “Manual PWM”. The above commands are available with username
“OPERATOR”.
The following parameters are available in the Local Operator Interface with username “SERVICE” for the proportional
valve tuning.
Case of bidirectional proportional valve with 2 solenoid or 2 unidirectional proportional valves with 1 solenoid
Restricted level
PWM module
Min PWM EV1 3
Max PWM EV1 3
Min PWM EV2 3
Max PWM EV2 3
Max PWM time 3
Case of bidirectional proportional valve with 1 solenoid

Restricted level
PWM module
Min PWM EV1 3
Max PWM EV1 3
PWM OFFSET (MO-PVAL-1C only) 3
Reverse polarity (MO-PVAL-1C only) 3
Max PWM time 3

10 Optional local lamps

On request, the door of the ECU1000 cabinet can be provided with 8 additional LED lamps to signal the condition listed
in the “Status relay table” of manual DTDE327 paragraph “Output relay”. Setting of conditions to switch on each lamp
can be done only by the manufacturer. Information of LED’s can be latched and cleared by an additional local
pushbutton
4 optional lamps 4 optional lamps The option “LED latched or

momentary”is available only if the
Local Selector (Local, Remote) is
not requested (see DTDE327 par.
Local Operator Interface, par. 19.2
ECU1000 cabinet and 19.3).
11 RS 485 MODBUS RTU Interface

On request the ECU1000 can be provided with RS485 MODBUS RTU interface. The above card is mounted on the
control card of ECU1000 and allows controlling the ECU1000 by a multidrop RS485 Modbus RTU communication
line. The manual DTDE332 gives detailed instructions relevant to the communication messages.
The following parameters can be set with username “Operator”.

BUS level
Modbus RTU
Node address (from 1 to 247) 2
Baud rate (1200, 9600, 19200) 2
Parity (Odd, Even, No parity) 2
Line termination (On, Off) 2
Logic card
RS485 Modbus RTU card
Base card
RS485 Modbus RTU connector

BIFFI ITALIA srl


ECU1000 BIFFI-Assistant
DTDE 330
ECU 1000
BIFFI-Assistant
USER MANUAL
ECU1000 cards PC or Tablet BIFFI-Assistant

INDEX
1 INTRODUCTION 2
2 REFERENCE DOCUMENTS 2
3 PC REQUIREMENTS 3
4 TO INSTALL THE BIFFI-ASSISTANT 3
5 TO UNINSTALL THE BIFFI-ASSISTANT 4
6 WORK ONLINE – WORK OFFLINE 5
7 WORK ONLINE 5
7.1 Connection to ECU1000 5
7.2 Channel selection 6
7.3 RS232 connection 7
7.4 Bluetooth connection 8
8 LOGIN 9
8.1 User Levels 9
9 NAVIGATION IN THE MENU 9

9.1 Menu structure 10
9.1.1 Status of parameters and ECU commands 12
9.2 View and setting mode 13
9.3 Read/Write functions 14
9.3.1 Read a parameter from ECU1000 memory 14
9.3.2 Write a parameter in the ECU1000 memory 14
9.3.3 Read a TAB from ECU1000 memory 15
9.3.4 Write a TAB in the ECU1000 memory 16
9.3.5 Read a Function Block from ECU1000 memory 17
9.3.6 Write a Function Block in the ECU1000 memory 17
9.3.7 Read the parameters of enabled functions from ECU1000 memory 18
9.3.8 Write the parameters of enabled functions in the ECU1000 memory 18
9.3.9 Write the full set of parameters in the ECU1000 memory 19
9.3.10 Change USER and OPERATOR passwords 19
9.4 Refresh structure function 20
10 IMPORT AND EXPORT 22

10.1 Export 22
10.1.1 Export of full set of data 23
10.2 Import 23
10.3 Use of “Full copy” command 25
10.3.1 Copy the full set of parameters in a new card 25

10.3.2 Copy all parameters except calibration, name plate and valve data 25
10.3.3 Copy all parameters except calibration and electronic card info 26
10.3.4 Copy all parameters after a firmware upgrade 26
11 LOG AND GRAPH FUNCTION BLOCK 27

11.1 Logger and Short Logger 27
11.2 Curves 29
11.3 Curves signature 32
12 DEVICE COMMANDS FUNCTION BLOCK 33

12.1 Operation 33
12.1.1 Actuator Variables 33
12.1.2 Failure 35
12.1.3 Alarm 35
12.1.4 Clear fail-alarm 36
12.1.5 Out. Relay Status 37
12.1.6 Digital Input 37
12.1.7 Actuator Status 38
12.1.8 Analogue Input 39
12.1.9 Analogue Output 39
12.1.10 Function summary 40
12.2 PST command 41
12.3 OP Limit Autocalib 42
12.4 Change Close Limit 44
12.5 CL Limit Manual Set 46
12.6 PSOV autocalibration 47
12.7 Clear logger 48
12.8 Full default 49
12.9 Clear Counters 50
12.10 HPU Config 51
13 WORK OFFLINE 52
13.1 Change of value of a parameter and save it in a new file 53
13.2 Change of Work Offline password 56
13.3 View of loggers 56
13.4 View of short logger 58
13.5 View of graphs 58


Warning: For any information regarding actuator parameters or settings please refer to the
relevant ECU1000 and Actuator documentation.
Wrong parameter settings may cause actuator malfunctions.
Warning:
All parameters changes not saved into the internal application database or sent to
the actuator will be lost once the application is closed.
Warning: It is assumed that the installation, setting, commissioning, maintenance and repair
works are carried out by qualified personnel and checked by responsible
Specialists. Operating the actuator and the ECU1000 could damage the actuator
and cause personal injury
Warning: Any repair work other than the operations outlined in this manual will be strictly
reserved to qualified BIFFI ITALIA personnel or to personnel directly authorised
by the Company itself.
Warning: Whenever the PC will be used in HAZARDOUS AREA as defined by the

applicable rules, it is mandatory to check whether the PC nameplates indicate
their suitability to an hazardous area, and the appropriate protection degree.

1 Introduction
BIFFI-Assistant is a PC SW tool to be used with ECU1000 and ELBS20. It provides the ability to configure, diagnose
and collect data from the above devices and a PC with Windows platform. The document DTDE330 provides the
instruction for installation and use of BIFFI-Assistant with reference to ECU1000.
Even if the ECU1000 is provided with a powerful Local Operator Interface, the BIFFI-Assistant is a very a useful tool.
In fact it allows the operator performing the complete set of operation available by the ECU1000 Local Operator
Interface (except Local Control) and in addition it allows easy navigation in the ECU1000 menu by using the PC
facilities and in particular
• Viewing of maintenance data collected by the ECU1000 in the loggers and graphs function blocks and saving
them in files on the PC (Failure, alarm and statistic loggers, Opening, Closing, PST and Recorder graphs)
• Graph comparison
• Saving of ECU1000 configuration parameters in files on the PC
• Saving and printing of ECU1000 data in text files on the PC
• Downloading of configuration file from PC to ECU1000
• Wireless connection to ECU1000 by Bluetooth interface
• Online and Offline operation
o Work Online: ECU1000 is connected to PC and BIFFI-Assistant
o Work Offline: BIFFI-Assistant works on files previously saved, without any connection to ECU1000
Import
Files Export
BIFFI-Assistant
Bluetooth or
RS232
ECU1000
cabinets
2 Reference Documents
DTDE326 “Installation and Maintenance” of ECU1000
DTDE 327 “Control functions and Local Operator Interface”
DTDE328 “Functions description”
DTDE300 “Product description”

3 PC requirements
Biffi Assistant is tested for working with the following OS:
• Windows XP - 32bit service pack 2 or 3 and .NET Framework >= 4.0
• Windows 7 - 32bit Enterprise
• Windows 7 - 64bit Enterprise
The connection to the ECU1000 requires an USB Bluetooth Dongle or an RS232 port and RS232 cable.
In the below table is the list of the tested Bluetooth Dongles.
Here below is the list of USB/Bluetooth Dongle tested with BIFFI-Assistant. They do not require the installation of the
driver
USB/Bluetooth adapter Windows XP Windows 7

HAMLET EXAGERATE XBTUS100 2.0 cl. 1 ok ok
BELKIN F8T017 Bluetooth Adapter cl. 1 no * ok
SITECOM CN-523 USB microadapter Bluetooth 2.1version 100m ok ok
ATLANTIS Mobile Life mini Bluetooth 2.1 30metri, POO8-BT-038 ok ok
KENSINGTON Bluetooth 2.1 USB Micro Adapter PN/MN:K33902 / M01011 ok ok
DIGICOM PALLADIO USB Bluetooth EDR 100 no * ok
TARGUS Mod.ACB10-US no * ok
* The Bluetooth adapters indicated with “no” can work only after installation of the appropriate driver.
The figures below show the RS232 cable and the position of RS232 connector on the ECU1000 card.
RS232cable ECU1000
USB/RS232
converter
4 To install the BIFFI-Assistant
Warning:
Installation can be done only by the administrator of PC
Important: “BIFFI-Assistant” for PC installation software consists of two files:

- BiffiAssistant.msi
- setup.exe
Before initiating the installation procedure of a new version of BIFFI-Assistant remove any previously installed version.
The installation process starts by a double click of the left key of mouse on “setup.exe”.
A simple wizard will guide through the installation process:

Click Next and then agree to End User License Agreement

Select installation folder and then click Next
Left click of mouse on “Next” to begin the program installation

When the message “Installation complete” appears left click on Close.
An icon with BIFFI logo, named BIFFI-Assistant will be created on the desktop and a new program folder, named
“Biffi”, will be added to Start Menu\Program folder.
The program starts by a double left click of mouse.
5 To Uninstall the BIFFI-Assistant

In the taskbar click “Start”. Left click of mouse on “Control Panel” and then double left click on “Programs and
Features”. Left click on BIFFI-Assistant.

Right click of mouse on Biffi Assistant. Left click on “Uninstall” and then “YES”. BIFFI-Assistant will be removed
and PC is ready to re-install a new version.
6 Work Online – Work Offline
Work Online: when the ECU1000

can be connected to BIFFI-Assistant,
for configuration, download / upload
data, maintenance operation
Work offline: when ECU1000 is not

connected to BIFFI-Assistant. It
allows handling file previously
uploaded from ECU1000 (curves,
loggers, etc.)
7 Work Online
7.1 Connection to ECU1000
User PC’s may be directly connected to an ECU1000 device by Biffi-Assistant SW tool, through Bluetooth or RS232.
A direct connection with Biffi Assistant is convenient for users that need to configure or diagnose many ECU1000
devices or users who require immediate detailed analysis on a large screen on-site. Note that Biffi Assistant may save
"transfer files" to review them at a later time.
Warning:
It is recommended to use only one Serial Communication Interface (RS232 or
Bluetooth) at a time to avoid configuration errors.

7.2 Channel selection

Launch the program by a double click of left key of mouse on the BIFFI-Assistant icon.
The following screen appears. By the left key of mouse, click on “Options” to set the Communication Channel.
On the right corner of “Options” it is available the SW version of BIFFI-Assistant.
Select the Communication channel,

RS232 or Bluetooth (RS485 is not
available in the ECU1000).
According to the selected “Channel Type”, set the parameters as follows (*):
RS232 Bluetooth
set the used COM - The table shows the typical value
COM port
of the parameters. In some cases
Baud Rate (bps) 115200 (fixed) 115200 (fixed) (PC with low performance) it
Channel Timeout (ms) 2000 2000 could be necessary to increase
Read timeout, dynamic length (ms) 40000 40000 the value of the following
COM parity 0 (fixed) 0 (fixed) parameters: “Channel Timeout”,
“Read timeout, dynamic length”
COM databits 8 (fixed) 8 (fixed) and “Bluetooth connection
COM stopbits 1 (fixed) 1 (fixed) timeout”.
Bluetooth connection timeout (ms) - 2500
Language en (fixed) en (fixed)
Left click of mouse on “Save” to save the settings or “Undo” to exit.

The selected Interface, with its settings, will be used by the Biffi Assistant, for the connection with the device.
In case of Bluetooth check that the Bluetooth interface is enabled by the ECU1000 Local Operator Interface.
Click the left key of mouse on “Restore the default settings” to set the default values.

7.3 RS232 connection
Check that the RS232 cable is correctly connected. Click the left key of mouse on “Work Online“, to connect the PC
with the ECU1000.
Enter username and password. Username and password are the same of the ECU1000 Local Operator Interface.
The manual DTDE327, Local Operator Interface, provides the description of password and username.
Click the left key of the mouse on “Login” (or press ENTER) to go ahead. To cancel the Login, click the left key of the
mouse on the left arrow near to “Work Online”.
If password and username are correct the communication between ECU1000 and PC starts. The following screen will
appear.
To Logout, left click of

the mouse on “Logout
Username”.
In the left low corner of

the screen is indicated
the type of connection
and the baud rate.
After having read the menu structure, the BIFFI-Assistant reads the full set of parameters of ECU1000, but the PC
shows only the data of the functions enabled to work in the connected ECU1000 device and having password less or
equal to the entered username.

7.4 Bluetooth connection

Bluetooth connection is possible only if the PC is few meters from the ECU1000 device.
Note that Bluetooth configuration in the PC is provided by your Bluetooth hardware manufacturer
Click the left key of the mouse on “Work Online“.
Click the left key of the mouse on “Start”, to search the Bluetooth devices.
The above screenshot shows all the Bluettoth devices found. Only ECU1000 and ELBS20 devices can be connected. By
a double left click on the desired ECU1000 start the connection.
Enter username and password. Username and password are the same of the ECU1000 Local Operator Interface.
The manual DTDE327, Local Operator Interface, provides the description of passwords and usernames.
Left click of mouse on “Login” (or

press ENTER) to launch the
program.
To cancel the Login, left click of
mouse on the left arrow near to
“Work Online”.
If password and username are
correct the communication
between ECU1000 and PC starts
To Logout, left click of mouse on
“Logout Username”.
In the left low corner of the screen is
indicated the type of connection and
the baud rate.
After having read the menu structure, the BIFFI-Assistant reads the full set of parameters of ECU1000, but the PC
shows only the data of the functions enabled to work in the connected ECU1000 device and having password less or
equal to the entered username.

8 Login
8.1 User Levels
In Work Online mode the BIFFI-Assistant use the same passwords and usernames of the ECU1000 Local Operator
Interface.
According to the instruction in DTDE327, Local operator Interface, the following “Username” are available: User (in
Actuator’s users), Operator (in Actuator’s users), Service (in Actuator’s users), Specialist (in Actuator’s users), and
Guest0 (in Special users), Guest1 (in Special users), Guest2 (in Special users). Each username requires a 6 character
(numbers or capital letters) password to connect the BIFFI-Assistant to ECU1000. Each username is associated to a
password level, as indicated in the instruction manuals DTDE326, DTDE327, DTDE328.
The combination of username and password defines the User level:

• Level USER: only the parameters and ECU cmd’s of active functions in the connected ECU1000 device with
password level 1 can be viewed/modified/executed. The default password is “100000”. The password is configurable
and allows modifying few parameters (Dead band, Recorder, output relay, etc.)
• Level OPERATOR: only the parameters and ECU cmd’s of active functions in the connected ECU1000 device with
password levels 1 and 2 can be viewed/modified/executed. The default password is “200000”. The password is
configurable and allows commissioning the actuator (positioner, ESD, status relay, travel limit calibration, etc.)
• Level SERVICE: only the parameters and ECU cmd’s of active functions in the connected ECU1000 device with
password levels 1, 2 and 3 can be viewed/modified/executed.
• Level SPECIALIST: this password (level 4) allows viewing/modifying/executing any parameter and ECU cmd.
• Level GUEST0: it allows viewing the full set of parameters and ECU commands, including the parameters and
ECU commands of the non-active functions. No write operation is allowed. The GUEST0 password is “10000A”.
• Level GUEST1: it allows only viewing the NAME PLATE function block. No write operation is allowed. The
GUEST1 password is “A0000A”
• Level GUEST2: it has the same permits of the SPECIALIST, but the maximum number of access to menu of
connected ECU1000 device is 10.
The instruction manuals DTDE326, DTDE327, DTDE328 give further information relevant to the password levels, the
menu structure and the parameter and command list. The passwords of SERVICE, SPECIALIST and GUEST2 are
available only to product specialists.
Important: Only the parameters and ECU-commands with username levels less or equal to
entered username level can be viewed/modified/executed. Parameters and
functions not enabled to work in the connected ECU1000 device will not showed
(except username GUEST0).
9 Navigation in the menu

During the connection process the BIFFI-Assistant reads the menu structure and the full set of data from ECU1000. The
data of each TAB are also read when the TAB is selected the first time. Any further update should be manually done by
the commands described in the next paragraphs (read object_x, read TAB_x, read block_x, read all objects).
Warning: Any change or write operation of parameter, TAB or Block should be done after a
read operation of the same parameter, TAB or Block.
It is suggested that any write operation is checked by a read operation of the
changed data.

9.1 Menu structure
As described in the manuals DTDE327 and DTDE328 the ECU1000 menu is organized in “Function block”,
“Function TAB”, “Parameters and ECU Commands”. Each “Function TAB” collects a group of “Parameters or
ECU Commands”, each “Function block” collects a group of “Function TAB”. The parameters are in the TAB’s of
function blocks “ACTUATOR SETUP”, “NAME PLATE”, “VALVE DATA” and “RESTRICTED”; the ECU
Commands (or ECU-cmd) are in the TAB’s of function blocks “DEVICE COMMANDS” and “LOG AND GRAPH”.
The “parameters” allow changing the behavior of the working functions in the ECU1000; the “ECU commands” allow
executing operations with the ECU1000 as “analogue I/O calibration”, “up-loading of logger and curves”, “travel limit
configuration”, “data memory setting”, etc.
• DEVICE NAME
The structure of the BIFFI-Assistant menu repeats
o FUNCTION BLOCK 1 the menu structure of the ECU1000 Local Operator
TAB 1_1 Interface (see manual DTDE 327)
o Parameter/Command 1_1_1
o …
o Parameter/Command 1_1_y
… The PC screen is divided in two sections: the left
TAB 1_x
o …
side shows Device Name, Function Blocks and
o … function TAB’s, the right side shows the
o FUNCTION BLOCK N
TAB N_1 Parameters, the ECU Commands, the Help, etc.
… Each parameter/ECU command is defined: by Name,
TAB N_z
o Parameter/Command N_z_1 Value, UM (Unit Measure), Min (Minimum value),
…
o
o Parameter/Command N_z_r Max (Maximum value) and the Flags (R, W, S).
The name of the device is

determined by the
parameter “Actuator setup,
Miscellaneous, Bluetooth
Name”. The available
options are “Actuator
Area of function
serial number, Valve tag Area of parameters,
blocks and
and Cabinet serial commands, help, curves,
TAB’s
number” logger, etc
Minimize or maximize
the menu:
• Single left-click of
mouse on the arrow on the
left of the Menu Name
• Double left-click of the
mouse on the Menu Name
Use the scroll bar to

view all function blocks
and TAB’s

Left click on the name of

the TAB.
The Parameters or ECU
Commands appear on
the right side of the
screen
Use the scroll bar on the
right side of screen to
view all parameters of
the selected TAB
Each parameter/command
line contains ID number,
Name, Value,
Engineering Unit, Min
value, max value and
Status (flag R=Readable,
W=Writable, S=Special).
The Help window is
shown as the parameter
line is selected.
If the box of value is

“blank”, the value of the
parameter is shown in an
optional window

If the box of value is

“******”, the value of
the parameter is not
visible
If the value of the

parameter is discrete,
click to see the list of
the available options
9.1.1 Status of parameters and ECU commands

The column “FLAGS” shows the status of each parameter and ECU cmd. The status “R” indicates that the
“parameter/ECUcmd” is readable. The status “W” indicates that the “parameter/ECU” cmd is writable. The status
“S=Special” is only for parameters; it indicates that the parameter is writable by the command “Write object_x”, but
writing it by the commands “Write active objects”, “Write Block_x”, “Write TAB_x” and “Full copy” requires a
further step with selection and confirmation. By the above mechanism the operator can write a set of standard
parameters (with “W” flag) using one only command, but he can choose to write/no-write the special parameters (with
flag “S”). The flag “S” collects the parameters whose value depends on the electronics or on the device which is
connected to the BIFFI-Assistant. Examples of parameters with flag “S” are :
• the parameters of the calibration of the analog inputs and outputs. They fix the relationship between mA/V and bits.
The calibration of the analogue inputs and outputs is done by the manufacturer, it is different for each ECU1000
device, it depends on the hardware tolerances of the electronic components and A/D and it should never be
changed except for a new calibration.
• The USER and OPERATOR password
• The parameters of the NAME PLATE block
• The parameters of the VALVA DATA block
The below table shows the list of parameters:
AI_x bit at 4mA AI_x bit at 20mA AO_x min bit AO_x max bit
AI_x bit at 2.5V AI_x bit at 4.5V NAME PLATE block VALVE DATA block
User PSW Operator PSW

9.2 View and setting mode
If ECU1000 is in LOCAL control by Local Operator Interface the switch to “SETTING” mode is not allowed
VIEW and SETTING

mode is selectable by
clicking on the buttons
VIEW and SETTING
located on the right low
corner of screen
The default mode is
“VIEW”.
In VIEW mode the
working parameters of
ECU1000 can be only
viewed but not changed.
Commands to open or
close are not available.
In SETTING mode the
ECU1000 parameters can
be changed and ECU1000
switches in configuration
mode (see instruction
manuals DTDE326,
DTDE327, DTDE328).
A red bar appears on the
screen to highlight that
ECU1000 is in
configuration mode
(stayput).
Warning: In CONFIGURATION mode the ECU1000 performs the commands “write

object_x/Tab_x/Block”_x/active objects, “full copy” and “send command_x” only
if they come from the communication channel that has previously set the
configuration mode. The other channels can work only in view mode.
For instance: if the Local Operator Interface sets configuration mode, the BIFFI-Assistant via Bluetooth or RS232 can
work only in VIEW mode (even if it indicates configuration (SETTING) status). On the contrary if BIFFI-Assistant via
Bluetooth sets “SETTING” mode, the Local Operator Interface allows only view operation, but write operations are
not carried out.
Warning: In SETTING mode the operator can change parameters, enable functions, send
ECU-commands, etc. The ECU1000 controls the actuator, it could control the
ECU, it could drive generic electric, pneumatic, mechanic and hydraulic devices, it
is mandatory to place the above devices in their safe condition to avoid injury of
people and damage of equipment and ambient (see installation and maintenance
manual)

9.3 Read/Write functions

At end of the connection process the complete set of data of the connected ECU1000 device is updated to the PC
memory. BIFFI-Assistant shows only the “parameters” and “ECU commands” enabled to work in the connected
ECU1000 device with password level less or equal to entered username.
The parameters of a single TAB are automatically updated at first access to the TAB; the updating of the parameters
must be done manually in the successive accesses to the TAB. The following table lists the Read/Write commands
Description Command
Read/write a single parameter By ” Read/Write object_x”
Read/write all parameters of the selected TAB By ” Read/Write TAB_x”
Read/write all parameters of the selected Block By ” Read/Write Block_x”
Read/write all parameters of the functions enabled to work in the ECU1000 device By ” Read/Write active objects”
Write the full set of ECU1000 parameters (including the disabled functions) By ” Full copy”
Send an ECU command (only function blocks “Device Commands” and “Log and Graph”) By “Send command_x”
The command “Full copy” is not available to username “USER” and “OPERATOR”.
9.3.1 Read a parameter from ECU1000 memory
Left click of mouse on the

selected TAB.
selected parameter.
Right click of mouse on
the object name to view
the available options.
Select “Read object_x”
The value will be read
from ECU1000 memory.
9.3.2 Write a parameter in the ECU1000 memory

Click the button
SETTING.
selected TAB.
selected parameter.
In the column “Value”
enter the new value. An
“*” appears on the line of
the function block and of
the TAB.


the object name to view
the available options
“Write obj_x”.
Left click of mouse on
“Write object x.
Click Yes.
The value will be written in the ECU1000 memory. By the “Read object x” procedure verify the value
9.3.3 Read a TAB from ECU1000 memory

selected TAB.
selected parameter.
an object name to view
Select “Read TAB_x”
The value of complete
TAB will be read from
ECU1000 memory.
Read TAB can also be

done on the left side of
the screen.
selected TAB.
the TAB name to view
Select “Read TAB_x”
The values of complete
TAB will be read from
ECU1000 memory.

9.3.4 Write a TAB in the ECU1000 memory

Click the button
SETTING.
selected TAB.
Modify the value of the
parameters as described
in the previous
paragraphs.
an object name to view
Select “Write TAB_x”.
Write TAB can be also

done on the left side of
the screen
selected TAB.
the TAB name to view
Select “Write TAB_x”.
Click YES. If the TAB does not contain any parameter with flag “S”, the complete set of
parameters of the TAB will be written in the ECU1000 memory. The only readable
parameters (flag “R”) will not be written. If the TAB contains parameters with flag “S”
a new screen-shoot appears with the list of Special objects to select
Select the Special objects to write and then click

“Write”.
The complete TAB will be written (except the only
readable parameters (flag “R”) and the parameters
with flag “S” not selected). In the example the
TAB to write is “Valve data”. The TAB contains 3
parameters with flag “S”. Only the parameter
“Valve Manufacturer” will be written to ECU1000

9.3.5 Read a Function Block from ECU1000 memory

selected BLOCK.
Select “Read Block_x”
BLOCK will be read
from ECU1000 memory.
9.3.6 Write a Function Block in the ECU1000 memory
Modify the value of the

parameters of the
BLOCK
Click the button
SETTING.
selected BLOCK.
the Block name to view
Select “Write block_x”. Click on YES. If the Block does not contain any parameter with flag “S”, the complete set of
parameters of the Block will be written in the ECU1000 memory. The only readable parameters (flag “R”) will not be
written. If the Block contains parameters with flag “S” a new screen-shoot appears with the list of Special objects.

“Write”.
The complete Block will be written (except the only
readable parameters (flag “R”) and the parameters
with flag “S” not selected). In the example the Block
to write is “Name Plate”. The Block contains 4 TAB’s
with parameters with flag “S”. Only the parameter
“HPU Power Supply” and the TAB “ECU1000
cabinet data” will be written to ECU1000

9.3.7 Read the parameters of enabled functions from ECU1000 memory

DEVICE NAME.
Select “Read active
objects”
device will be read from
ECU1000 memory.
9.3.8 Write the parameters of enabled functions in the ECU1000 memory
Modify the parameters.

Click the button
SETTING.
DEVICE NAME.
Select “Write all active
objects”. Click on YES
If no parameter with flag “S” is present, the complete set of parameters will be written in the ECU1000 memory. The
only readable parameters (flag “R”) will not be written. If some parameter with flag “S” is present, a new screen-shoot
appears with the list of the Special objects.
“Write”.
The complete set of active parameters will be written
(except the only readable parameters (flag “R”) and
the parameters with flag “S” not selected). In the
example the Blocks “Name Plate”, “Valve data” and
“Restricted” have parameters with flag “S”. Only the
Block “Name Plate” and the parameter “Valve
manufacturer” will be written to ECU1000.

9.3.9 Write the full set of parameters in the ECU1000 memory
The option “Full copy” is

available only with
username “SPECIALIST”
and “GUEST2”. It allows
writing the complete set of
ECU1000 parameters,
including the parameters not
visibile because the relevant
function is not enabled to
work.
If no parameter with flag “S” is present, the complete set of parameters will be written in the ECU1000 memory. The
only readable parameters (flag “R”) will not be written. If some parameter with flag “S” is present, a new screen-shoot
appears with the list of the Special objects.

“Write”.
The complete set of active parameters will be written
(except the only readable parameters (flag “R”) and the
parameters with flag “S” not selected). In the example
the Blocks “Name Plate”, “Valve data” and “Restricted”
have parameters with flag “S”. Only the Block “Name
Plate” and the parameter “Valve manufacturer” will be
written to ECU1000.
The paragraph “IMPORT and EXPORT” shows how to use the function.
9.3.10 Change USER and OPERATOR passwords
In Work Online mode

the username and
operator passwords of the
ECU1000 Local Operator
Interface are the same of
the BIFFI-Assistant. The
password corresponding
to username USER and
OPERATOR can be
changed by the end user.
The “change password”
procedure can be done by
or by BIFFI-Assistant.

Left click of mouse on the button SETTING. Maximize the function block “Actuator setup”. Click the left key of
mouse on the TAB “Miscellaneous”. Enter the new password (USER or OPERATOR). The value is not visible, it is
indicated by “*”. Right click of mouse on the name of the parameter. Left click of mouse on “Write object_x”.
Passwords cannot be written by the commands “write TAB, write Block, write all active objects and full copy”.
Click on YES to confirm.

button VIEW
When the new password is enterd the old one is no longer valid, both for Local Operator Interface and BIFFI-Assistant.
9.4 Refresh structure function
The “Refresh Structure” function allows updating the BIFFI-Assistant menu if a new function has been enabled in the
ECU1000 device.
In fact the BIFFI-Assistant read the menu structure from ECU1000 at the connection time. The parameters and
commands shown are according to the user level and the ECU1000 functions not active are not viewed.
If a function is enabled to work it need to re-read the menu structure as follows:
• after having enabled the function by the instruction in the previous paragraphs perform a logout and then a new
login
• after having enabled the function by the instruction in the previous paragraphs click on the “Refresh Structure”
option (available by clicking the right key of mouse on the DEVICE NAME)
Example : Input Characterization function disabled
The TAB “Input Characterization” is not present in the function block ACTUATOR SETUP
By the instructions of the previous paragraphs the function can be enabled in the function block RESTRICTED, TAB
FUNCTION SELECTOR, parameter INP CHARACTERIZ (OFF/ON).
After having enabled the function, it is still not present in the ACTUATOR SETUP block

Click the right key of

mouse on the DEVICE
NAME
Click the left key of

mouse to select “Refresh
Structure”
Maximize the function block ACTUATOR SETUP

Now the TAB INPUT CHARACTERIZATION is present and the menu structure is updated.

10 Import and Export

10.1 Export
The Export function allows saving the set of ECU1000 data or a part of them in a file. The set of saved data depends on
the user level and the active ECU1000 functions. The full set of data available in the ECU1000 (including the not active
functions) can be saved only with password corresponding to username GUEST0. Two export options are available:
• Save of data as text file *.txt. The saved file is printable and can be used for comparison, analysis and filing.
The *.txt file cannot be used by the BIFFI-Assistant
• Save of data in the BIFFI-Assistant data base, as file *.biffia. The file can be imported by the BIFFI-Assistant
and used for configuration, analysis and filing in online and offline mode. The files can be managed only by
the BIFFI-Assistant.

EXPORT (on the right high
corner of screen).
In the Export windows
select the set of data to
export.
Use and the scroll bar
to maximize, minimize.
Select the data to export.
button Export.
Confirm or change the file name. The default name contains:

Device Name, Date and Time, Username.
The file extension is .biffia or .txt according to the export
option selected.
Click on SAVE.
The export process starts. BIFFI-Assistant read the data from
the actuator and save them in the file.
In the above figure all the ECU1000 data (according to user level) will be exported in the BIFFI-Assistant data base.
The figures below show examples of setting:
1) Export of parameters and loggers (no graphs) in the BIFFI-Assistant data base
2) Export of parameters, logger, opening curve 1, closing curves, PST curves in the BIFFI-Assistant data base
3) Export of parameters and loggers as text file

10.1.1 Export of full set of data
Use the BIFFI-Assistant with username GUEST0 and password “10000A”. Connect the BIFFI-Assistant to the
ECU1000 card with the parameters to be read. Export the ECU1000 parameters in the BIFFI-Assistant data base, as file
*.biffia. Export only the parameters. The name of saved file contains date,time and username (GUEST0).
10.2 Import
The Import function allows copying the previously saved file (with extension .biffia) in the PC memory. If the PC is
connected with the ECU1000 and the PC memory already contains data (read from ECU1000), the new data are
overwritten, but only in the PC memory. The data are not sent to ECU1000. The imported file contains data according
to the username level and the number of enabled functions. It is suggested to import files with the same password level
used in the connection to ECU1000. The functions described in the previous paragraphs “write object_x”, “write
Tab_x”, “write Block_x”, “write active parameters” “full copy” should be used to send all data or a part of them to
the ECU1000. Graphs, Logger, in general any “only readable” data (flag “R”) cannot be written to ECU1000.


IMPORT (on the right
high corner of screen).
Select the file to import

and then click OPEN. The
file will be overwritten in
the PC BIFFI-Assistant
memory
If the imported file contains objects not present or

not correct, the BIFFI-Assitant shows a report with
the list of the wrong objects. Wrong or not present
objects will not written in the ECU1000 memory.
The report can be saved in a *.txt file.
Scroll bar

SETTING.
the function block or
TAB (left screen side)
“Write all active objects,
or Full copy” to update
the ECU1000 data.
Alternatively select a
Block, a TAB or a
parameter and then use
the commands “Write
Block_x, Write Tab_x,
or Write object_x”
The commands “Write all active objects, Full copy, Write Block_x, Write Tab_x, and Write object_x” decribed in
the previous paragraphs allow to send the parameter to the ECU1000 memory.
By the left key of mouse click VIEW to exit from setting mode.

10.3 Use of “Full copy” command
The procedure allows exporting the full set of parameters from an ECU1000 card and copy it in a new ECU1000 card.
By BIFFI-Assistant and the procedures described in the prevoius paragraphs export the full set of data and save them in
a file (use username GUEST0 and password “10000A”).
Exit from BIFFI-Assistant and disconnect the previous ECU1000 card.
Connect the new ECU1000 card. Run the BIFFI-Assistant with username SPECIALIST or GUEST2. Import the file
saved prevoiusly with username GUEST0.
Send the full set of data to the new ECU1000 card by the BIFFI-Assistant command “full copy”, as decribed in the
prevoius paragraphs. The command is not active with password USER and OPERATOR.
Export the full set Import the full set

of data of data
BIFFI-Assistant

“Setting”
device name
Right click of mouse on the
device name
Left click of mouse on “Full
copy”
Left click of mouse on “Yes”
10.3.1 Copy the full set of parameters in a new card
Include all “S” data

Left click of mouse on “Write”
The complete set of active parameters
will be written in the ECU1000
memory
Left click of mouse on “VIEW”
10.3.2 Copy all parameters except calibration, name plate and valve data
This procedure allow copying in a new card all parameters except the data relevant to calibration of analog input and
outputs, name plate and valve data. The above data will not be changed.

Select the “S” data to send

The complete set of active parameters will be
written in the ECU1000 memory
10.3.3 Copy all parameters except calibration and electronic card info
This procedure allow copying in a new card all parameters except the data relevant to calibration of analog input and
outputs and the electronic card info TAB. The above data will not be changed.

10.3.4 Copy all parameters after a firmware upgrade
This procedure allows saving in a file all parameters and restore them in the ECU1000 memory after a FW upgrade and
a “Full default” command (see paragraph “Full default “ command).
Export the full set of data

Tool to upgrade
the FW BIFFI-Assistant
BIFFI-Assistant
Import the full set of data Full default command

BIFFI-Assistant


11 Log and Graph function block

Loggers and Graphs are memorized in the ECU1000 memory. BIFFI-Assistant allows viewing the content of the above
memory. The instruction manuals DTDE326, DTDE327, DTDE328 describe the features of the loggers and graphs.
The function block “LOG AND GRAPH” contains the TABS “LOGGER, SHORT LOGGER and CURVES”
The TAB’s LOGGER and SHORT LOGGER can only be read. The LOGGER can contain upto 255 lines. The SHORT
LOGGER contains only 10 lines and is faster to read from ECU1000.
The TAB CURVES allows viewing the curves memorized in the ECU1000 and setting the the curve signatures. The
curves can be visualized using the full area of PC screen and exported by the command EXPORT (as file *.biffia or
*.txt described in the previous paragraphs) or by a printable file *.png.
11.1 Logger and Short Logger

the tab LOGGER.
“Read the tab LOGGER”.
The LOGGER will be
read from ECU1000
memory

“EVENT LOG”.
“Read object_ x”.
Use the scrollbar to view
the complete event list


“FAILURE LOG”.
“Read object _x”.
the complete failure list

“ALARM LOG”.
“Read object x”.
the complete alarm list

“STATISTIC LOG”.
“Read object _x”.
the complete failure list

11.2 Curves
By the Recorder function the ECU1000 can save different types of curves, (opening, closing, record, PST). The
instruction manuals DTDE326, DTDE327, DTDE328 describe the features of the Recorder function. The data saved in
the ECU1000 memory can be read in the function block “LOG and GRAPH” and viewed as tables or Y-t or Y-X graphs
on the PC screen.

TAB “CURVES”.
By the left key of mouse
select “Read tab
CURVES”.
The graphs can also be exported as *.png files. In the TAB “CURVES” are also available the commands to set the
signature of each type of curve.
The following procedure describes the operation available on the OPENING CURVE. The same procedure can be used
for CLOSING CURVE, RECORD CURVE and PST CURVE.

OPENING CURVE.
By the left key of mouse
select “Read object_x”.
The GEN VIEW shows
the list of curves
available.
The signature is marked
with 0.


GRID VIEW.
Select the curve number
(0,1,2,3,4,5).
The values of the curve
are shown by a table
Use the scroll bar to view
the values

CHART VIEW.
Select the curve number
(0,1,2,3,4,5).
Select the variable to
view (Position Demand,
Actuator Position, etc.
The curve are shown by a
Y-t graph.
By the options “X-axis”
and “Reverse X axis”
change graph in Y-X
mode
Each curve has max. 4

variables.
Max 2 curves at a time
can be viewed.
“Track Points” to view
the X and Y measures.
Use the ZOOM function
to zoom the picture

Right click of mouse in

the graph area to select
“Export” as *.png file or
“Full screen” to view the
curve on the complete PC
screen
Full Screen view of Y-t

curve.
Click X to return to
normal view.
to zoom the picture
Full screen view of Y-X

graph (PST function, Y=
Pressure in bar, X=
Actuator position in %,
Reversed X axis.
Click X to return to
normal view.
Right click of mouse to
select Export as *.png
file.

11.3 Curves signature

The example shows the procedure to set the Opening Signature. The same procedure can be used to set the Closing,
Record and PST signatures. Before setting the signature it is necessary to verify that at least one curve is present in the
ECU1000 memory by means of the procedure described in the previous paragraph.

SETTING
Left click of mouse to
select SET OPENING
SIGNATURE.
Enter the number of the
curve (from 1 to 5).
Right click of mouse.
send the command to
ECU1000.
The new signature will be marked with 0

Click OK
Click the left key of mouse on the button VIEW

12 Device Commands function block

The function allows monitoring status, variables and I/O of ECU1000. The function can be useful also to send
commands to ECU1000 unit for testing or calibration purposes. Commands availability depends on the user level
entered. Commands like “Memory and AI/AO calibration” are available only for Service or Specialist username. The
present manual describes the procedures
• to view the data in the TAB “OPERATION”, commands “Actuator variables”, “Failure”, “Alarm”, “Clear fail-
alarm”, “Out relay status”, “Digital input”, “Actuator status”, “Analogue input” and “Analogue output”
• to send the command “PST START” in the TAB “PST command” (if the PST function is enabled).
• to send the command “CL limit autocalib”, “Change close limit” and “CL limit manual set” in the TAB “Travel
limit setting”
The procedure is the same for the rest of the commands of the Device Commands function block.
The TAB “AI/AO calibration” is not available since the calibration of the analogue inputs and outputs needs using the
Local Operator Interface of the ECU1000.
Important:
All command of TAB’s of Device Commands block (except the TAB Operation)
can be carried out only if the BIFFI-Assistant is in SETTING mode
12.1 Operation
In the TAB Operation are present the following data:

• Actuator status: to view actuator status, operating mode, etc.
• Actuator variables: to view the analogue variables of ECU1000 in engineering units
• Failure: to view the present failures of the ECU1000
• Alarm: to view the present alarms of the ECU1000
• Variables and counters: to view special internal counter
• Out.relay status: to view the present status of the output relays (on, off)
• Digital input: to view the status of the digital inputs (0 or 1)
• Digital output: to view the status of the digital outputs (0 or 1)
• Analogue input: to view the value in bits of the analogue inputs (from 0 to 4095)
• Analogue output: to view the value in bits of the analogue outputs (from 0 to 4095)
• Clear fail-alarm: to send the commands to clear the detected alarms and failures. If the alarm/failure is present
it will reappear again
• Function summary: to view the list of function enabled by the manufacturer to control the actuator/HPU/HCU
The option “Start cyclical reading” allows updating the read value about every 2 sec.
12.1.1 Actuator Variables
The following variables can be monitored:

• Position %: actuator position in % of opening
• Position Demand %: position demand in % of opening (after characterization function if it is enabled)
• Position Error %: position error %
• In-Position Demand %: position demand input %
• Temperature °C: temperature of ECU1000 device
• Acceleration X-g, Y-g, Z-g: acceleration of ECU1000 device
• AO1 %: analogue output AO1 in % of output (0-10V)
• Oil Pressure bar: HPU pressure (only if the ECU1000 controls an HPU)
• Next PST: date of the next PST (only if PST function is enabled)
• Pump Switch: time to the next pump switch (only if the ECU controls an HPU with double pump)
• EV1-2 monitor (e:0 1:0 2:0): in case of PWM driver it shows the PWM command% and the PWM out%
• EV1-2 rate (1:0 2:0): in case of PWM driver it shows the utilization rate% of PWM 1 and PWM 2 channels

Maximize the function

block DEVICE
COMMANDS.
OPERATION.
Use the scroll bar to see

ACTUATOR
VARIABLES.
“Start cyclical reading”.

the available variables.
“Stop cyclical reading”
to stop updating of data.

12.1.2 Failure
block DEVICE
COMMANDS.
OPERATION.
FAILURE.

the list of present failures.
to stop data updating.
12.1.3 Alarm

block DEVICE
COMMANDS.
OPERATION.
ALARMS.


the list of present alarms.
12.1.4 Clear fail-alarm

block DEVICE
COMMANDS.
OPERATION.
CLEAR FAIL-ALARM.

CLEAR FAIL-ALARM.
“Send command_ x”.
Click on OK

12.1.5 Out. Relay Status

block DEVICE
COMMANDS.
OPERATION.
OUT. RELAY STATUS.

the list of relay status.
Compare the relay status

with the expected status
of output contacts
indicated in the electrical
diagram of ECU1000.
12.1.6 Digital Input

block DEVICE
COMMANDS.
OPERATION.
DIGITAL INPUT.


“Stop cyclical reading”.
Compare the Digital

Input with the hardware
status of the digital
inputs indicated in the
electrical diagram of
ECU1000.
12.1.7 Actuator Status

block DEVICE
COMMANDS.
OPERATION.
ACTUATOR STATUS.


12.1.8 Analogue Input

block DEVICE
COMMANDS.
OPERATION.
ANALOGUE INPUT.

Compare the Analogue

Input with the hardware
value of the analogue
inputs indicated in the
electrical diagram of
ECU1000.
12.1.9 Analogue Output

block DEVICE
COMMANDS.
OPERATION.
ANALOGUE OUTPUT.


Compare the Analogue

Outputs with the
hardware value of the
analogue outputs
indicated in the electrical
diagram of ECU1000.
12.1.10 Function summary

block DEVICE
COMMANDS.
OPERATION.
FUNCTION
SUMMARY.
The command shows the

list of ECU1000 functions
enabled to work by the
manufacturer. The
command shows also the
main characteristic of the
functions (for instance:
FAILSAFE is enabled
and if it is performed the
action will be “GO TO
POSITION%)
Click on “Stop cyclical

reading” to stop data
updating.

12.2 PST command

The command is performed only if the function PST is enabled in the ECU1000 device. The PST function is described
in the instruction manuals DTDE326, DTDE327, DTDE328. Check that the parameters in the function block “Actuator
Setup”, Tab “ PST SETUP” are correct.

button SETTING
block DEVICE
COMMANDS.

PST COMMAND.

If the value of PST

START is OFF, left click
of mouse on .
value ON.

PST START.
“Send command _x”.
button VIEW.
Wait for the response and
then left click on OK.
12.3 OP Limit Autocalib
Warning: Before executing the command it is mandatory to check that the calibration of 4-
20mA Position feedback and the mechanical stops are OK, according to
instructions in DTDE327”Travel Limit Setting”. It is also mandatory to check that
the configuration of parameters in the function Block “Restricted”, TAB “Travel
Limit” is OK.
Important:
The procedure described below is valid also for the command “CL Limit
Autocalib”


button SETTING
block DEVICE
COMMANDS.
Check the value of

SPEED. The default
value is 10%.
If necessary enter a new
value (in case of actuator
provided with PSOV’s
the value could be 70%).
Then click the right key
of mouse

“SPEED”
“Send command_x”.
Click on OK


“OP LIMIT
AUTOCALIB”.

“OP LIMIT
AUTOCALIB”
“Send command_x”
Click on OK.
Click the button VIEW
12.4 Change Close Limit
Limit” is OK.
Important:
The procedure described below is valid also for the command “Change Open
Limit”


button SETTING
block DEVICE
COMMANDS.
“Travel Limit Setting”

“CHANGE CLOSE
LIMIT” .
Enter the new value.

“CHANGE CLOSE
LIMIT”.

Rigth click of mouse on

“CHANGE CLOSE
LIMIT”.
Click on OK
12.5 CL Limit Manual Set
Limit” is OK.
Important:
The procedure described below can be used only if the actuator is fully closed
Important:
The procedure described below is valid also for the command “OP Limit Manual
Set”. The procedure can be used only if the actuator is fully open

button SETTING
block DEVICE
COMMANDS.
“Travel Limit Setting”

Enter the value “ON”.

“CLLIMIT MANUAL
SET”.

“CL LIMIT MANUAL
SET”.
Click on OK
Click the button VIEW.
12.6 PSOV autocalibration

button SETTING
block DEVICE
COMMANDS.
“PSOV-SOV
CONTROL”
“PSOV’s AUTOCALIB”
“ON”.


line “PSOV’s
AUTOCALIB”
“Send command_x”
Wait until the command
ends
Click on OK
The above ECU command is available only if the parameter “positioner mode” is configured “MO-2PSOV” and the
actuator is controlled by BIFFI Proportional SOlenoid Valves (PSOV). It used to set the minimum and maximum PWM
signal to control the PSOV’s.
12.7 Clear logger
The command clears the EVENT, FAILURE and ALARM logger. It is available with password “SERVICE”,
“SPECIALIST” and “GUEST2”.

button SETTING
block DEVICE
COMMANDS.
“MEMORY”
“CLEAR LOGGER”
“CLEAR LOGGER”.
Click on OK

12.8 Full default
The command is available only with username level “service”, “specialist” and “guest2”. The command sets each
parameter of ECU1000 to the default value. The command is used after an ECU1000 firmware upgrade (see paragraph
“Copy all parameters after a FW upgrade”).

button SETTING
block DEVICE
COMMANDS.
“MEMORY”
“FULL DEFAULT”

“FULL DEFAULT”.
Click on OK
Warning: By the above command each parameter of the ECU1000 is configured with its
default value and the previous configuration is lost. It is mandatory to save the
configuration of the ECU1000 in a file before executing the command and restore
the configuration by the command “full copy” after having performed the
command, as described in the paragraphs “Import and Export”.
The ECU1000 controls the actuator, it could control the ECU, it could drive
generic electric, pneumatic, mechanic and hydraulic devices, it is mandatory to
place the above devices in their safe condition to avoid injury of people and
damage of equipment and ambient (see installation and maintenance manual)

12.9 Clear Counters
The command is available only with username level “service”, “specialist” and “guest2”. The commands clears the
counters “n° of start of pump1”, “n° of starts of pump2”, “number of starts of D-SOV”. Each counter can be cleared
individually with options “Pump1, PUMP2, D-SOV START” or all counters can be cleared with the option “ALL”.

button SETTING
block DEVICE
COMMANDS.
“MEMORY”
“CLEAR COUNTERS”
desired options “ALL,
Pump1, PUMP2, D-SOV
START”.

CLEAR COUNTERS
CLEAR COUNTERS
Click on OK
and check the value of
counters in the statistic
log.

12.10 HPU Config
The command is available only with username level “specialist” and “guest2”. The command sets some typical
parameters of the HPU. Below are listed the HPU parameters set by the command

button SETTING
block DEVICE
COMMANDS.
“MEMORY”
“HPU CONFIG”
desired options “A, B, C,
D, E”.

HPU CONFIG
HPU CONFIG
Click on OK
Click the button VIEW .
"A": hpu type=dual m-s, pressure discharge SOV=energized, oil pressure sensor=pres transm, DSOV mode=both, pump
duty=continuous,max-time alarm=pump stop, mec-unloader=absent
"B": hpu type=single, pressure discharge SOV=absent, oil pressure sensor=pres tr-sw, DSOV mode=start-pump, pump
duty=intermit, max-time alarm=pump run, mec-unloader=absent
"C": hpu type=single, pressure discharge SOV=energized, oil pressure sensor=pres transm, DSOV mode=both, pump
duty=intermit, max-time alarm=pump stop, mec-unloader=absent
"D": hpu type=single, pressure discharge SOV=absent, oil pressure sensor=pres switch, DSOV mode=start pump, pump
duty=intermit, max-time alarm=pump stop, mec-unloader=absent
"E" : hpu type=dual cycle, pressure discharge SOV=energized, oil pressure sensor=pres transm, DSOV mode=both,
pump duty=intermit,max-time alarm=pump stop, mec-unloader=absent

13 Work Offline
The prevoius paragraphs describe the features of the BIFFI-Asssistant when it is connected to ECU1000 and works
Online.
The next paragraph describes the features available when the BIFFI-Assistant works Offline, not connected to
ECU1000. In such mode BIFFI-Assistant can handle only files previously saved with extension *. biffia. The Offline
mode allows
• Change the value of parameters and save them in a new file
• View the loggers
• View the graphs
Launch the program by

the double left click of of
mouse on the BIFFI-
Assistant icon.
Click on Work Offline
As described in the work Online mode use the left and right button of mouse and the PC keyboard to enter data.
Enter the password.

The default password in
Work Offline is “biffi”.
The password can be
changed by the user

Select the file

mouse on Import file.
The following appears on
the PC screen
By the facilities described in the previous paragraphs minimize / maximize the menu and use the scroll bar to view
function blocks, function TAB’s, parameters / command lines, loggers and graphs. The commands “Write Object_x,
Write Block_x, Write Tab_x” are active and are used to modify the value of parameters in the PC memory. The options
available on the high right corner are:
• Import: to read a file from PC memory
• Export: to save the file in the PC memory
• Change password: to modify the existing password in Work Offline mode
• Logout : to exit
13.1 Change of value of a parameter and save it in a new file
Import the file to be modified by the procedure described in the prevoius paragraph. Maximize the function block and
the TAB contaning the parameters. Modify the parameters. By the commands “write Object_x, write TAB_x, write
Block_x, write all Objects” set the changes in the PC memory. Export the modified file in a new file.
Example 1: to change a parameter and save in a new file

Launch the BIFFI-

Assistant and select Work
Offline.
Enter the password.
Import the file to be
modified.
By the mouse, select the
function Block, select the
TAB, select the
Parameter.
By the right key of mouse
open the window with the
available options.
Select “write object _x”
Click YES to confirm
Export.
Enter the name of the new file. The default name is

“Biffi-Assistant_date_time__OFFLINE.biffia.
Click the button SAVE

Example 1: to change 2 parameters in different TAB’s and save them in a new file
Launch the BIFFI-

Offline.
Enter the password
modified
By the mouse, select the
function Block, select the
TAB and the Parameter.
Select the TAB and

change the second
parameter
Click the right key of

mouse on the Block name
to open the window with
Select “write Block_ x”
Click YES to confirm
mouse on Export

Enter the name of the new file. The default name is

“Biffi-Assistant_date_time__OFFLINE.biffia.
Click the button SAVE
13.2 Change of Work Offline password
Launch the BIFFI-Assistant and select Work Offline.

Enter the password
Import the file.
Click the left key of mouse on “Change password”
Enter the old password
Enter the new password
Confirm the password
Click on SAVE
Now neither the old password nor the default one are valid
Important: It is important that the new password is not forgot. It is suggested to save it in a
safe location. Contact Biffi Service if the password is lost
13.3 View of loggers
The procedure to view the loggers is the same described in the previous paragraphs for the Work Online mode. The
loggers previously saved can only be viewed, they cannot be modified.

Launch the BIFFI-

Offline.
Enter the password
viewed
block “LOG and
GRAPH”

TAB “LOGGER”.
“EVENT LOG”.
the events

TAB “LOGGER”.
“FAILURE LOG”.
the events


TAB “LOGGER”.
“ALARM LOG”.
the events

TAB “LOGGER”.
“STATISTIC log”.
the events
13.4 View of short logger
The procedure to view the short logger is the same described for viewing the LOGGER.
13.5 View of graphs
The procedure to view the curves is the same described in the previous paragraphs in Work Online mode. The graphs
previously saved can only be viewed, they cannot be modified. Here below is described the procedure to work on the
“Opening curve”, but the procedure is the same for the “Closing, Recorder and PST curves”.

Launch the BIFFI-

Offline.
Enter the password
viewed
block “LOG and
GRAPH”

TAB “CURVES”.
“OPENING CURVE”.
The General view shows
the list of visible curves.
The curve number 0 is
the signature (if it was
previously set in Work
Online mode)

“Grid View”.
number of the curve (4).
The values are shown as
table.


“Chart View”.
number of the curve (0).
select the variables
“Actuator position,
Position Demand, etc”.
“Track point” to view the
values.
Curve 0 = signature

to zoom the picture
Right click of the mouse
to view the options
Export and Full screen
“Full Screen” to view the
graph on the complete PC
screen. Left click of
mouse on Export to save
the graph as *.png file.
Use “X axis” and
“Reverse X axis” options
to view the graph in Y-X
mode
FULL SCREEN VIEW

Left click pf mouse on
“X” to return to previous
screen.
Use “Track point to view
the measures
to zoom the picture
Right click of the mouse
to view the option
“Export”
“Export” to save the
graph as *.png file.
Use “X axis” and
“Reverse X axis” options
to view the graph in Y-X
mode

Graph of 2 curves, 2
variables each curve.
Comparison between
“signature” (curve 0) and
curve 3
Full screen view of one

closing curve with 2
variables.
Graph of curve recorded

in “Record” mode.

PST curve in closing.

graph “Pressure inside the
cylinder in bar” versus
“Actuator position in %”.

graph “Pressure inside the
cylinder in bar” versus
“Actuator position in %”.
X in reversed mode

BIFFI ITALIA srl


8.2. Instruction and operating manual

MANUALE USO E MANUTENZIONE
CODICE HPU: 19.021.262
DOCUMENTO : IOM_14479
2 27/09/2016 Updated E. Masini C. Montanari

1 30/Ago/2016 Issued E. Masini C. Montanari
Rev. Date Description By Approved
Via Isacchi, 3 - 42124 Reggio Emilia (Italy) - Tel. (0522) 305902 - 381830  Fax (0522) 381831  e-mail: oleoreva@oleoreva.it
CAPITALE SOCIALE € 0.9 0,00 i.v.  R.E.A. N. 145768  ISCR.REG.IMPR. DI RE, CODICE FISCALE E PARTITA IVA n. 00642890354
IOM_14479_2 (09.16) Pages 1/59

1 INFORMAZIONI GENERALI ............................................................................................................ 6
1.1 COSTRUTTORE ....................................................................................................................... 6
1.2 CERTIFICAZIONE .................................................................................................................... 6
1.3 DESTINATARI, SCOPO E CONTENUTO DEL MANUALE ........................................................... 6
1.4 CONSERVAZIONE DEL MANUALE .......................................................................................... 7
1.5 SIMBOLI UTILIZZATI SUL MANUALE ...................................................................................... 7
1.6 IDENTIFICAZIONE CENTRALE ................................................................................................ 7
2 DESCRIZIONE CENTRALE ............................................................................................................... 8
2.1 DESCRIZIONE, INGOMBRI, PRESTAZIONI............................................................................... 8
2.2 DESCRIZIONE FUNZIONAMENTO ........................................................................................ 12
2.3 CONDIZIONI AMBIENTALI .................................................................................................... 12
2.4 ILLUMINAZIONE CENTRALE ................................................................................................. 12
2.5 COMPONENTE DI SICUREZZA .............................................................................................. 13
3 “ICURE))A NELL’U“O E MANUTEN)IONE................................................................................... 14
3.1 AVVERTENZE GENERALI....................................................................................................... 14
3.2 CONTROINDICA)IONI D’U“O ............................................................................................... 14
3.3 ZONE PERICOLOSE ............................................................................................................... 14
3.4 DISPOSITIVI DI PROTEZIONE ................................................................................................ 15
3.5 FUNZIONE DI ARRESTO........................................................................................................ 15
3.6 PROCEDURE DI LAVORO SICURE ......................................................................................... 15
4 INSTALLAZIONE ........................................................................................................................... 16
4.1 PREMESSA ........................................................................................................................... 16
4.2 MOVIMENTAZIONE ............................................................................................................. 16
4.3 STOCCAGGIO ....................................................................................................................... 18
4.4 PIAZZAMENTO E MONTAGGIO............................................................................................ 18

IOM_14479_2 (09.16) Pages 2/59

4.5 RIEMPIMENTO E FLUIDO IDRAULICO .................................................................................. 19
4.6 COLLEGAMENTI IDRAULICI .................................................................................................. 22
5 AVVIAMENTO.............................................................................................................................. 23
5.1 ADDETTI ............................................................................................................................... 23
5.2 CONTROLLI PRELIMINARI ................................................................................................... 23
5.3 MESSA IN FUNZIONE ........................................................................................................... 24
5.4 REGOLAZIONI/CONTROLLI................................................................................................... 25
5.5 ARRESTO NORMALE ............................................................................................................ 26
5.6 ARRESTO DI EMEREGENZA .................................................................................................. 26
5.7 RIPRISTINO........................................................................................................................... 26
5.8 MESSA FUORI SERVIZIO ....................................................................................................... 26
6 MANUTENZIONE ......................................................................................................................... 27
6.1 STATO DI MANUTENZIONE, ADDETTI.................................................................................. 27
6.2 ISOLAMENTO ELETTRICO DELLA CENTRALE ........................................................................ 27
6.3 PRECAUZIONI PARTICOLARI ................................................................................................ 27
6.4 PULIZIA ................................................................................................................................ 28
6.5 MANUTENZIONE ORDINARIA .............................................................................................. 28
6.6 MANUTENZIONE STRAORDINARIA ...................................................................................... 28
6.7 MANUTENZIONE ORDINARIA .............................................................................................. 29
6.8 SCHEDA RICERCA GUASTI .................................................................................................... 30
7 RICAMBI ...................................................................................................................................... 32
7.1 ELENCO RICAMBI CONSIGLIATI ........................................................................................... 32
8 DEMOLIZIONE ............................................................................................................................. 33
8.1 SMALTIMENTO OLIO ........................................................................................................... 33
8.2 DEMOLIZIONE DELLA CENTRALE ......................................................................................... 33

IOM_14479_2 (09.16) Pages 3/59

9 ALLEGATI ..................................................................................................................................... 34
9.1 SCHEMA FUNZIONALE, DISTINTA 19.011.262 .................................................................... 34
9.2 DISEGNO DI INGOMBRO 19.021.262 ............................................................................... 35
9.3 DICHIARA)IONE CONFORMITA’ CABLAGGI ......................................................................... 36
9.4 MANUALE MOTORE ELETTRICO ABB .................................................................................. 37
9.5 MANUALE MANOMETRI ...................................................................................................... 38
9.6 MANUALE COOLER .............................................................................................................. 39
9.7 MANUALE TRASMETTITORE DI TEMPERATURA .................................................................. 40
9.8 MANUALE TRASMETTITORE DI LIVELLO .............................................................................. 41
9.9 MANUALE TAPPO DI CARICO .............................................................................................. 42
9.10 SCHEDA TECNICA LIVELLO VISIO ...................................................................................... 43
9.11 MANUALE POMPA ........................................................................................................... 44
9.12 MANUALE PRESSOSTATO ................................................................................................ 45
9.13 SCHEDA TECNICA PK3 ..................................................................................................... 46
9.14 MANUALE RELIEF VALVE HAWE ...................................................................................... 47
9.15 SCHEDA TECNICA VALVOLA DI MASSIMA FLUCOM ........................................................ 48
9.16 SCHEDA TECNICA RITEGNO FLUCOM .............................................................................. 49
9.17 SCHEDA TECNICA RITEGNO TOGNELLA ........................................................................... 50
9.18 SCHEDA TECNICA FILTRO COOLER ................................................................................... 51
9.19 SCHEDA TECNICA FILTRO IN PRESSIONE.......................................................................... 52
9.20 SCHEDA TECNICA NEEDLE VALVE REVA ........................................................................... 53
9.21 SCHEDA TECNICA NEEDLE VALVE TOGNELLA .................................................................. 54
9.22 SCHEDA TECNICA NEEDLE VALVE INDRA ......................................................................... 55
9.23 SCHEDA TECNICA STOP VALVE MHA ............................................................................... 56
9.24 SCHEDA TECNICA STOP VALVE EFFEBI ............................................................................. 57

IOM_14479_2 (09.16) Pages 4/59

9.25 SCHEDA TECNICA VALVOLA PROTEZIONE SERBATOIO .................................................... 58
9.26 DOCUMENTAZIONE TUBI FLESSIBILI ................................................................................ 59
Figura 1 - POSIZIONE ELETTROPOMPE ................................................................................................. 8

Figura 2 - DETTAGLIO SERBATOIO – PARETI - STRUTTURA .................................................................. 9
Figura 3 - PORTE DI INGRESSO CENTRALE ......................................................................................... 10
Figura 4 - PORTE DI ISPEZIONE........................................................................................................... 10
Figura 5 - DETTAGLIO QUADRO ELETTRICO - ACCUMULATORI – TETTOIE – FINESTRE AERAZIONE . 11
Figura 6 - POSIZIONE INTERRUTTORE ILLUMINAZIONE ..................................................................... 13
Figura 7 - DETTAGLIO 1 SOLLEVAMENTO – BARICENTRO SENZA OLIO ............................................. 16
Figura 8 - POSIZIONE PIEDI DI APPOGGIO.......................................................................................... 19
Figura 9 - DETTAGLIO MANDATE - RITORNI ....................................................................................... 19
Figura 10 - DETTAGLIO FILTRI - OBLO' ............................................................................................... 20
Figura 11 - DETTAGLIO RUBINETTO DI SPURGO SERBATOIO ............................................................ 21
Figura 12 - DETTAGLIO COMPENSATORE POMPA ............................................................................. 25
IOM_14479_2 (09.16) Pages 5/59

1 INFORMAZIONI GENERALI
1.1 COSTRUTTORE
 OLEODINAMICA REVA s.r.l.
 Via Isacchi, 3 – 42124
 Reggio Emilia (Italy)
 Tel. (0522) 305902 – 381830
 Fax (0522) 381831
 e-mail: oleoreva@oleoreva.it
 CAPITALE “OCIALE € .9 , i.v.
 R.E.A. N. 145768 ISCR.REG.IMPR. DI RE
 CODICE FISCALE E PARTITA IVA n. 00642890354
1.2 CERTIFICAZIONE
La Oleodinamica REVA s.r.l. dichiara che il prodotto è conforme alle seguenti normative (la dichiarazione
oi volge sola e te i ate iali all’i te o dello s opo di fo itu a di OLEODINAMICA REVA:
 2004/108/CE Direttiva compatibilità elettromagnetica
 2006/95/CE Direttiva bassa tensione
 2006/42/CE Direttiva macchine
 97/23/CE Direttiva apparecchi a pressione
 UNI EN ISO 4413:2012 (Regole generali e requisiti di sicurezza per i sistemi oleodinamici e i loro
componenti).
1.3 DESTINATARI, SCOPO E CONTENUTO DEL MANUALE
Il a uale i oggetto ivolto sia all’ope ato e he ai te i i a ilitati alla a ute zio e della e t ale, ed
ha lo scopo di fornire tutte le informazioni necessarie affinché, oltre ad un adeguato utilizzo della
apparecchiatura il Cliente sia in grado di operare nel modo più autonomo e sicuro possibile. E’ e essario
prima di effettuare qualsiasi operazione sulla apparecchiatura oleodinamica, che gli operatori ed i
manutentori leggano attentamente le istruzioni contenute nel presente manuale di istruzioni.
IOM_14479_2 (09.16) Pages 6/59

1.4 CONSERVAZIONE DEL MANUALE
Il manuale di istruzioni è parte integrante della centrale pertanto deve essere conservato nelle
immediate vicinanze della stessa, dentro un apposito contenitore e, soprattutto, al riparo da liquidi e
ua t’alt o e possa o p o ette e lo stato di leggi ilità.
1.5 SIMBOLI UTILIZZATI SUL MANUALE
SIMBOLO SIGNIFICATO DESCRIZIONE
PERICOLO Indica un pericolo con rischio, anche mortale, per l’utilizzato e
Indica una avvertenza od una nota su funzioni chiave o su

informazioni utili.
AVVERTENZE
Prestare la massima attenzione ai blocchi di testo indicati da
questo simbolo.
“i i hiede all’utilizzato e di ileva e u valo e di misura, di

OSSERVAZIONE
controllare una segnalazione, ecc.
Occorre consultare il libro istruzioni prima di effettuare una

CONSULTAZIONE
determinata operazione.
In casi particolari funzionamenti e/o anomalie, può essere

REGOLAZIONE
richiesta una determinata regolazione meccanica e/o elettrica.
1.6 IDENTIFICAZIONE CENTRALE

Nelle vicinanze di ogni componente della centralina si trova una targhetta identificativa in plastica che
riporta stampigliato il numero del componente come da schema oleodinamico 19.011.262 allegato e
p ese te all’i te o della tas a po tado u e ti e allegato al p ese te a uale.
Oggetto della fornitura:
N°2 centrali codice 19.021.262 – IDENTIFICATIVI ENEL: CFI-001 ; CFI-002
IOM_14479_2 (09.16) Pages 7/59

2 DESCRIZIONE CENTRALE
2.1 DESCRIZIONE, INGOMBRI, PRESTAZIONI
La centrale è costituita da:

Elettropompe
ELETTROPOMPA
Figura 1 - POSIZIONE ELETTROPOMPE
IOM_14479_2 (09.16) Pages 8/59

Struttura esterna portate
Serbatoio olio
Pareti esterne
PARETI DI CHIUSURA
SERBATOIO
STRUTTURA PORTANTE
Figura 2 - DETTAGLIO SERBATOIO – PARETI - STRUTTURA
IOM_14479_2 (09.16) Pages 9/59

Porte ingresso/ispezione
Figura 3 - PORTE DI INGRESSO CENTRALE
Figura 4 - PORTE DI ISPEZIONE
IOM_14479_2 (09.16) Pages 10/59

Accumulatori – Quadro elettrico – Tettoie
TETTOIE
QUADRO ELETTRICO
FINESTRE AERAZIONE
ACCUMULATORI
Figura 5 - DETTAGLIO QUADRO ELETTRICO - ACCUMULATORI – TETTOIE – FINESTRE AERAZIONE
La centrale viene fornita con le tettoie separate per esigenze di ingombri spedizione.
Movimentare la centrale SENZA le tettoie , montarle dopo installazione.
IOM_14479_2 (09.16) Pages 11/59

Sulle pareti di chiusura, sul serbatoio sono posizionate tutte le apparecchiature oleodinamiche.
Il serbatoio è fissato alla struttura portante che ha la funzione di vasca recupero olio in caso di perdite o
gocciolamenti durante la manutenzione; il basamento della centralina è provvista di 4 piedi pe l’appoggio a
pavimento.
Ingombro (larghezza x lunghezza x altezza) 2400 mm x 3262 mm x 2548 mm (senza tettoie)
2840 mm x 3950 mm x 2639 mm (con tettoie)
Massa complessiva (escluso olio) 4500 Kg senza olio e tettoie
5380 Kg con olio senza tettoie
Livello massimo olio 910 lt
Livello minimo olio 515 lt
Tensione alimentazione motore 400 Vac/3Ph/50 Hz
Potenza motore 3 x 20,5 Kw
Portata massima erogata alla pompa singola pompa 63.0 lt/ ’
Pressione di compensazione Pompa a Pistoni 170 BARG
2.2 DESCRIZIONE FUNZIONAMENTO

La centrale è progettata in modo da fornire la potenza idraulica ad un massimo di 22 UTENZE (attuatore +
valvola), attraverso la logica del quadro elettrico vengono azionate in parallelo le elettropompe fino ad
massimo di 3 in contemporanea.
Per avviare la centrale ollega la elett i a e te all’ali e tazio e ed agi e sull’i te uto e ge e ale e
posizionarlo su I.
Per i comandi logici da quadro elettrico consultare lo schema elettrico di riferimento (non in scopo di forntua
REVA)
2.3 CONDIZIONI AMBIENTALI

La centrale è idonea per essere installata in luogo aperto e posizionata su pavimento solido. E’ idonea per
funzionare con temperatura ambiente compresa fra -35°C e +35°C.
2.4 ILLUMINAZIONE CENTRALE
L’illu i azio e della centrale è prevista attraverso un neon centrale , l’ ute te può attiva e
l'illu i azio e age do sull’i te utto e posto a si ist a all’i g esso della e t ale,
Nel caso di interventi straordinari di manutenzione non diurna, prima di operare, il personale deve accertarsi
di operare con sufficiente visibilità.
IOM_14479_2 (09.16) Pages 12/59

Interruttore
illuminazione
Figura 6 - POSIZIONE INTERRUTTORE ILLUMINAZIONE
2.5 COMPONENTE DI SICUREZZA
La centrale è dotata di COMPONENTI DI SICUREZZA, sono presenti 3 valvole di massima pressione

certificate PED, 3 valvole di massima pressione sulle singole linee pompa e un compensatore su ogni pompa
a pistoni assiali (TARATO P MAX 170 BARG). L’effi ie za di uesti dispositivi garantisce un corretto
fu zio a e to i si u ezza della e t ali a e pe ta to e essa io ve ifi a e l’effi ie za o pe iodi ità,
consultare i singoli manuali di uso e manutenzione dei componenti specifici.
IOM_14479_2 (09.16) Pages 13/59

3 SICUREZZA NELL’USO E MANUTENZIONE
3.1 AVVERTENZE GENERALI
Gli operatori ed i manutentori devono leggere con molta attenzione le informazioni riportate nel
presente manuale, con particolare riguardo alle opportune precauzioni per sicurezza elencate in questo
capitolo.
E’ i dispe sa ile, i olt e, he ve ga o seguite le avve te ze di seguito ele ate:
 Mantenere le apparecchiature e la zona di lavoro in ordine e pulita.
 Non rimuovere od alterare le targhe apposte dal costruttore
 Non rimuovere od eludere i sistemi di sicurezza della centralina
 Non variare la taratura delle valvole senza apposita autorizzazione
 “eg ala e e ip isti a e eve tuali pe dite d’olio
 Co t olla e pe iodi a e te la ta atu a e l’effi ie za delle valvole di massima posti sulla
centrale.
3.2 CONTROINDICAZIONI D’USO
L’i pia to o deve esse e utilizzato:

 Se non sono stati messi in opera tutti i dispositivi di sicurezza
 Con ponticelli elettrici e/o mezzi meccanici che escludano utenze/parti del quadro elettrico di
comando
 Con tarature di pressione e portata superiori a quanto dichiarato da REVA
 Da operatori non abilitati
 Con prestazioni diverse da quelle citate nel presente manuale (punto 2.1)
 Se non si è provveduto ad un piazzamento e montaggio come descritto al punto 4.4
3.3 ZONE PERICOLOSE
E’ a dato io depressurizzare l’i pia to prima di effettuare manutenzione sulla centrale.

E’ a dato io toglie e te sio e p i a di ap i e il uad o elett i o!
IOM_14479_2 (09.16) Pages 14/59

3.4 DISPOSITIVI DI PROTEZIONE
L’a esso all’a ea dove è installata/ubicata la centrale deve essere consentito solo al personale abilitato
e responsabile.
All’i te o della centrale non sono previste protezioni o schermi contro incidenti generati dalla rottura di
componenti, e dal distacco/disgiunzione di raccordi sulle tubazioni (vedi par. 4.4), pertanto il personale
addetto alla messa in funzione e alla manutenzione deve essere dotato di opportune protezioni (guanti,
occhiali, scarpe antinfortunistiche).
I dispositivi di protezione individuale devono rispondere ai requisiti minimi di legge vigente presso il sito di
installazione centrale elettroidraulica , CERRO PABELLON – CILE ed a quelli indicati dal datore di lavoro.
3.5 FUNZIONE DI ARRESTO
La funzione di a esto dell’i pia to oleodi a i o è gestita dall’i pia to elett i o.

I aso di i te ve to di a ute zio e o ligato io he l’ope ato e si a e ti
personalmente che la centrale non sia sotto tensione!
3.6 PROCEDURE DI LAVORO SICURE

 Pe l’utilizzo della centrale i dispe sa ile he l’ope ato e sia ualifi ato e he ai o a di sia
presente solo un operatore
 Tutte le apparecchiature devono essere ben manutenzionate, secondo intervanti programmati
(vedi capitolo 6).
IOM_14479_2 (09.16) Pages 15/59

4 INSTALLAZIONE
4.1 PREMESSA
La centrale prima della messa in funzione è stata sottoposta a collaudo per verificare il corretto
funzionamento in accordo allo schema idraulico.
A fine collaudo vie e svuotato l’olio, è a carico cliente sia il primo riempimento che i successivi cambi olio; la
centrale è idonea per funzionare con olio idraulico AEROSHELL FLUID 41.
4.2 MOVIMENTAZIONE
La movimentazione della centrale deve essere effettuata da personale professionalmente qualificato in
modo da evitare qualsiasi danno accidentale.
La centrale è movimentabile attraverso 4 golfari posti sulla struttura. I golfari sono stati forniti insieme alla
e t ale id auli a, il solleva e to di uest’ultima è approvato solo con i golfari forniti.
Questo è il solo modo consentito per poterla movimentare.
NON UTILIZZARE ALTRI FORI FILETTATI PRESENTI O FASCE AVVOLGENTI LA CENTRALE O CARRELLI ELEVATORI
CON FORCHE.
Figura 7 - DETTAGLIO 1 SOLLEVAMENTO – BARICENTRO SENZA OLIO
GOLFARI: RUD - VLBG 4t M24
IOM_14479_2 (09.16) Pages 16/59

Max. transport load in kg for different load types
Article-No.: 8600386
Load ring VLBG 4t M24 with variable length
WLL: 4000 kg
1 Leg:
4000 kg 4000 kg
2 Leg:3/4 Leg:*
vertical: 8000 kg 8000 kg 12000 kg 12000 kg
symmetrical: 5600 kg 4000 kg 8400 kg 6000 kg
*Please note: The values mentioned for 3/4 legs are only achieved when it is guaranteed that the load is evenly spread
over more than 2 legs. Otherwise please use the values of 2 legs. See BGR 500/DGUV Regel 100-500
(regulation for the prevention of industrial accidents), chapter 2.8 paragraph 3.5.3
CERCHIATO CASO PER IL NOSTRO SOLLEVAMENTO IN CUI SI PUO’ “OLLEVARE FINO AD UN

MASSIMO DI 8400 Kg
UTILIZZARE CATENE IDONEE , LUNGHEZZA MINIMA SINGOLA CATENA DA GANCIO GRU A

GOLFARE 2600 mm (LUNGHEZZA MINIMA PER NON SUPERARE I 45°)
IOM_14479_2 (09.16) Pages 17/59

4.3 STOCCAGGIO
In caso di lunga inattività la centrale deve essere immagazzinata con precauzioni relative al luogo ed ai
tempi di stoccaggio:
 Immagazzinare in luogo chiuso e asciutto
 Proteggere da urti e sollecitazioni accidentali
 P otegge e dall’u idità e da es u sio i te i he elevate (superiori al range di
funzionamento indicato)
 Evitare il contatto con sostanze corrosive
 Tappare tutte le connessioni (la centrale è fornita con tutte le connessioni tappate)
 Ingrassare le parti in movimento non protette (se applicabile)
4.4 PIAZZAMENTO E MONTAGGIO

Pe l’i stallazio e della centralina si deve predisporre u ’a ea adeguata alle di e sio i della centralina,
che dovrà essere ubicata in modo da rendere possibile tutti gli interventi di manutenzione/regolazione senza
alcun pericolo pe l’ope ato e.
Il montaggio della centralina deve essere effettuato seguendo le istruzioni di seguito elencate:
 Posizionare la centralina nella zona prestabilita attenendosi alle indicazioni del par. 4.2
 Appoggiare la centrale al suolo utilizzando gli appositi piedi
 Togliere i tappi protettivi (flange) posti sulle connessioni della centrale solo quando si è
pronti a collegarla al esto dell’i pia to
 Predisporre i collegamenti come da schema idraulico (19.011.262) seguendo le istruzioni del
par. 4.6
 Riempimento del serbatoio utilizza do l’apposito tappo di a i o ta ghetta con olio
idraulico indicato precedentemente (vedi par. 4.5).
IOM_14479_2 (09.16) Pages 18/59

PIEDI DI APPOGGIO
(FORO DI FISSAGGIO Ø20)
Figura 8 - POSIZIONE PIEDI DI APPOGGIO
4.5 RIEMPIMENTO E FLUIDO IDRAULICO

La centrale presenta le connessioni idrauliche sigillate con flange, pertanto prima dell’avviamento si deve
verificare prima che tipo di olio richiede la specifica del pannello/cabina che si deve collaudare e dopo se si
e essita a ia e o o l’olio all’i te o del se atoio per evitare di mescolare due tipi di olio diversi.
MANDATE
RITORNI
Figura 9 - DETTAGLIO MANDATE - RITORNI
IOM_14479_2 (09.16) Pages 19/59

Dopo aver effettuato tali o t olli, si deve p ovvede e o al ie pi e to d’olio del se atoio o al a ia e to
dell’olio. Pe il a ia e to d’olio vede e pa . . s heda a ute zio e p og a ate .
Pe effettua e il ie pi e to d’olio del se atoio si devo o effettua e i collegamenti idraulici della centrale
al pannello/cabina da collaudare. Si provvede al riempimento attraverso il tappo di carico pos. 561
assi u a dosi he il livello dell’olio o superi il livello massimo indicato sul livello visivo pos. 559
considerando il cilindro idraulico già pieno e completamente chiuso. L’olio utilizzato è del tipo AEROSHELL
FLUID 41 in accordo alla specifica del cliente. La centrale è idonea a funzionare ad una temperatura ambiente
di -35°C.
ATTENZIONE dopo il pri o avvia e to si verifi herà u otevole a assa e to del livello dell’olio
dovuto al fatto che si è riempito il circuito idraulico e gli accumulatori idraulici pos. 33 G-L-H-, NON
ra o are ai l’olio al livello ax o a u ulatore ari o e cilindro aperto! IN CASO DI SVUOTAMENTO
ACCUMULATORI O MANOVRE ATTUATORI SI VERIFICHEREBBE UNA FUORIUSCITA DI OLIO DAL SERBATOIO.
L’olio id auli o va sostituito ogni 3000-4000 ore o prima se un esame visivo dovesse presentare
deterioramento del fluido. Quando si effettua il cambio olio è buona norma effettuare il cambio dei filtri olio,
pos. 356 A-B (filtro in pressione – vedere allegato del filtro) e la pulizia del serbatoio rimuovendo l’o lò di
ispezione.
FILTRI IN PRESSIONE
OBLO’ DI I“PE)IONE / PULI)IA
Figura 10 - DETTAGLIO FILTRI - OBLO'

IOM_14479_2 (09.16) Pages 20/59

Al fine di evitare qualsiasi tipo di problema al o e to dell’avvia e to della a hi a, e e atte e si a
quanto di seguito descritto.
Nei circuiti oleodinamici il fluido è mezzo di trasmissione della potenza ed allo stesso tempo il lubrificante dei
componenti e pe u a uo a o se vazio e dell’i pia to i po ta te he il fluido sia di qualità con elevato
indice di viscosità e con additivi antischiuma ed antiossidanti; i olt e l’olio deve ave e u a vis osità adeguata
alle o dizio i li ati he del luogo d’i stallazio e della a hi a a alla temperatura di esercizio
dell’i pia to. E’ e essa io i olt e o side a e he l’olio, come fornito dalla società fabbricante contiene
sempre un certo numero di particelle contaminanti; pertanto è buona norma prima di immettere il fluido nel
circuito, provvedere ad una accurata pulizia del fluido ed è comunque consigliabile riempire il serbatoio
utilizzando gruppi mobili di flussaggio. E’ o siglia ile o u ue a alizza e periodicamente campioni di
fluido pe o t olla e l’i teg ità delle sue proprietà chimico-fisiche, poiché la durata sopra indicata è del tutto
indicativa e dipendente non solo dalle a atte isti he dell’i pia to e del se vizio a a he dalle o dizio i
li ati he dell’a u atezza della filt azio e e della a ute zio e. Eve tuali a o hi devo o esse e
effettuati con fluido della stessa marca e tipo per evitare inconvenienti funzionali di varia natura. Se la
e t ali a esposta a fo ti es u sio i te i he e p o a ile he all’i te o del se atoio si fo i o de sa la
quale tende a depositarsi sul fondo del serbatoio ed è eliminabile con il rubinetto pos. 351 D.
RUBINETTO DI SPURGO (MOSTRATO

IN POSIZIONE APERTA)
Figura 11 - DETTAGLIO RUBINETTO DI SPURGO SERBATOIO
IOM_14479_2 (09.16) Pages 21/59

4.6 COLLEGAMENTI IDRAULICI
E’ necessario che il montaggio delle tubazioni di collegamento sia eseguito in ambiente pulito e non
polveroso. Il collegamento è da effettuarsi con tubi e raccordi del tipo e diametro definito dal costruttore
dell’i pia to. Per non trasmettere vibrazioni, le tubazioni devono essere opportunamente vincolate con
sufficiente numero di elementi di fissaggio. A e ta si he el o so dell’ese uzio e del collegamento
vengano rimossi eventuali tappi presenti sulle connessioni. Effettuare il flussaggio/lavaggio dell’i pia to
(velocità di flussaggio 5÷6mt/sec nelle tubazioni, olio 40°C) oppure utilizzare tubazioni già flussate. Tutti i
tubi di collegamento dalla centrale al cilindro dovranno essere realizzati in modo tale che siano evitati sifoni
e strozzature che impediscono u ’agevole flusso d’olio.
IOM_14479_2 (09.16) Pages 22/59

5 AVVIAMENTO
5.1 ADDETTI
Il personale addetto ad operare sull’i te o i pia to, deve possedere (oppure acquisire tramite adeguata
formazione ed addestramento) i requisiti di seguito indicati, ed essere, inoltre, a conoscenza del presente
manuale e di tutte le informazioni relative alla sicurezza:
 Cultura generale e tecnica a livello sufficiente per comprendere il contenuto del manuale ed interpretare
correttamente i disegni e lo schema idraulico (allegati 9.1 e 9.2)
 Conoscenza delle principali norme igieniche, antinfortunistiche e tecnologiche
 Sapere come comportarsi in caso di emergenza, dove reperire i mezzi di protezione individuali e come
usarli correttamente
I manutentori oltre alle caratteristiche sopracitate, devono avere una adeguata preparazione tecnica.
5.2 CONTROLLI PRELIMINARI

Prima della messa in funzione, è necessario eseguire una serie di verifiche e controlli allo scopo di
prevenire errori od incidenti durante la fase di messa in funzione:
 Verificare che la centrale non abbia subito danni durante la fase di installazione
 Verificare, con particolare cura, pannelli di comando, elettrici e tubazioni
 Controlla e l’esatto collegamento di tutte le fonti di energia esterne ed un adeguato
ie pi e to d’olio el se atoio
 Controllare che le valvole a sfera siano posizionate nel modo corretto secondo schema e il
disegno complessivo
 Co t olla e l’esatto pe o so delle tu azio i, ve ifi a do i pa ti ola odo he o i
siano restringimenti nei tubi, raggi di curvatura eccessivamente stretti nei flessibili
 Controllare che eventuali tubi flessibili non siano a contatto con componenti (catene, funi,
fonti di calore, ecc) in movimento, ed abbiano idonee protezioni contro la loro eventuale
rottura accidentale
 Controllare che tutti i raccordi sulle tubazioni siano ben serrati
 Verificare che siano soddisfatte tutte le condizioni richieste sul manuale
 Co t olla e la p e a i a dell’a u ulato e se o fo e a ua to sta ilito e p evede e
l’adegua e to utilizza do l’apposito st u e to VGU (verificatore/gonfiatore, vedi
scheda tecnica accumulatore)
IOM_14479_2 (09.16) Pages 23/59

5.3 MESSA IN FUNZIONE
Prima della messa in funzione della centralina, è assolutamente necessario consultare il

manuale e seguire tutte le istruzioni riguarda ti l’avvia e to e la sicurezza.
Si può iniziare la messa in funzione della centrale azionando ad impulsi il motore elettrico (controllare il
corretto senso di rotazione del motore) pe favo i e l’ades a e to o pleto della po pa.
Durante la fase di riempimento del circuito si deve p ovvede e allo spu go dell’a ia, la cui presenza è fonte
di disturbi di funzionamento e apida usu a dei o po e ti. L’a ia a hiusa elle tu azio i può esse e
eliminata allentando i raccordi o su apposite prese di spurgo se sono state preventivamente installate. Dopo
aver eseguito le operazioni di riempimento e di spu go dell’a ia, o t olla e il livello del fluido el se atoio
ed eventualmente rabboccare.
IOM_14479_2 (09.16) Pages 24/59

5.4 REGOLAZIONI/CONTROLLI
La centrale è collaudata al valore massimo di pressione nella nostra sede e le valvole sono state regolate
secondo i parametri richiesti. E’ o u ue e essa io pe iodi a e te (durante gli interventi di
manutenzione ordinaria) ve ifi a e l’effi ie za ed eve tual e te ripristinarne i valori stabiliti.
Pos. Funzione Intervento

-chiudere tutti i rubinetti pos. 351
-avviare il motore elettrico 956
COMPENSATORE -verificare sul manometro pos. 621° che la pressione non
545 A-B-C POMPA A PISTONI superi il valore di taratura della valvola stabilito (170 BARG)
ASSIALI Eventualmente regolare con la vite di registro posta sulla
valvola (vedere manuale di dettaglio pompa)
RIPETERE L’OPERAZIONE SU TUTTE E TRE LE POMPE (A-B-C)
VITE DI REGOLAZIONE
COMPENSATORE
Figura 12 - DETTAGLIO COMPENSATORE POMPA
IOM_14479_2 (09.16) Pages 25/59

Pos. Funzione Intervento
-Dep essu izza e l’i te o sistema
-Avvitare il verificatore gonfiatore OLAER (non fornito da
33 G-H-L Precarica accumulatore
REVA) e controllare che la precarica sia conforme a
schema
5.5 ARRESTO NORMALE
Vedere manuale quadro elettrico (non fornito da OLEDINAMICA REVA)
5.6 ARRESTO DI EMEREGENZA

5.7 RIPRISTINO
5.8 MESSA FUORI SERVIZIO

Per preservare la centrale dal lungo tempo di inattività, si consiglia di mettere il lucchetto
ell’i te utto e ge e ale pe evita e eve tuali a o issio i della e t ali a e di immagazzinarla
seguendo le istruzioni elencate nel par. 4.3.
IOM_14479_2 (09.16) Pages 26/59

6 MANUTENZIONE
6.1 STATO DI MANUTENZIONE, ADDETTI
È espo sa ilità dell’utilizzato e della e t alina assi u a e he l’attività di a ute zio e sia o dotta da
personale qualificato (vedi paragrafo 5.1) con modalità conformi alle leggi sanitarie e sulla sicurezza
includendo la valutazione dei rischi.
Le operazioni di manutenzione devono essere effettuate con la centrale oleodinamica nelle stato
indicato nella scheda di manutenzione programmata 6.7.
6.2 ISOLAMENTO ELETTRICO DELLA CENTRALE
Prima di procedere a ualsiasi a ute zio e o ligato io pe la si u ezza dell’ope ato e

isolare elettricamente la centrale. Prima di effettuare interventi di manutenzione può essere
necessario depressurizzare la centrale (vedi paragrafo 3.3, 6.7).
6.3 PRECAUZIONI PARTICOLARI
Nell’effettua e i lavo i di manutenzione o riparazione, è bene applicare quanto di seguito riportato:

 P i a di i izia e i lavo i, espo e u a tello IMPIANTO IN MANUTEN)IONE i posizio e
ben visibile
 Non utilizzare solventi o materiali infiammabili
 Prestare attenzione a o dispe de e ell’a ie te li uidi lu o-refrigeranti od il fluido
dell’i pia to
 Vista l’ubicazione della centrale, l’addetto alla a ute zio e deve prendere tutti gli
accorgimenti necessari per rendere sicura l’attività
 Prima di iniziare i lavori accertarsi che siano rispettate le raccomandazioni esposte nel
presente manuale.
IOM_14479_2 (09.16) Pages 27/59

6.4 PULIZIA
E’ e e p ovvede e saltua ia e te alla pulizia este a della e t ale e dei suoi componenti idraulici così da
poter permettere una facile localizzazione di eventuali perdite.
Durante il cambio dei filtri è consigliato pulire il fondo del serbatoio dove si possono essere depositati residui
di vario genere. Prima di richiudere l’o lò prestare particolare attenzione che o sia o las iati all’i te o
della e t ale ate iali est a ei fluidi, o te ito i, st a i o ua t’alt o sia stato utilizzato pe la pulizia e la
manutenzione).
6.5 MANUTENZIONE ORDINARIA
Un impianto oleodinamico, ben installato e curato nella fase di montaggio e messa in servizio, assicura una
lunga durata senza inconvenienti e non necessita di particolari manutenzioni. È assolutamente necessario
controllare periodicamente la qualità e la pulizia del fluido che trasmette potenza per garantire l’affida ilità
di qualsiasi centrale oleodinamica. Si raccomandano le operazioni periodiche descritte sulla scheda 6.7.
Queste operazioni vanno eseguite nelle tempistiche indicate, il mancato rispetto di quanto richiesto esonera
il costruttore da qualunque responsabilità agli effetti della garanzia.
6.6 MANUTENZIONE STRAORDINARIA
La manutenzione straordinaria, comprende interventi che si effettuano in occasioni ed eventi eccezionali:

 Rotture componenti o guasti (vedi paragrafo 6.8)
 Revisioni di componenti usurati o danneggiati
I uesti asi lo stato della e t ali a sa à di ISOLAMENTO PER MANUTENZIONE e l’attività di fe o può
richiedere tempi di fermo piuttosto lunghi.
OLEODINAMICA REVA non è responsabile dei tempi di approvvigionamento di eventuali componenti
danneggiati, non è presente magazzino su tutte le parti centrale, si consiglia per questa ragione di
approvvigionare tali ricambi preventivamente per non incorrere in lunghi fermo impianto.
IOM_14479_2 (09.16) Pages 28/59

6.7 MANUTENZIONE ORDINARIA
Di seguito si segnalano le manutenzioni ordinarie della centrale, consultare i manuali di uso e
manutenzione della singola componentistica (forniti allegati) per conoscere la manutenzione
ordinaria da effettuare sui singoli componenti.
DESCRIZIONE STATO DELLA TIPO DI INTERVENTO TEMPISTICA
CENTRALINA
Verifica presenza In funzione Visivo esterno MENSILE
trafilamenti
Verifica livello visivo olio In funzione Visivo esterno SETTIMANALE
pos. 559
Sostituzione cartuccia In funzione Vedi scheda tecnica allegata. La centrale può 1)ogni cambio olio
filtro in mandata pos. essere lasciata in funzione scambiando i 2)segnalazione filtro
356 A-B rubinetti di selezione filtro 460 A-B intasato
3) ogni qualvolta il
pressostato 523
segnala caduta di
pressione monte-
valle filtro
Cambio olio Isolamento per Per una corretta manutenzione eseguire le Ogni 3000-4000ore
manutenzione seguenti operazioni: di funzionamento
● ap i e il tappo di a i o pos. 561
● ediante un pompa di travaso aspirare
l’olio p ese te el se atoio e i ette lo i
un serbatoio per lo stoccaggio/smaltimento
● posizio a e un contenitore sotto il
rubinetto pos. 351D, dopo aver rimosso il
tappo di protezione, aprire il rubinetto per
far svuotare completamente il serbatoio
● a se batoio vuoto prima di riempirlo è
buona norma effettuare la pulizia interna
smontando l’oblò.
● alla fi e di ueste ope azio i i o ta e
l’o lò, chiudere il rubinetto pos. 351D ed
effettuare il riempimento del serbatoio con
olio idoneo (vedi 4.5 per il tipo di olio).
IOM_14479_2 (09.16) Pages 29/59

Rabbocco fluido In funzione Tramite tappo di carico 561 In caso di minimo
livello
Controllo precarica Isolamento per Tramite il verificatore gonfiatore OLAER semestrale
azoto accumulatori pos. manutenzione
33 G-H-L
Controllo taratura Isolamento per Vedi par. 5.4 annuale
compensatore pompa manutenzione
6.8 SCHEDA RICERCA GUASTI

IPOTESI PER
INCONVENIENTI CAUSE PROBABILI
L'INTERVENTO
PRESSIONE INSUFFICIENTE 1) Valvola di max. pressione semi aperta a -Per pressione di taratura troppo bassa
b -Per usura delle sedi di tenuta
o caduta della pressione c -Per impurità sotto le sedi
rispetto al livello previsto nel d -Per rottura della molla
circuito 2) Pompa in difetto -Vedi punti da 5 a 11
3) Fughe interne eccessive a -Tenute usurate nei cilindri

b -Usura delle valvole
c -Viscosità dell'olio troppo bassa
4) Eccessive perdite di carico a -Viscosità dell'olio troppo alta

b -Insufficiente dimensionamento dei
passaggi dell'olio
c -Passaggi dell'olio parzialmente istruiti
POMPA IN DIFETTO 5) Aspirazione strozzata a -Rubinetto in aspirazione chiuso

b -Tubo di aspirazione ostruito
Per portata nulla o scarsa
rispetto ai valori normali 6) Entrate d'aria a -Nella presa di aspirazione nel serbatoio
b -Nei raccordi in aspirazione
c -Nella tenuta sull'albero della pompa
d -Per aspirazione di olio con schiuma
7) Viscosità dell'olio troppo alta - Vedi le prescrizioni per la pompa
8) Guasti interni nella pompa a -Guarnizioni interne rotte

b -Palette, piattello o pistoni incollati
9) Pompa eccessivamente usurata - Pompa da sostituire
IOM_14479_2 (09.16) Pages 30/59

POMPA RUMOROSA 10) Cavitazione a -aspirazione strozzata: vedi punto 5
b -Viscosità alta: vedi punto 7
in modo anormale
11) Entrata d'aria - Vedi punto 6
12) Usure interne - Giochi eccessivi nei supporti
13) Vibrazioni dell'impianto - Risonanze, ecc.
SURRISCALDAMENTO 14) Fughe interne eccessive - Vedi punto 3
Cioè sopraelevazione della 15) Eccessive perdite di carico - Vedi punto 4
temperatura dell'olio oltre il

16) Capacità olio insufficiente - Aggiungere olio in serbatoio
limite prudenziale di 50°C -
60°C
MOVIMENTI ERRATI 17) Aria nel circuito a -Sfiatare le bocche d'aria nei punti alti
b -Eliminare le entrate d'aria. Vedi punto 6
degli organi azionati
idraulicamente rispetto al 18) Bloccaggio delle valvole -Valvole semi aperte per interposizione di
impurità
ciclo stabilito 19) Eccessive perdite di carico
-Vedi punto 4
USURA ECCESSIVA 20) Olio contenente abrasivi a -Olio troppo vecchio

b -Filtri inefficienti
Cioè eccessivamente rapida in
rapporto al tempo di effettivo 21) Insufficiente lubrificazione a -Olio di qualità scadente
b -Olio troppo fluido alla temp. d'esercizio
esercizio al servizio
22) Pressione d'esercizio elevata - Sforzi anormali sugli alberi e sugli steli
23) Accoppiamenti difettosi - Sforzi anormali sugli alberi e sugli steli
IOM_14479_2 (09.16) Pages 31/59

7 RICAMBI
7.1 ELENCO RICAMBI CONSIGLIATI
Non potendo stabilire a priori il tempo di vita di un componente idraulico, si consiglia l’utilizzato e della
centrale di avere a disposizione un kit minimo di ricambi dei componenti la cui rottura può causare un fermo
impianto.
Kit ricambi completi consigliati di scopo fornitura OLEODINAMICA REVA
QTY Descrizione Pos. schema
1 ASSIEME MOTORE-POMPA 965+545+35+36
4 CARTUCCIA FILTRO MANDATA 356
2 FILTRO COMPLETO MANDATA 356
1 FILTRO COMPLETO RAFFREDDAMENTO 359
4 MANOMETRI 621
1 TEMPERATURE TRANSDUCER 565
1 ELECTRIC LEVEL TRANSMITTER 562
1 DIFFERENTIAL ELECTRIC PRESSURE SWITCH 523
1 3/2 HAND ACTUATED VALVE 460
1 RELIEF VALVE 395 A-B-C
1 RELIEF VALVE (PED) 395 G-H-L
1 CHECK VALVE 379 F
1 CHECK VALVE 379 D
1 CHECK VALVE 379 A-B-C
4 STOP VALVE 351 R-M
Si consiglia di re-i teg a e la s o ta dopo l’uso dei componenti dopo una manutenzione o sostituzione.
Si rammenta che solo un tecnico qualificato può effettuare riparazioni sulla macchina.
E’ ui di o sigliato l’i te ve to del centro assistenza tecnica del costruttore, che è disponibile con personale
qualifi ato, att ezzatu e ido ee, o h o pa ti di i a io o igi ali. Pe effettua e l’o di e di i a i
sopra-elencati, seguire le istruzioni elencate al paragrafo 1.2 .
Si precisa che il costruttore non ha alcun dovere di predisporre ricambi per interventi in
urgenza anche durante il periodo di garanzia della centrale; pertanto si suggerisce di
approvvigionare per tempo il necessario per ogni emergenza
IOM_14479_2 (09.16) Pages 32/59

8 DEMOLIZIONE
8.1 SMALTIMENTO OLIO
“i p e isa he il fluido id auli o dell’i pia to deve esse e s altito i a o do alla Direttiva 2008/98/CE e
alle leggi vigenti.
8.2 DEMOLIZIONE DELLA CENTRALE
All’atto della de olizio e e essa io sepa a e le pa ti i ate iale plasti o e componentistica elettrica,
che devono essere inviati a raccolte differenziate nel rispetto della normativa vigente. Per quanto concerne
la massa metallica della macchina, è sufficiente la suddivisione tra le parti in acciaio e quelle di altri metalli o
leghe, per il corretto invio al riciclaggio per fusione.
IOM_14479_2 (09.16) Pages 33/59

9 ALLEGATI
9.1 SCHEMA FUNZIONALE, DISTINTA 19.011.262
IOM_14479_2 (09.16) Pages 34/59

PNEUMATIC CONNECTION NO. 16 P CONNECTIONS NO. ? T CONNECTIONS NITROGEN TEST ANO (REVA OWG. 19.011.262 PAG.1 /2)
1" SAE 3000 1-1 /4" SAE .3000 RECHARGE CONNECTIONS
HYDRAULIC CONNECTION NO. 6 P CONNECTIONS NO. 16 T CONNECTIONS
33 HYORAULIC ACCUMULATOR (BLAOOER TYPE)
1-1/4" SAE 3000 1" SAE 3000 106 PNEUMATIC FILTER
ELECTRIC CONNECTION 123 CHECK VALVE WITHOUT SPRING
267 PRESSURE TRANSOUCER
301 CABINET
: :- .~ .~ _--_ -=- -=- -=- ~ - .---u-.---2R

351 STOP VALVE
E. C.P. 954 352 NEEDLE VALVE
356 HYORAULIC FILTER
SUPPLY
ON-OFF
EMERGENCY
STOP
ps----3~1~ 359 HYORAULIC FILTER WITH BY-PASS ANO VISUAL INO.
- - - - - - 950H I
A - FILTER
tj] 9~A
950A
~
953A
- -
621A
- 267C
p
2678
i p
267A
i p
l
'"'" B -
C -
BY-PASS CHECK VALVE
CLOGGING VISUAL INOICATOR
352G 27A 379 CHECK VALVE
LOC-REM EMERGENCY 395 RELIEF VALVE
EMERGENCY RESET 352F '~ 352P 352N 352E'~ 460 3/2 HANO ACTUATED VALVE
RESET
~ [2:1 - - r-- --1] 523 OIFFERENTIAL ELECTRIC PRESSURE SWITCH (AOJUST. SETIING)
tj]
950G
953C
MAl N PUMPS ENABLING

- ~ - __::__----=-__::__ - + ----, 395RJ
351H
542
545
555
559
HYORAULIC ROTATING PUMP
VARIABLE OISPLACEMENT PUMP WITH PRESSURE CONTROL
OIL TANK
LEVEL GAUGE
A B c 460~\ITY l
561
562
OIL POURING PLUG WITH FILTER
ELECTRIC LEVEL TRANSMITTER
tj] tj] tj] l
l
352H 27B
565
570
TEMPERATURE TRANSOUCER
COOLER
9508 950C 9500 3 5 6 A 0 3568
Vos
Y L.,l,<(~
1 621 PRESSURE GAUGE
395~
MAl N COOLER l
624 CHECK VALVE
PUMP PUMP 352A ..... 3528 l
950 HAND OPERATED ELECTRIC SWITCH
A-B-C AUTO-MAN ON-OFF
rn
l l l 351L 951 HANO OPERATED ELECTRIC SWITCH (3 POSITIONS)
tj] tj] 114111-c,

4 6 DA f---il--J ~
l
l
953
954
PUSHBUTTON PANEL
ELECTRIC CONTROL PANEL
951 950E 950F l 956 ELECTRIC MOTOR
3521_ 27C
PUMP RUNNING 3s2c 1 l 959 SOCKET WITH MECHANICAL INTERLOCK
A B c COOLER l 379A 3798 379C 960 LAMP
® ® ® ® l
9600 9605
PUMP FAILURE
960T 960U
959 l
i
L _ 395i1:'-J
_
~i
A B c - HYDRAULIC POWER UNIT WORKING PRINCIPLE
395A -180 THE MAIN UNIT (MOTOR 956 + PUMP 545) IS SELECTED BY THE SWITCH 951 ANO
®
9608
®
960C
®
9600 ""'- CONTINUOUSLY RUN TO MAINTAIN THE PRESSURE INSIOE ACCUMULATORS 33 WITHIN
A RANGE SET BY THE PUMPS 545 PRESSURE CONTROL OEVICE.
3958
l
MOTOR THERMAL PROTECTION MANAGEMENT OF BACKUP ANO EMERGENCY MOTOR/PUMP UNITS
A B c L IN CASE OF OIL LOW PRESSURE THE BACKUP MOTOR/PUMP UNIT IS STARTED TO
HELP THE MAIN ONE. THE MAIN PUMP FAILURE ALARM IS ACTIVATED ANO THE
® ® ® f---- RELEVANT LAMP 960A/B/C SWITCHES ON.
960E 960F 960G
c::: f - - - - 20 IF THE PRESSURE RETURNS TO NORMAL VALUES THE BACKUP MOTOR/PUMP UNIT
IS STOPPED ANO THE FAILURE ALARM IS OEACTIVATED, THE LAMP STAYS SWITCHED
OIL OIL ON UP TO THE RESET PUSHBUTTON 9538 IS PRESSED.
CLOGGED HIGH LOW-LOW IF THE OIL PRESSURE REMAINS LOW THE EMERGENCY MOTOR/PUMP UNIT IS
FILTER TEMPERATURE LEVE L STARTED TO HELP THE MAIN ANO BACKUP ONES. THE BACKUP PUMP FAILURE
®
960H
®
960L
®
960M
ALARM IS ACTIVATED ANO THE RELEVANT LAMP 960A/B/C SWITCHES ON.
IF THE PRESSURE RETURNS TO NORMAL VALUES THE BACKUP ANO EMERGENCY
MOTOR/PUMP UNITS ARE STOPPED ANO THE FAILURE ALARMS ARE OEACTIVATED,
THE LAMPS STAY SWITCHED ON UP TO THE RESET PUSHBUTTON 9538 IS PRESSED.
IF THE PRESSURE REMAINS LOW ALL THE MOTOR/PUMP UNITS ARE STOPPED. THE
EMERGENCY PUMP FAILURE ALARM IS ACTIVATED ANO THE RELEVANT LAMP
960A/B/C SWITCHES ON.
AN OPERATOR LOCAL INTERVENTION IS REQUIRED TO VERIFY THE STATUS OF
ELECTRO HYORAULIC POWER UNIT ANO ALLOW ITS START BY PRESSING THE RESET
PUSHBUTTON 9538.
MOTOR/PUMP UNITS AUTOMATIC STOP

THE MOTOR/PUMP UNITS ARE STOPPED IN THE FOLLOWING CASES:
-
- OIL LOW-LOW LEVEL. THE RELEVANT ALARM IS ACTIVATED ANO THE LAMP 960M
SWITCHES ON.
~B 31 ( - OIL HIGH TEMPERATURE. THE RELEVANT ALARM IS ACTIVATED ANO THE LAMP 960L
29c(
~
SWITCHES ON.
MAIN ELECTRICAL SUPPLY
400 VAC 3ph 50 Hz
AUXILIARY ELECTRICAL SUPPLY
110 VOC
ANALOGUE SIGNALS 4-20 mA:
- OIL PRESSURE L ~~ - - - ~~ -
JOB
____.......
- ~~
---
9560
542
-- J
M
l
- MOTOR THERMAL PROTECTION INTERVENTION. THE RELEVANT ALARM IS ACTIVATED
ANO ONE OF THE LAMPS 960E/F /G SWITCHES ON.
AN OPERATOR LOCAL INTERVENTION IS REQUIRED TO VERIFY THE STATUS OF
ELECTRO HYORAULIC POWER UNIT ANO ALLOW ITS START BY PRESSING THE RESET
PUSHBUTION 9538.
IN CASE OF MOTOR THERMAL PROTECTION INTERVENTION THE RESET OPERATION
- OIL TEMPERATURE L-----------------------------------~ MUST BE PERFORMED INSIDE THE ELECTRIC CONTROL PANEL 954.
- OIL LEVEL
OIGITAL SIGNALS
- PSL: OIL LOW PRESSURE
- PSLL' OIL LOW-LOW PRESSURE
SET 565 TEMPERATURE TRANSDUCER Rev. Dote Approved
- PSH A/B/C: MOTOR/PUMP RUNNING 5(Rml 31/08/16 By EM Description AS BUILT AFTER FINAL TEST
- POSH: CLOGGED FILTER
- LSLL: OIL LOW-LOW LEVEL 33"C! START 956D Rev. 4(REVA) Dote 10/DB/16 By NV Approved Description AS BUILT
- CUMULATIVE ALARM INCLUOING' 30"C j STOP 956D
- 400 VAC SUPPLY FAILURE Rev. 3(REVA) Dote 16/03/16 By NV Approved Description UPDATE OIAGRAM ANO ADDED PART LIST
- MANUAL CONTROL ENABLED
55"C! ALARM HIGH TEMPERATURE (STOP PUMP)
-
-
PUMPS FAILURE
MOTOR THERMAL PROTECTION TRIPPED SET 562 LEVEL TRANSMITIER
TAG Rev. 2 Dote DS/03/16 By Approved Description AOOED ITEMS 2678, 352N, 267C, 352P, 950H, 960R,
959, 110 VDC AUXILIARY SUPPLY.
- CLOGGED FILTER CFI-001 Rev. Dote By Approved GUO Oescription AOOED ITEMS 953C, 950F G, 395G H L, 3790, TAG,
- OIL HIGH TEMPERATURE MAX VISUAL OIL LEVE L ~ 100% 1 16/02/16 GF PUMP ORAIN ANO ELECTRICAL HEATER CONNECTIONS
- OIL LOW LEVEL MIN VISUAL OIL LEVEL ~ 4%
CFI-002
- OIL LOW PRESSURE Drowing Number
- OIL LOW-LOW PRESSURE MIN VISUAL OIL LEVEL +50mm ~ 14% (STOP PUMP)
ELECTRO HYDRAULIC SLAPZ030
j0
ONE PUMP: 601t/1' WITH 155BAR
POWER UNIT File SLAPZ030
TWO PUMP: 12Dit/1' WITH 155BAR
THREE PUMP: 1801t/1' WITH 155BAR BIFFI OPERATING DIAGRAM By GF
Dote 1 7/12/1 5
Approved GUD
(REVA DWG. 19.011.262 PAG.2/2)
352 F 1 NEEDLE VALVE FT2290-12 TOGNELLA

352 p-B-C-[ 7 NEEDLE VALVE 060-BB-DLN-T ( 1/ 4"NPTF -1/ 4"NPTF) IN ORA
E-P-N
351 RDI .. 16 STOP VALVE (T UNE 1"SAE3000) PKH-DN 10-442A ( -40') Cod.94904-20-401-62544 MHA/REVA
... RI6 +LOCKING DEVI CE DWG. l 9.102.851
960 R1 LAMP INCLUDED IN POS. 954 BIFFI 351 POI .. 16 STOP VALVE (P LI NE 1"SAE300) PKH-DN 10-442A ( -40') Cod.94904-20-401-62544 MHA/REVA
959 - 1 SOCKET WITH MECHANICAL INTERLOCK INCLUDED IN POS. 954 BIFFI ... PI6 +LOCKING DEVI CE DWG. l 9.102.851
956 D 1 ELECTRIC MOTOR INCLUDED IN POS. 570 351 NOI .. 6 STOP VALVE(T UNE 1"1/4SAE3000) PKH-DN10-442A ( -40') Cod.94904-20-401-62544 MHA/REVA
956 A-B-C 3 ELECTRIC MOTOR Cod. 3GAA 202 031-ADG ABB ... N06 +LOCKING DEVI CE DWG. 19.102.851
M3AA 200MLA 4 B3/B5 20,5Kw 4POLI 400V/D/50Hz 351 MDI .. 6 STOP VALVE(P UNE 1"1/4SAE3000) PKH-DN10-442A ( -40') Cod.94904-20-401-62544 MHA/REVA
IP65, HEATER 230/50 ... M06 +LOCKING DEVI CE DWG. l 9.102.851
954 - 1 ELECTRIC CONTROL PANEL Cod. 2340000980 BIFFI 351 G-H-L 3 STOP VALVE PKH-DN 10-442A ( -40') MHA
950 H 1 HAND OPERATED ELECTRIC SWITCH INCLUDED IN POS. 954 BIFFI 351 D 1 STOP VALVE MONOBLOCK 3/ 4"+PLUG 3/ 4" COMER/EFFEBI
621 B 1 PRESSURE GAUGE 233.50DN63.0/1 6BAR/PSI.I / 4"GASrod WIKA 351 A-B-C- T 4 STOP VALVE MONOBLOCK 1"l/ 4 +MECHANICAL BLOCK COMER/EFFEBI
FILLING SILICONIC FLUID; SAFETY GLASS 301 - 1 CABINET DWG. 19.373.017 REVA
ALL IN OX AISI31 6; ACCURACY CLASS l ,6 267 A-B-C 3 PRESSURE TRANSDUCER 2088G P/1 0-276BAR 4-20mA (8960298305) ROSEMOUNT /BIFFI
621 A 1 PRESSURE GAUGE 233.50DN 100.0/315BAR/PSI1 /2"GASrod WIKA 123 - 1 TANK PROTECTION VALVE DWG. 19.102.830 (SET 0.15BAR) REVA
FILLING SILICONIC FLUID; SAFETY GLASS 106 -
1 PNEUMATIC FILTER INCLUDED IN POS. 561 REVA
ALL INOX AISI31 6; ACCURACY CLASS 0,5 36 A-B-C 3 ELESTIC JOINT RTX42 55 +RTX42 32 +RTX42 92 T KTR
570 - 1 COOLER LOC3-016-4-D-C MA(3,5KW 4Poli 400V/50Hz PARKER 35 A-B-C 3 COUPLING BELL PK400/4/3 KTR
565 - 1 TEMPERATURE TRANSDUCER TR1 0-B-ZZZ +TW45 WIKA 33 G-L-H 3 HYDRAULIC ACCUMULATOR EHV50/330/90-PED-Po=88BAR-HNBR(APSII 0500880) OLAER/BI FFI
562 - 1 ELECTRIC LEVEL TRANSMITTER LCT S52.05 670/750 S.50.GS.I1 02.R VAL CO 32 A-B 2 FLEXIBLE PIPES COOLER SAE100R1/492-16/DN25 PARKER
561 -
1 OIL POURING PLUG WITH FILTER TA70.B1 OAA.P03 (SET 0,2BAR) MP FILTRI FD l" IN OX - FD l" IN OX L~2200
559 - 1 LEVEL GAUGE DWG. 19.102614/500/MFO REVA 31 - 1 FLEXIBLE PIPES PUMP SUCTION SAE100R4/811-24/DN40 L~11 00 PARKER
555 - 1 OIL TANK DWG. 19.373.020 REVA WITH CLAMP òSI INOX
545 A-B-C 3 HYDRAULIC DISPLACEMENT PUMP PV046R1 K1T1 NMMC PARKER 30 A-B-C 3 FLEXIBLE PIPES PUMP DRAIN SAE100R1/492-12/DN20 PARKER
(FLOW RATE ;>601t/l' WITH ISSBAR) FD 3/ 4" IN OX - F90 3/ 4" INOX L~l450
(SET PRESSURE COMPENSATOR 170BAR) 29 A-B-C 3 FLEXIBLE PIPES PUMP SUCTION SAE100R4/811-24/DN40 L~2300 PARKER
542 - 1 HYDRAULIC ROTATING PUMP INCLUDED IN POS.570 WITH CLAMP ò51 INOX
523 - 1 DIFFERENTIAL ELECTRIC PRESSURE SWITCH 162P48C6 +BOX (SET 11BAR!) ITT -NEODYN 28 A-B-C 3 FLEXIBLE PIPES PUMP DEUVERY SAE100R2/462-12/DN20 PARKER
460 A-B 2 3/2 HAND ACTUATED VALVE PK3-DN20-4424-SB58 (-40) MHA FD 3/ 4" IN OX - F90 3/ 4" INOX L~l450
395 G-H-L 3 RELIEF VALVE (PED) MVPX4C (SET 207BAR) (TUV /CE) HAWE 27 A-B-C 3 FIXED FLOW REGULATOR 1/16"NPT WITH HOLE 01.2 REVA
395 A-B-C 3 RELIEF VALVE LPIJ0/0-N (SET 180BAR l) EXTERNAL IN OX FLUCOM 26 -
1 ACCUMULATOR MANIFOLD DWG. 19.145.750 REVA
379 F 1 CHECK VALVE CAE50/Z (SET 8BAR) FLUCOM 25 - 1 LEVER FOR BALL VALVE DWG. 19.102.829 REVA
379 D 1 CHECK VALVE FT2257 /6 1OONPT (SET 0,35BAR) TOGNELLA 24 - 1 FILTER MANIFOLD DWG. 19.145.749 REVA
379 A-B-C 3 CHECK VALVE CAE50/P FLUCOM 23 A-B 2 OUTLET MANIFOLD DWG. 19.145.748 REVA
359 - 1 HYDRAULIC FILTER FRI250-BFF1 A06NP01 +V6XF MP FILTRI 22 - 1 BY-PASS MANIFOlD FOR HEART EXCHANGE DWG. 19.145.751 REVA
356 A-B 2 HYDRAULIC FILTER FHB320-2-S-F-F-1A-10H+PLUG T2F MFO MP FILTRI 21 -
1 PRESSURE GAUGE MANIFOLD DWG. 19.145.761 REVA
352 M 1 NEEDLE VALVE INCLUDED IN POS.559 20 - 1 PRESSURE MANIFOLD DWG. 19.145.760 REVA
352 l 1 NEEDLE VALVE FT2290-14 TOGNELLA 18 - 1 TOP DRAIN MANIFOLD DWG. 19.145.763 REVA
352 G-H-L 3 NEEDLE VALVE DWG. 49.020.247 REVA 17 - 1 SIDE DRAIN MANIFOLD DWG. 19.145.762 REVA
Pos. Code N. Denominotìon Description Firm Pos. Code N. Denominotion Description Firm
Rev. 5(REVA) Dote 31/08/16 By EM Approved Description AS BUILT AFTER FINAL TEST
Rev. 4(REVA) Dote 10/0B/16 By NV Approved Description AS BUILT
Rev. J(REVA) Dote 16/03/16 By NV Approved Description UPDATE DIAGRAM ANO ADDED PART LIST
Rev. Dote DS/03/16 By Approved Oescription ADDED ITEMS 2678, 352N, 267C, 352P, 950H, 960R,
2 959, 110 VDC AUXILIARY SUPPLY.
Rev. By Approved GUD Oescription ADDED ITEMS 953C, 950F G, 395G H L, 3790, TAG,
1 Dote 16/02/16 GF PUMP DRAIN AND ELECTRICAL HEATER CONNECTIONS
m Drowing Number
o Poth T'\SCH
o
o
N ELECTRO HYDRAULIC SLAPZ030
D
u
o
POWER UNIT File SLAPZ030 Dote l 7/12/ l 5
2
"
<(
BIFFI -OPERATING DIAGRAM- By GF Approved GUD
Commessa 16/00129/C : 1 & 2 Data 29/8/16
Componente Impostazioni generali Relè 1

Riferimenti SLAPZ030 Disp. Disp. Err. Off.
(SEANA018) IN type Range Unit Dec.p LO HI Rel.un R1.func R1.cont R1.Stp Act. Dir R1.Hy Act On.Del Del
Txt3 Txt4 Txt 11 Txt 12 Txt 13 Txt 14 Txt 15 Txt 19 Txt 20 Txt 21 Txt 22 Txt 23 Txt 24 Txt 25 Txt 26
Trasmettitore di Pressione 267A
(131Z2) CURR 4/20ma bar 1111 0 276 DISP SETP NO 110 INCR 1 / 0 0
Trasmettitore di Livello 562

(132Z2) CURR 4/20ma % 1111 -30 115 DISP SETP NC 4 DECR 0 / 0 0
Trasmettitore di Temperatura 565

(133Z2) CURR 4/20ma C° 111.1 -35 100 DISP SETP NC 33 INCR 3 / 0 0
Componente Relè 2 Analogica uscita

Riferimenti SLAPZ030 Act. Err. Off. Out. Out.
(SEANA018) R2.func R2.cont R2.Stp Dir R2.Hy Act On.Del Del Anal.out Range Error Out.L0 Out.HI
Txt 19 Txt 20 Txt 21 Txt 22 Txt 23 Txt 24 Txt 25 Txt 26 Txt 36 Txt 37 Txt 38 Txt 41 Txt 42
Trasmettitore di Pressione 267A
(131Z2) SETP NO 150 INCR 15 / 10 sec 0 CURR 4/20ma / / /
Trasmettitore di Livello 562

(132Z2) SETP NC 14 DECR 0 / 0 0 CURR 4/20ma / / /
Trasmettitore di Temperatura 565

(133Z2) SETP NC 55 INCR 5 / 0 0 CURR 4/20ma / / /
ENEL GP - Cerro Pabellon Project - BIFFI 15/1981
Logica gestione pompe su centrali CFI
Rev. 01 - Data 26/08/2016
Pompa PRINCIPALE AVVIATA
Pompa RISERVA FERMA
1
Pompa EMERGENZA FERMA
Portata erogata 62,5 l/min a 155 barg (sui manifold esterni)
Portata richiesta dal 25% delle 28 utenze con tempo manovra 15 secondi = 37,9 l/min
2 Portata richiesta da drenaggio delle 28 utenze 7 l/min
Portata totale richiesta = 37,9 + 7 = 44,9 l/min
3 Portata richiesta SUPERA la portata erogata da pompa/e AVVIATE
4 Pressione erogata SCENDE a 135 barg
Lampada di segnalazione OIL LOW PRESSURE ACCESA su fronte quadro.
Lampada di segnalazione PUMP FAILURE PRINCIPALE ACCESA su fronte quadro.
5 Segnale PSL ATTIVO.
Segnale GUASTO POMPE ATTIVO in ALLARME QUADRO cumulativo.
Segnale OIL LOW PRESSURE ATTIVO in ALLARME QUADRO cumulativo.
Pompa RISERVA AVVIATA
Pompa EMERGENZA FERMA Portata totale richiesta = 37,9 + 7 = 44,9 l/min
Portata erogata 120 l/min a 152,5 barg (sui manifold esterni)
Pressione erogata RISALE a 150 barg
entro 1 minuto da AVVIAMENTO pompa di RISERVA
ATTENZIONE: aggiundo un ritardo di 10 secondi sul consenso allo spegnimento pompa di
7
RISERVA anche se raggiunta pressione erogata di 150 barg. (Richiesta agg. da ENEL)
Tempo di risalita da 135 a 150 barg = 25 (ipotizzato)
con pompe PRINCIPALE + RISERVA AVVIATE
Pompa RISERVA FERMA
8 Portata richiesta SUPERA la portata erogata da pompa/e AVVIATE
Pompa EMERGENZA FERMA
Premere pulsante 953B ALARM RESET per ottenere:
Pressione erogata NON RISALE a 150 barg
Lampada di segnalazione OIL LOW PRESSURE SPENTA su fronte quadro.
entro 1 minuto da AVVIAMENTO pompa di RISERVA
9 Lampada di segnalazione PUMP FAILURE PRINCIPALE SPENTA su fronte quadro.
ATTENZIONE: aggiundo un ritardo di 10 secondi sul consenso allo spegnimento pompa di
Segnale PSL ANNULLATO.
RISERVA anche se raggiunta pressione erogata di 150 barg. (Richiesta agg. da ENEL)
Segnale GUASTO POMPE ANNULLATO in ALLARME QUADRO cumulativo.
Lampade di segnalazione PUMP FAILURE PRINCIPALE + RISERVA ACCESA
10 su fronte quadro.
Segnale PSL ATTIVO.
Pompa RISERVA AVVIATA
Pompa EMERGENZA AVVIATA Portata totale richiesta = 37,9 + 7 = 44,9 l/min
Portata erogata 180 l/min a 145 barg (sui manifold esterni)
Pressione erogata RISALE a 150 barg
entro 10 minuti da AVVIAMENTO pompa di EMERGENZA
12
Tempo di risalita da 135 a 150 barg = 17 secondi (ipotizzato)
con pompe PRINCIPALE + RISERVA + EMERGENZA AVVIATE
Pressione erogata NON RISALE a 150 barg Pompa RISERVA FERMA
13
entro 10 minuti da AVVIAMENTO pompa di EMERGENZA Pompa EMERGENZA FERMA
Premere pulsante 953B ALARM RESET per ottenere:
Lampada di segnalazione OIL LOW PRESSURE SPENTA su fronte quadro.
Lampade di segnalazione PUMP FAILURE PRINCIPALE + RISERVA SPENTA
14 Portata richiesta SUPERA o EQUIPARA la portata erogata da pompa/e AVVIATE
su fronte quadro.
Segnale PSL ANNULLATO.
Segnale GUASTO POMPE ANNULLATO in ALLARME QUADRO cumulativo.
15 Pressione erogata SCENDE a 110 barg oppure TERMINA il tempo di attesa impostato
Lampada di segnalazione OIL LOW-LOW PRESSURE ACCESA su fronte quadro
Lampade di segnalazione PUMP FAILURE PRINCIPALE + RISERVA + EMERGENZA
16 ACCESA su fronte quadro.
Segnale PSL ATTIVO.
Segnale PSLL ATTIVO.
Pompa PRINCIPALE FERMA
Pompa RISERVA FERMA
17 Pompa EMERGENZA FERMA
Portata erogata 0 l/min a 0 barg
Centrale CFI FUORI SERVIZIO
ENEL GP - Cello Parbellon Project Rev. 01
14/03/2016
BIFFI 15/1981 - HPUs + Actuators - Load List
Device Device Total
Equipment TAG Diagrams Device description Nominal voltage/power
no. quantity consumption
Nominal voltage = 400 VAC 3ph 50 Hz
956 TEFC, 3-phase,
3Nominal power = 30,0 kW each 65,4 kW
A-B-C squirrel cage induction motor
Real power = 20,5 kW each
956 TEFC, 3-phase, Nominal voltage = 400 VAC 3ph 50 Hz
1 3,5 kW
D squirrel cage induction motor Nominal power = 3,0 kW
Nominal voltage = 230 VAC 1ph 50 Hz
960R Iternal light by LED lamp 1 0,018 kW
Operating Nominal power = 18 W
Common
SLAPZ030 Nominal voltage = 230 VAC 1ph 50 Hz
CFI 959 Socket with mech. interlock 1 3,7 kW
CFI-001 Max current = 16 A
Power
CFI-002 Wiring Required power from 400 VAC 3ph 50 Hz main supply 72,6 kW
Packs
SEANA018 Electrical control panel Nominal input voltage = 110 VDC
954 including accessories and 1 Nominal output voltage = 24 VDC 0,96 kW
instruments Max output current = 20 A
Required power from 110 VDC auxiliary supply 0,96 kW
267 Nominal voltage = 24 VDC
Pressure transmitter 1 1W
B-C Nominal power = 0,5 W each
Required power from 24 VDC instrument supply 1W
TEFC, 3-phase, Nominal voltage = 400 VAC 3ph 50 Hz
956 1 1,81 kW
squirrel cage induction motor Nominal power = 1,5 kW
Required power from 400 VAC 3ph 50 Hz main supply 1,8 kW
Nominal voltage = 24 VDC
ECU1000 Electronic postioner 1 35 W
Nominal power = 35 W
Proportional solenoid valve 2 51 W
A-B Nominal power = 51 W
Operating
PV-0504C SLASE006 Stay-put solenoid valve 1 33 W
C Nominal power = 33 W
PV-0504F
PV-0504J Wiring Position transmitter 1 0,5 W
E.P.T. Nominal power = 0,5 W
SEAKM006
Required power from 110 VDC auxiliary supply 120 W
ESD solenoid valve 2 80 W
A-B Nominal power = 40 W each
Required power from 110 VDC ESD supply 80 W
ECU1000 Position control signal 1 0,5 W
Nominal power = 0,5 W
Required power from 24 VDC instrument supply 0,5 W
LV-0301C Nominal voltage = 24 VDC
LV-0301F ECU1000 Electronic postioner 1 35 W
Nominal power = 35 W
LV-0301J
LV-0300A
LV-0300B 585 Proportional solenoid valve 1 50 W
Actuators Nominal power = 50 W
LV-0300D
LV-0300E
LV-0300G 424 Nominal voltage = 110 VDC
Stay-put solenoid valve 1 40 W
LV-0300H C Nominal power = 40 W
LV-0006A
LV-0006B 41 Nominal voltage = 24 VDC
Position transmitter 1 0,5 W
PV-0206 Operaring E.P.T. Nominal power = 0,5 W
PV-0205 SLAHE002
PV-0201C SLAHB005
Required power from 110 VDC main supply 127 W
PV-0201F
PV-0201J Wiring
FV-0306 SEAKM004 424 Nominal voltage = 110 VDC
PV-0508C ESD solenoid valve 2 80 W
A-B Nominal power = 40 W each
PV-0508F
PV-0508J
LV-0310C Required power from 110 VDC ESD supply 80 W
LV-0310F
LV-0310J
FV-0311C ECU1000 Position control signal 1 0,5 W
Nominal power = 0,5 W
FV-0311F
FV-0311J
LV-0016 Required power from 24 VDC instrument supply 0,5 W
FV-0005
_ENEL Cerro Parbellon - BIFFI 15-1981 - Load List.xlsx / List 01 Page 1 / 1

9.2 DISEGNO DI INGOMBRO 19.021.262
IOM_14479_2 (09.16) Pages 35/59

A2-14 SCREW M12x20 +WASHER A6-12 SCREW M10x25
+WASHER e30 (x2)
+NUT AUTOBLOCK M10
(FOR FIXING 3 ROOF AT THE FRAME)
MAIN DOOR FOR INLET OPERATOR DOORS FOR MOTOR PUMP MAINTENANCE
2639
2030
1030
20
PRESSURE LINE CONNECTION RETURN LINE CONNECTION
CUSTOMER ELECTRIC CABLE ENTRY (N 6 x 1 1/4" SAE3000)
(N 6 x 1 1/4" SAE3000)
(N 16 x 1" SAE3000) (N 16 x 1" SAE3000)
ELECTRIC CABLE PASSAGE
3950
A
INSTRUCTION FOR SUN SHADE ROOF ASSEMBLING:
B
A1-REMOVE SCREW M12 FROM THE TOP OFCABINET
(SEE PAGE 2)(14 PIECES)
A2-INSTALL SUN SHADE ROOF "B" AS IN DRAWING
WITH 4 BOLTS M12x20
C
A3-INSTALL SUN SHADE ROOF "A" AND HIS
5 BOLTS M12x20
A4-INSTALL SUN SHADE ROOF "C" AND HIS
2840
5 BOLTS M12x20
A5-INSTALL SCREW M8(x4) BETWEEN 3 SUN SHADE
ROOF TO OBTEIN ONE ROOF CONTINUOS
A6-TIGHTEN 12 BOLT M10x25
A B C
(REVA DWG. 19.021.262 PAG.1/3)

3 10.08.16 NV AS BUILT REVISED CAD ONLY
2 14.06.16 NV ADDED PART NUMBER MODIFICARE SOLO CON CAD
A5-4 SCREW M8x25
1 29.04.16 NV REVIDED LAY OUT
+2 WASHER Description
Rev. Date Drm Chkd
+NUT AUTOBLOCK M8 Drawing Number
ELECTRO HYDRAULIC 2112750000
scale date
POWER UNIT 1:25 16.03.16
drm chkd
ATTUATORI E SISTEMI DI CONTROLLO
VALVE ACTUATORS AND CONTROL SYSTEM -OVERAL DIMENSION- Nardone
BOLT-EYES M24 UNIONS AERATION FURNITURE WITH NETWORK
FOR LIFTING (OPENING HOLES MESH ~ 1mm 2) MOTOR PUMP SIDE
954 33G 624G 33H 624H 624L 33L
F G
2548
2500 (WITHOUT BOLT-EYES)

M10 FOR EARTH
F G 1700
INTERNAL SECTION: F-F 51 3160 51 426 1840 125
3262
FILTER MANIFOLD SEE PAG.3/3 379D 352F 621A 267C 352P 267B
A1-N 14 BOLTS M12x20 +WASHER

267A LOCATED ON THE TOP OF THE CABINET
TO ASSEMBLING SUN SHADE ROOF
(3 PIECES A+B+C SEE PAGE 1)
352N COOLER RETURN FILTER
SEE PAG.3/3
562 561
352E
559
545C 35C 36C 959C
ACCUMULATOR
MANIFOLD 352M
SEE PAG.3/3
545B 35B 36B 956B
351D
1700
545A 36A 35A 956A
565 351T 956D 542 570 351C 351B 351A
INTERNAL SECTION:G-G
3100 (4 HOLES 20)

960R
950H
959
(REVA DWG.19.021.262 PAG.2/3)
2 14.06.16 NV ADDED PART NUMBER MODIFICARE SOLO CON CAD
1 29.04.16 NV REVISED LAY-OUT

Rev. Date Drm Chkd Description
MAX OIL LEVEL (WITH EMPTY ACCUMULATOR)= 910lt Drawing Number
RETURN LINE PRESSURE LINE MINIMUM OIL LEVEL=515lt ELECTRO HYDRAULIC 2112750000
scale date
MANIFOLD MANIFOLD POWER UNIT 1:20 16.03.16
SEE PAG.3/3 drm chkd
SEE PAG.3/3 MASS (WITHOUT OIL)= ~ 4500Kg ATTUATORI E SISTEMI DI CONTROLLO
ACCUMULATOR MANIFOLD PRESSURE LINE MANIFOLD
351P04 351P03
P03 P04 351P02
P02 P07 P08 M01 M02 351P08 351P07

351M01 351P01
P01
P06 351P06
395G 395H 395L 351M02
P05
M03 351P05
352G 352H 352L P09 351M03
351P09
M04
351M04
P10 351P10
M06
P13 351M06
M05 351P13
P11 P12
P14 351P12 351P11 351P14
P16 351M05
P15
351G 351H 351L 351P16 351P15
COOLER RETURN FILTER

RETURN LINE MANIFOLD
621B R03 R04 351R04 351R03
351R02
R02 R07 R08 N01 N02 351R08 351R07
352I 351R01
R01 351N01
R06
351R06
351N02
R05
N03 351R05
R09 351N03
351R09
N04
359 351N04
R10 351R10
379F N06
R13
351N06 351R13
N05
R11 R12 351R12 351R11 351R14
R14 351N05
R15 R16
351R16 351R15
FILTER MANIFOLD
460A 460B 523
352C
352D
395C (REVA DWG.19.021.262 PAG.3/3)
379C
356A 356B
395B 2 14.06.16 NV ADDED PART NUMBER MODIFICARE SOLO CON CAD
379B 1 29.04.16 NV REVISED LAY-OUT
352B Rev. Date Drm Chkd Description
395A 352A Drawing Number
379A
ELECTRO HYDRAULIC 2112750000
scale date
POWER UNIT 1:7 16.03.16
drm chkd
9.3 DICHIARAZIONE CONFORMITA’ CABLAGGI
IOM_14479_2 (09.16) Pages 36/59

DICHIARAZIONE DI CONFORMITA'
Il sottoscritto MONTI PAOLO, responsabile tecnico della ditta Project Group s.r. l. , con sede in San Polo d'Enza (RE), Via Galilei Nr.l ,
partita iva Nr.00281040352, iscritta nel registro delle i mprese al Nr.125411 della C.C.LA.A. di Reggio Emilia, iscritta nel registro delle
imprese al Nr.8233 del tribunale di Reggio Emilia, esecutrice dell'impianto elettrico:
Disegno Nr: SEANA018

Commessa Nr: 16/00195/C
Numero di serie : 16/00195- 16/00129/C 1:2
Riferimento Cliente: Ordine 16284 Rif. Comm. 14479
Descrizione: Cablaggio utenze per bordo impianto

A servizio di:
Commissionato da : OLEODINAMICA REVA s.r.l.

Via lsacch i, 3
421 24 Reggio Emilia (RE)
DICHIARA
Che l' impianto elettrico oggetto della presente dichiarazione,

• E' stato real izzato conformemente alle disposizioni delle seguenti Direttive:
2004/108/CE Direttiva compatibilità elettromagnetica
2006/95/CE Direttiva bassa t ensione
In quanto per la realizzazione dell'impianto elettrico sopra citato sono st at e seguite le Norme:
• EN 60204-1:2006-06 (Sicurezza del macchinario- Equipaggiamento elettrico delle macchine parte 1: Regole generali ).
• EN 60204-1/A1:2009-02 (Sicurezza del macchinario- Equipaggiamento elettrico delle macchine parte 1: Regole genera li).
Allegati:
San Polo d'Enza 22/08/ 16
Il Dichiarante
PROJECT GROUP s.r.l.
Via G. Galilei. 1
42020 SAN POLO D'ENZA (RE)
Tel. 0522.873376 Fax 0522.873098
Cod. Fisc. o P IVA 00281040352
9.4 MANUALE MOTORE ELETTRICO ABB
IOM_14479_2 (09.16) Pages 37/59

ABB Motors Technical Data Sheet - DOL
jl 1111
and Generators
Project Location ,.,l· l·
Department/Author Customer name Customer ref_ ltem name
1,00002
Our ref_ Rev/Changed by Date of issue
Saving ident Pages
A 26/02/2016 untitled.xls 1(3)
No. Def init ion Dat a Un it Remarks
1 Produci TEFC~hase sguirrel caae in duction motor
2 Produci code 3GAA 202 031-A DG Cale. ref. 3GZF021020-329
3 Type/Frame M3AA 200MLA 4
4 Mounting IM2001 B35(foo t-nange)
5 Rated output PN 205 kW
6 Service factor 1
7 IYI:>e of duty S10EC1100%
8 Rated voltaqe UN 400 VD ± 5 % (lEC 60034- 1~
9 Rated frequency fN 50 Hz ± 2 % (IEC 60034- 1)
10 Rated s~eed nN 1486 r/min
11 Rated current IN 39 9 A
12 No-load current 18 6 A
13 Starting current 15&t, 10,2
14 Nominai torque T N 132 Nm -- No! within lE C 60034-12 design N,H
-
15 Locked rotor torque T s!TN 41
16 Maximum torque T wax!TN 44
17 Minimum torque T min/TN 32
18 Speed at minimum torque 1050 r/min
Load characteristics (IEC 60034-2- 1:2007) Load % Current A Efficiency % Power factor
19 PLL determi ned from residua! loss 100 39 9 94 1 o 79
20 75 32,4 93,8 o 73
21 50 26 2 92 o 61
22 Starl 408 o 47
23 Maximum starting !ime from hot 15 s
24 Maximum starting !ime from cold 27 s
25 lnsulation class l Tem~:>erature class -FI B
26 Ambient temoerature 40 oc
27 Altitude 4500 m.a.s.l.

28 Enclosure IP65
29 Cooling system IC411 self ventilated
30 8earing DE/NDE 6312-2ZIC3 • 6210-2ZIC3
31 Type of Grease
32 Sound pressure level (LP d8(A ) 1m) 63 d8(A ) at load
33 Moment of inertia J = Y. GD2 309 o ka-m2
34 8alancing
35 Vibration class
36 Position of terminai box TOQ_
37 Terminai box entries; no, dimens.
38 Number of power terminals
39 Direction of rotation CW orCCW
40 Total weight of motor 218 kg
41 Dimension drawing no.
42
43
44 - --
45
Ex-motors
46
47
48
Option Variant Codes l Definition
49 +002 Restami:>!D_g voltage, freguenc}! and outeut. continuous dU!J!
50 +009 IM 2001 fooUflange mounted, IEC flange, from IM 100 1 (835 from 8 3}
51 + 451 Heatina element 200-240V
52
53
54
55
Remarks:
Data based on situation 18/09/2015

Ali data subiect to tolerances in accordance with IEC
Guaranteed values on request
Motor Type: Document No:
Motor Dimension Print

M3AA 200 IM 2001 3GZV 102 028-C
A1.4782
Description: Three phase motor,
Unit: ABB AB, LV Motors, Sweden. Issued by: H Thorstenson Replaces:
Date: 2008-01-22 Approved by: N Jonsson Replaced by:
Customer Reference:
Low voltage motors
Installation, operation, maintenance and safety manual
Installation, operation, maintenance and safety manual............................................................................................ EN 3
Montage-, Betriebs-, Wartungs- und Sicherheitsanleitung ...................................................................................... DE 21
Manuel d’installation, d’exploitation, de maintenance et de sécurité ....................................................................... FR 41
Manual de instalación, funcionamiento, mantenimiento y seguridad ....................................................................... ES 61
Manuale d’installazione, funzionamento e manutenzione .......................................................................................... IT 81
Manual de instalação, operação, manutenção e segurança ..................................................................................PT 101
Installations-, driffts-, underhålls- och säkerhetsmanual ....................................................................................... SV 123
Asennus-, käyttö-, kunnossapito- ja turvallisuusohje .............................................................................................. FI 141
Kurulum, işletim, bakım ve emniyet kılavuzu ..................................................................................................... TR 159
More languages – see web site www.abb.com/motors&generators > Motors > Document library
Low voltage motors
Installation, operation, maintenance and safety manual
Contents
1. Introduction .................................................................................................................................5
1.1 Declaration of Conformity ....................................................................................................5
1.2 Validity .................................................................................................................................5
2. Safety considerations .................................................................................................................5
3. Handling .......................................................................................................................................6
3.1 Reception check..................................................................................................................6
3.2 Transportation and storage ..................................................................................................6
3.3 Lifting ..................................................................................................................................6
3.4 Motor weight .......................................................................................................................6
4. Installation and commissioning.................................................................................................7
4.1 General................................................................................................................................7
4.2 Motors with other than ball bearings ....................................................................................7
4.3 Insulation resistance check ..................................................................................................7
4.4 Foundation ..........................................................................................................................7
4.5 Balancing and fitting coupling halves and pulleys .................................................................7
4.6 Mounting and alignment of the motor ..................................................................................8
4.7 Radial forces and belt drives ................................................................................................8
4.8 Motors with drain plugs for condensation ............................................................................8
4.9 Cabling and electrical connections.......................................................................................8
4.9.1 Connections for different starting methods ...........................................................9
4.9.2 Connections of auxiliaries .....................................................................................9
4.10 Terminals and direction of rotation .......................................................................................9
5. Operation ..................................................................................................................................10
5.1 General..............................................................................................................................10
Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 3
6. Low voltage motors in variable speed operation .................................................................11
6.1 Introduction .......................................................................................................................11
6.2 Winding insulation..............................................................................................................11
6.2.1 Selection of winding insulation for ABB converters..............................................11
6.2.2 Selection of winding insulation with all other converters .....................................11
6.3 Thermal protection ............................................................................................................11
6.4 Bearing currents ................................................................................................................11
6.4.1 Elimination of bearing currents with ABB converters ...........................................11
6.4.2 Elimination of bearing currents with all other converters ......................................12
6.5 Cabling, grounding and EMC .............................................................................................12
6.6 Operating speed ................................................................................................................12
6.7 Motors in variable speed applications ................................................................................12
6.7.1 General ..............................................................................................................12
6.7.2 Motor loadability with AC_8_ _ – series of converters with DTC control...............12
6.7.3 Motor loadability with AC_5_ _ – series of converter ...........................................12
6.7.4 Motor loadability with other voltage source PWM-type converters ......................12
6.7.5 Short time overloads...........................................................................................13
6.8 Rating plates .....................................................................................................................13
6.9 Commissioning the variable speed application ...................................................................13
7. Maintenance ..............................................................................................................................14
7.1 General inspection .............................................................................................................14
7.1.1 Standby motors .......................................................................................................14
7.2 Lubrication ........................................................................................................................14
7.2.1 Motors with permanently greased bearings ........................................................14
7.2.2 Motors with regreasable bearings .......................................................................15
7.2.3 Lubrication intervals and amounts ......................................................................15
7.2.4 Lubricants ..........................................................................................................17
8. After Sales Support...................................................................................................................18
8.1 Spare parts........................................................................................................................18
8.2 Dismantling, re-assembly and rewinding ............................................................................18
8.3 Bearings ............................................................................................................................18
9. Environmental requirements ....................................................................................................18
10. Troubleshooting ........................................................................................................................19
4 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
1. Introduction 2. Safety considerations
The motor is intended for installation and use by qualified
NOTE!
personnel, familiar with health and safety requirements and
These instructions must be followed to ensure
national legislation.
safe and proper installation, operation and
maintenance of the motor. They should be brought Safety equipment necessary for the prevention of accidents
to the attention of anyone who installs, operates at the installation and operating site must be provided in
or maintains the motor or associated equipment. accordance with local regulations.
The motor is intended for installation and use by
qualified personnel, familiar with health and safety
requirements and national legislation. Ignoring these WARNING!
instructions may invalidate all applicable warranties. Emergency stop controls must be equipped with
restart lockouts. After emergency stop a new start
command can take effect only after the restart
1.1 Declaration of Conformity lockout has been intentionally reset.
The conformity of the end product according to Directive

2006/42/EC (Machinery) has to be established by the
commissioning party when the motor is fitted to the Points to be observed:
machinery. 1. Do not step on the motor.
2. The temperature of the outer casing of the motor
1.2 Validity may be hot to the touch during normal operation and
especially after shut-down.
These instructions are valid for the following ABB electrical 3. Some special motor applications may require additional
machine types, in both motor and generator operation: instructions (e.g. when supplied by frequency
converter).
series MT*, MXMA,
4. Observe rotating parts of the motor.
series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, 5. Do not open terminal boxes while energized.
M2V*/M3V*
in frame sizes 56 - 450.
There is a separate manual for e.g. Ex motors ‘Low voltage

motors for explosive atmospheres: Installation, operation
and maintenance and safety manual (3GZF500730-47)
Additional information is required for some machine types

due to special application and/or design considerations.
Additional manual is available for the following motors:

– roller table motors
– water cooled motors
– smoke extraction motors
– brake motors
– motors for high ambient temperatures
– motors in marine applications for mounting on open deck
of ships or offshore units
3. Handling Lifting eyebolts must be tightened before lifting. If needed,
the position of the eyebolt can be adjusted using suitable
washers as spacers.
3.1 Reception check
Ensure that proper lifting equipment is used and that the
Immediately upon receipt, check the motor for external sizes of the hooks are suitable for the lifting lugs.
damage (e.g. shaft-ends, flanges and painted surfaces)
and, if found, inform the forwarding agent without delay. Care must be taken not to damage auxiliary equipment and
cables connected to the motor.
Check all rating plate data, especially voltage and winding
connections (star or delta). The type of bearing is specified Remove eventual transport jigs fixing the motor to the
on the rating plate of all motors except the smallest frame pallet.
sizes.
Specific lifting instructions are available from ABB.
In the case of a variable speed drive application check
the maximum loadability allowed according to frequency
stamped on the motor’s second rating plate. WARNING!
During lifting, mounting or maintenance work, all
necessary safety considerations shall be in place
3.2 Transportation and storage and special attention to be taken that nobody will be
The motor should always be stored indoors (above subject to lifted load.
–20 °C), in dry, vibration-free and dust-free conditions.
During transportation, shocks, falls and humidity should
be avoided. In other conditions, please contact ABB. 3.4 Motor weight
Unprotected machined surfaces (shaft-ends and flanges) The total motor weight can vary within the same frame size
should be treated against corrosion. (center height) depending on different output, mounting
arrangement and auxiliaries.
It is recommended that shafts are rotated periodically by
hand to prevent grease migration. The following table shows estimated maximum weights
for machines in their basic versions as a function of frame
Anti-condensation heaters, if fitted, are recommended to material.
be used to avoid water condensing in the motor.
The actual weight of all ABB’s motors, except the smallest
The motor must not be subject to any external vibrations at frame sizes (56 and 63), is shown on the rating plate
standstill so as to avoid causing damage to the bearings.
Frame size Aluminum Cast iron Add.
Motors fitted with cylindrical-roller and/or angular contact for brake
bearings must be fitted with locking devices during Weight kg Weight kg
transport. 56 4.5 - -
63 6 - -
3.3 Lifting 71 8 13 5
80 14 20 8
All ABB motors above 25 kg are equipped with lifting lugs 90 20 30 10
or eyebolts. 100 32 40 16
112 36 50 20
Only the main lifting lugs or eyebolts of the motor should be
132 93 90 30
used for lifting the motor. They must not be used to lift the
160 149 130 30
motor when it is attached to other equipment.
180 162 190 45
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 200 245 275 55
fans) or terminal boxes must not be used for lifting the 225 300 360 75
motor. Because of different output, mounting arrangements 250 386 405 75
280 425 800 -
and auxiliary equipment, motors with the same frame may
315 - 1700 -
have a different center of gravity.
355 - 2700 -
Damaged lifting lugs must not be used. Check that 400 - 3500 -
eyebolts or integrated lifting lugs are undamaged before 450 - 4500 -
lifting.
If the motor is equipped with a separate fan, contact ABB
for the weight.
4. Installation and commissioning
WARNING! WARNING!
Disconnect and lock out before working on the To avoid risk of electrical shock, the motor frame
motor or the driven equipment. must be grounded and the windings should be
discharged against the frame immediately after each
measurement.
4.1 General
All rating plate values must be carefully checked to ensure If the reference resistance value is not attained, the
that the motor protection and connection will be properly winding is too damp and must be oven dried. The oven
done. temperature should be 90 °C for 12-16 hours followed by
105 °C for 6-8 hours.
4.2 Motors with other than If fitted drain hole plugs must be removed and closing
ball bearings valves must be opened during heating. After heating, make
sure the plugs are refitted. Even if the drain plugs are fitted,
Remove transport locking if employed. Turn the shaft of the it is recommended to disassemble the end shields and
motor by hand to check free rotation, if possible. terminal box covers for the drying process.
Windings drenched in seawater normally need to be

Motors equipped with roller bearings:
rewound.
Running the motor with no radial force applied to the shaft
may damage the roller bearing due to “sliding”, 4.4 Foundation
Motors equipped with angular contact bearing: The end user has full responsibility for preparation of the
foundation.
Running the motor with no axial force applied in the right
direction in relation to the shaft may damage the angular Metal foundations should be painted to avoid corrosion.
contact bearing.
Foundations must be even and sufficiently rigid to
withstand possible short circuit forces.
WARNING!
For motors with angular contact bearings the axial They must be designed and dimensioned to avoid the
force must not by any means change direction. transfer of vibration to the motor and vibration caused by
resonance. See figure below.
The type of bearing is specified on the rating plate.

Ruler
Motors equipped with regreasing nipples:

When starting the motor for the first time, or after long
storage, apply the specified quantity of grease. Note! Height difference shall
not exceed ± 0,1mm referred
See section “7.2.2 Motors with re-greasable bearings” for to any other motor foot
more details.
When fitted in a vertical position with the shaft pointing

downwards, the motor must have a protective cover
to prevent foreign objects and fluid from falling into the
ventilation openings. This task can also be achieved by Foot location
a separate cover not fixed to the motor. In this case, the
motor must have a warning label.
4.3 Insulation resistance check 4.5 Balancing and fitting coupling

Measure insulation resistance before commissioning and
when winding dampness is suspected.
halves and pulleys
As standard, balancing of the motor has been carried out
Insulation resistance, corrected to 25 °C, may not in any using half key.
cases be below 1 MΩ (measured with 500 or 1000 VDC)
The insulation resistance value is halved for each 20 °C Coupling halves or pulleys must be balanced after
increase in temperature. Figure 1 can be used for the machining the keyways. Balancing must be done in
insulation correction to the desired temperature. accordance with the balancing method specified for the
motor.
Coupling halves and pulleys must be fitted on the shaft by 4.8 Motors with drain plugs
using suitable equipment and tools which do not damage
the bearings and seals. for condensation
Never fit a coupling half or pulley by hammering or Check that drain holes and plugs face downwards. In
removing it by using a lever pressed against the body of the vertical position mounted motors, the drain plugs may be in
motor. horizontal position.
Motors with sealable plastic drain plugs are delivered in an

4.6 Mounting and alignment open position. In very dusty environments, all drain holes
should be closed.
of the motor
Ensure that there is enough space for free airflow around
the motor. It is recommended to have a clearance between
4.9 Cabling and electrical
the fan cover and the wall etc. of at least ½ of the air connections
intake of the fan cover. Additional information may be
found from the product catalog or from the dimension The terminal box on standard single speed motors normally
drawings available on our web pages: www.abb.com/ contains six winding terminals and at least one earth
motors&generators. terminal.
Correct alignment is essential to avoid bearing, vibration In addition to the main winding and earthing terminals, the
and possible shaft failures. terminal box can also contain connections for thermistors,
heating elements or other auxiliary devices.
Mount the motor on the foundation using the appropriate
bolts or studs and place shim plates between the Suitable cable lugs must be used for the connection of all
foundation and the feet. main cables. Cables for auxiliaries can be connected into
their terminal blocks as such.
Align the motor using appropriate methods.
Motors are intended for fixed installation only. Unless
If applicable, drill locating holes and fix the locating pins into otherwise specified, cable entry threads are metric. The IP
position. class of the cable gland must be at least the same as those
of the terminal boxes.
Mounting accuracy of coupling half: check that clearance
b is less than 0.05 mm and that the difference a1 to a2 is Certified conduit hub or cable connector has to be used at
also less than 0.05 mm. See figure 2. the time of installation.
Re-check the alignment after final tightening of the bolts or

studs. NOTE!
Cables should be mechanically protected and
Do not exceed permissible loading values for bearings as clamped close to the terminal box to fulfill the
stated in the product catalogs. appropriate requirements of IEC/EN 60079-0 and
local installation standards.
Check that the motor has sufficient airflow. Ensure that no
nearby objects or direct sunshine radiate additional heat to
the motor.
Unused cable entries must be closed with blanking
For flange mounted motors (e.g. B5, B35, V1), make sure elements according to the IP class of the terminal box.
that the construction allows sufficient air flow on the outer
surface of the flange. The degree of protection and diameter are specified in the
documents relating to the cable gland.
4.7 Radial forces and belt drives WARNING!

Belts must be tightened according to the instructions of the Use appropriate cable glands and seals in the cable
supplier of the driven equipment. However, do not exceed entries according to the type and diameter of the
the maximum belt forces (i.e. radial bearing loading) stated cable.
in the relevant product catalogs.
Earthing must be carried out according to local regulations

WARNING! before the motor is connected to the supply voltage.
Excessive belt tension will damage bearings and can
cause shaft damage. The earth terminal on the frame has to be connected to
PE (protective earth) with a cable as shown in Table 5 of
IEC/EN 60034-1:
Minimum cross-sectional area of protective Direct-on-line starting (DOL):
conductors Y or D winding connections may be used.
Cross-sectional area of phase Minimum cross-sectional area For example, 690 VY, 400 VD indicates Y-connection for
conductors of the installation, of the corresponding protective 690 V and D-connection for 400 V.
S, [mm2] conductor, SP, [mm2]
4 4 Star/Delta (Wye/Delta) starting (Y/D):
6 6
10 10
The supply voltage must be equal to the rated voltage of
16 16
the motor when using a D-connection.
25 25
Remove all connection links from the terminal block.
35 25
50 25 Other starting methods and severe starting
70 35 conditions:
95 50 In cases where other starting methods e.g. converter or
120 70 soft starter will be used in the duty types of S1 and S2, it
150 70 is considered that the device is “isolated from the power
185 95 system when the electrical machine is running” as in the
240 120 standard IEC 60079-0 and thermal protection is optional.
300 150
400 185
4.9.2 Connections of auxiliaries
In addition, earthing or bonding connection facilities on
the outside of electrical apparatus must provide effective If a motor is equipped with thermistors or other RTDs
connection of a conductor with a cross-sectional area of at (Pt100, thermal relays, etc.) and auxiliary devices, it is
least 4 mm2. recommended they be used and connected by appropriate
means. For certain applications, it is mandatory to use
The cable connection between the network and motor thermal protection. More detailed information can be found
terminals must meet the requirements stated in the in the documents delivered with the motor. Connection
national standards for installation or in the standard diagrams for auxiliary elements and connection parts can
IEC/EN 60204-1 according to the rated current indicated be found inside the terminal box.
on the rating plate.
The maximum measuring voltage for the thermistors is
2.5 V. The maximum measuring current for Pt100 is 5 mA.
NOTE!
Using a higher measuring voltage or current may cause
When the ambient temperature exceeds +50 °C,
errors in readings or a damaged temperature detector.
cables having permissible operating temperature
of +90 °C as minimum shall be used. Also all other The insulation of thermal sensors fulfills the requirements of
conversion factors depending on the installation basic insulation.
conditions shall be taken into account while sizing
the cables.
Ensure that the motor protection corresponds to the

4.10 Terminals and direction
environment and weather conditions. For example, make of rotation
sure that water cannot enter the motor or the terminal
boxes. The shaft rotates clockwise when viewing the shaft face at
the motor drive end, and the line phase sequence - L1, L2,
The seals of terminal boxes must be placed correctly in L3 - is connected to the terminals as shown in figure 3.
the slots provided to ensure the correct IP class. A leak
could lead to penetration of dust or water, creating a risk of To alter the direction of rotation, interchange any two
flashover to live elements. connections on the supply cables.
If the motor has a unidirectional fan, ensure that it rotates in

4.9.1 Connections for different starting the same direction as the arrow marked on the motor.
methods
The terminal box on standard single speed motors normally
contains six winding terminals and at least one earth
terminal. This enables the use of DOL- or Y/D –starting.
For two-speed and special motors, the supply connection

must follow the instructions inside the terminal box or in the
motor manual.
The voltage and connection are stamped on the rating

plate.
5. Operation
5.1 General
The motors are designed for the following conditions unless
otherwise stated on the rating plate:
- Motors are to be installed in fixed installations only.

- Normal ambient temperature range is from -20 °C to
+40 °C.
- Maximum altitude is 1000 m above sea level.
- The variation of the supply voltage and frequency may
not exceed the limits mentioned in relevant standards.
Tolerance for supply voltage is ±5 %, and for frequency
±2 % according to the figure 4 (EN / IEC 60034-1,
paragraph 7.3, Zone A). Both extreme values are not
supposed to occur at the same time.
The motor can only be used in applications for which

it is intended. The rated nominal values and operation
conditions are shown on the motor rating plates. In
addition, all requirements of this manual and other related
instructions and standards must be followed.
If these limits are exceeded, motor data and construction

data must be checked. Please contact ABB for further
information.
WARNING!
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
the use of the motor.
6. Low voltage motors in variable speed operation
6.1 Introduction 6.2.2 Selection of winding insulation with
all other converters
This part of the manual provides additional instructions for
motors used in frequency converter supplies. The motor The voltage stresses must be limited below accepted limits.
is intended to operate from a single frequency converter Please contact the system supplier to ensure the safety of
supply and not motors running in parallel from one the application. The influence of possible filters must be
frequency converter. Instructions given by the converter taken into account while dimensioning the motor.
manufacturer shall be followed.
Additional information may be required by ABB to decide

on the suitability for some motor types used in special
6.3 Thermal protection
applications or with special design modifications. Most of the motors covered by this manual are equipped
with PTC thermistors or other type of RTD’s in the stator
windings. It is recommended to connect those to the
6.2 Winding insulation frequency converter. Read more in chapter 4.9.2.
Variable speed drives create higher voltage stresses

than the sinusoidal supply on the winding of the motor.
Therefore, the winding insulation of the motor as well as
6.4 Bearing currents
the filter at the converter output must be dimensioned Insulated bearings or bearing constructions, common
according following instructions. mode filters and suitable cabling and grounding methods
must be used according to the following instructions and
6.2.1 Selection of winding insulation for using table 6.1.
ABB converters
6.4.1 Elimination of bearing currents with
In the case of ABB e.g. AC_8_ _-series and AC_5_ _-series
single drives with a diode supply unit (uncontrolled DC
ABB converters
voltage), the selection of winding insulation and filters can In case of ABB frequency converter e.g. AC_8_ _- and
be made according to table 6.1. AC_5_ _-series with a diode supply unit, the methods
according to table 6.1 must be used to avoid harmful
bearing currents in motors.
PN < 100 kW PN ≥ 100 kW or PN ≥ 350 kW or

IEC315 ≤ Frame size ≤ IEC355 IEC400 ≤ Frame size ≤ IEC450
UN ≤ 500 V Standard motor Standard motor Standard motor
+ Insulated N-bearing + Insulated N-bearing
+ Common mode filter
500V >UN ≤ 600V Standard motor Standard motor Standard motor
+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
OR + Insulated N-bearing + dU/dt –filter (reactor)
Reinforced insulation OR + Common mode filter
Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
500V >UN ≤ 600V Standard motor Standard motor Standard motor
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
600V >UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation

+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
+ Insulated N-bearing + dU/dt –filter (reactor)
600V >UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
Table 6.1 Selection of winding insulation for ABB converters
Please contact ABB for more information on resistor braking and converters with controlled supply units.
NOTE!
6.7 Motors in variable speed
Insulated bearings which have aluminum oxide applications
coated inner and/or outer bores or ceramic rolling
elements are recommended. Aluminum oxide
6.7.1 General
coatings shall also be treated with a sealant to
prevent dirt and humidity penetrating into the porous With ABB’s frequency converters, the motors can be
coating. For the exact type of bearing insulation, see dimensioned by using ABB’s DriveSize dimensioning
the motor’s rating plate. Changing the bearing type program. The tool is downloadable from the ABB website
or insulation method without ABB’s permission is (www.abb.com/motors&generators).
prohibited. For application supplied by other converters, the motors
must be dimensioned manually. For more information,
6.4.2 Elimination of bearing currents with please contact ABB.
all other converters The loadability curves (or load capacity curves) are based
The user is responsible for protecting the motor and driven on nominal supply voltage. Operation in under or over
equipment from harmful bearing currents. Instructions voltage conditions may influence on the performance of the
described in chapter 6.4.1 can be used as guideline, but application.
their effectiveness cannot be guaranteed in all cases.
6.7.2 Motor loadability with AC_8_ _ – series
6.5 Cabling, grounding and EMC of converters with DTC control
The loadability curves presented in Figures 5a - 5d are
To provide proper grounding and to ensure compliance
valid for ABB AC_8_ _-series converters with uncontrolled
with any applicable EMC requirements, motors above
DC-voltage and DTC-control. The figures show the
30 kW shall be cabled by shielded symmetrical cables and
approximate maximum continuous output torque of the
EMC glands, i.e. cable glands providing 360° bonding.
motors as a function of supply frequency. The output
Symmetrical and shielded cables are highly recommended torque is given as a percentage of the nominal torque of
also for smaller motors. Make the 360° grounding the motor. The values are indicative and exact values are
arrangement at all the cable entries as described in the available on request.
instructions for the glands. Twist the cable shields into
bundles and connect to the nearest ground terminal/bus
NOTE!
bar inside the terminal box, converter cabinet, etc.
The maximum speed of the motor and application
may not be exceeded!
NOTE!
Proper cable glands providing 360° bonding must 6.7.3 Motor loadability with AC_5_ _ – series
be used at all termination points such as motor,
of converter
converter, possible safety switch, etc.
The loadability curves presented in Figures 6a - 6d are
valid for AC_5_ _ -series converters. The figures show
For motors of frame size IEC 280 and above, additional the approximate maximum continuous output torque of
potential equalization between the motor frame and the the motors as a function of supply frequency. The output
driven equipment is needed, unless both are mounted on torque is given as a percentage of the nominal torque of
a common steel base. In this case, the high frequency the motor. The values are indicative and exact values are
conductivity of the connection provided by the steel available on request.
base should be checked by, for example, measuring the
potential difference between the components.
NOTE!
More information about grounding and cabling of variable The maximum speed of the motor and application
speed drives can be found in the manual “Grounding and may not be exceeded!
cabling of the drive system” (Code: 3AFY 61201998).
6.7.4 Motor loadability with other voltage
source PWM-type converters
6.6 Operating speed For other converters, with uncontrolled DC voltage and
For speeds higher than the nominal speed stated on the minimum switching frequency of 3 kHz (200…500 V), the
motor’s rating plate or in the respective product catalog, dimensioning instructions as mentioned in chapter 6.7.3
ensure that either the highest permissible rotational speed can be used as guidelines. However, it shall be noted that
of the motor or the critical speed of the whole application is the actual thermal loadability can also be lower. Please
not exceeded. contact the manufacturer of the converter or the system
supplier.
NOTE!
6.9 Commissioning the variable
The actual thermal loadability of a motor may be speed application
lower than shown by guideline curves.
The commissioning of the variable speed application must
6.7.5 Short time overloads be done according to the instructions of the frequency
converter and local laws and regulations. The requirements
ABB motors can usually be temporarily overloaded as well and limitations set by the application must also be taken
as used in intermittent duties. The most convenient method into account.
to dimension such applications is to use the DriveSize tool.
All parameters needed for setting the converter must be
6.8 Rating plates taken from the motor rating plates. The most often needed
parameters are:
The usage of ABB’s motors in variable speed applications
do not usually require additional rating plates. The - nominal voltage
parameters required for commissioning the converter - nominal current
can be found from the main rating plate. In some special - nominal frequency
applications, however, the motors can be equipped with - nominal speed
additional rating plates for variable speed applications. - nominal power
Those include the following information:
- speed range NOTE!

- power range In case of missing or inaccurate information, do not
- voltage and current range operate the motor before ensuring correct settings!
- type of torque (constant or quadratic)
- and converter type and required minimum switching
frequency. ABB recommends using all the suitable protective features
provided by the converter to improve the safety of the
application. Converters usually provide features such as
(names and availability of features depend on manufacturer
and model of the converter):
- minimum speed
- maximum speed
- acceleration and deceleration times
- maximum current
- maximum torque
- stall protection
7. Maintenance 2. The bearing must be greased while rotating the shaft
every year (to be reported). If the motor has been
provided with roller bearing at the driven end, the
WARNING! transport lock must be removed before rotating the
Voltage may be connected at standstill inside the shaft. The transport locking must be remounted in case
terminal box for heating elements or direct winding of transportation.
heating. 3. All vibrations must be avoided to prevent a bearing from
failing. All instructions in the motor instruction manual for
commissioning and maintenance have to be followed.
The warranty will not cover the winding and bearing
7.1 General inspection damages if these instructions have not been followed.
1. Inspect the motor at regular intervals, at least once a
year. The frequency of checks depends on, for example,
the humidity level of the ambient air and on the local 7.2 Lubrication
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
2. Keep the motor clean and ensure free ventilation WARNING!
airflow. If the motor is used in a dusty environment, Beware of all rotating parts!
the ventilation system must be regularly checked and
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial WARNING!
seal) and replace if necessary. Grease can cause skin irritation and eye
inflammation. Follow all safety precautions specified
4. Check the condition of connections and mounting and
by the manufacturer of the grease.
assembly bolts.
5. Check the bearing condition by listening for any unusual
noise, vibration measurement, bearing temperature, Bearing types are specified in the respective product
inspection of spent grease or SPM bearing monitoring. catalogs and on the rating plate of all motors, except
Pay special attention to bearings when their calculated smaller frame sizes.
rated life time is coming to an end.
Reliability is a vital issue for bearing lubrication intervals.
When signs of wear are noticed, dismantle the motor, ABB uses mainly the L1 -principle (i.e. that 99 % of the
check the parts and replace if necessary. When bearings motors are certain to make the life time) for lubrication.
are changed, replacement bearings must be of the same
type as those originally fitted. The shaft seals have to be
replaced with seals of the same quality and characteristics 7.2.1 Motors with permanently greased
as the originals when changing bearings. bearings
Bearings are usually permanently greased bearings of 1Z,
In the case of the IP 55 motor and when the motor
2Z, 2RS or equivalent.
has been delivered with a plug closed, it is advisable to
periodically open the drain plugs in order to ensure that As a guide, adequate lubrication for sizes up to 250 can
the way out for condensation is not blocked and allows be achieved for the following duration, according to L1. For
condensation to escape from the motor. This operation duties with higher ambient temperatures, please contact
must be done when the motor is at a standstill and has ABB. The informative formula to change the L1 values
been made safe to work on. roughly to L10 values: L10 = 2.0 x L1.
7.1.1 Standby motors

If the motor is in standby for a longer period of time on
a ship or in other vibrating environment the following
measures have to be taken:
1. The shaft must be rotated regularly every 2 weeks (to

be reported) by means of starting up of the system. In
case a start-up is not possible, for any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
should be minimized by regular operation/hand turning.
Duty hours for permanently greased bearings at ambient Regreasing while the motor is at a standstill
temperatures of 25 °C and 40 °C are: If it is not possible to re-grease the bearings while the
motors are running, lubrication can be carried out while the
Duty hours Duty hours motor is at a standstill.
Frame size Poles at 25° C at 40° C – In this case, use only half the amount of grease and then
56 2 52 000 33 000 run the motor for a few minutes at full speed.
56 4-8 65 000 41 000 – When the motor has stopped, apply the rest of the
63 2 49 000 31 000 specified amount of grease to the bearing.
63 4-8 63 000 40 000 – After 1-2 running hours, close the grease outlet plug or
71 2 67 000 42 000 closing valve, if fitted.
71 4-8 100 000 56 000 B. Automatic lubrication
80-90 2 100 000 65 000
80-90 4-8 100 000 96 000 The grease outlet plug must be removed permanently with
100-112 2 89 000 56 000 automatic lubrication or open closing valve, if fitted.
100-112 4-8 100 000 89 000
ABB recommends only the use of electromechanical
132 2 67 000 42 000
systems.
132 4-8 100 000 77 000
160 2 60 000 38 000 The amount of grease per lubrication interval stated in the
160 4-8 100 000 74 000 table should be multiplied by three if a central lubrication
180 2 55 000 34 000 system is used. When using a smaller automatic re-grease
180 4-8 100 000 70 000 unit (one or two cartridges per motor) the normal amount of
200 2 41 000 25 000 grease can be used.
200 4-8 95 000 60 000 When 2-pole motors are automatically re-greased, the note
225 2 36 000 23 000 concerning lubricant recommendations for 2-pole motors in
225 4-8 88 000 56 000 the Lubricants chapter should be followed.
250 2 31 000 20 000
250 4-8 80 000 50 000 The used grease should be suitable for automatic
lubrication. The automatic lubrication system deliverer and
Data is valid up to 60 Hz. the grease manufacturer’s recommendations should check.
7.2.2 Motors with regreasable bearings Calculation example of amount of grease for
automatic lubrication system
Lubrication information plate and general lubrication Central lubrication system: Motor IEC M3_P 315_ 4-pole in
advice 50 Hz network, re-lubrication interval according to Table is
If the motor is equipped with a lubrication information plate, 7600 h/55 g (DE) and 7600 h/40g (NDE):
follow the given values.
(DE) RLI = 55 g/7600h*3*24 = 0,52 g/day
Greasing intervals regarding mounting, ambient
temperature and rotational speed are defined on the (NDE) RLI = 40 g/7600*3*24 = 038 g/day
lubrication information plate.
Calculation example of amount of grease for single
During the first start or after a bearing lubrication a automation lubrication unit (cartridge)
temporary temperature rise may appear, approximately 10 (DE) RLI = 55 g/7600h*24 = 0,17 g/day
to 20 hours.
(NDE) RLI = 40 g/7600*24 = 0,13 g/day
Some motors may be equipped with a collector for old
grease. Follow the special instructions given for the RLI = Re-lubricaion interval, DE = Drive end, NDE = Non drive end
equipment.
A. Manual lubrication 7.2.3 Lubrication intervals and amounts

Regreasing while the motor is running Lubrication intervals for vertical motors are half of the values
– Remove grease outlet plug or open closing valve if fitted. shown in the table below.
– Be sure that the lubrication channel is open.
As a guide, adequate lubrication can be achieved for the
– Inject the specified amount of grease into the bearing.
following duration, according to L1. For duties with higher
– Let the motor run for 1-2 hours to ensure that all excess
ambient temperatures please contact ABB. The informative
grease is forced out of the bearing. Close the grease
formula to change the L1 values roughly to L10 values is L10
outlet plug or closing valve, if fitted.
= 2.0 x L1, with manual lubrication.
The lubrication intervals are based on a bearing operating

temperature of 80 °C (ambient temperature +25 °C).
Higher speed operation, e.g. in frequency converter
NOTE!
applications, or lower speed with heavy load will require
An increase in the ambient temperature raises the
shorter lubrication intervals.
temperature of the bearings correspondingly. The
interval values should be halved for a 15 °C increase
in bearing temperature and may be doubled for a WARNING!
15 °C decrease in bearing temperature. The maximum operating temperature of the grease
and bearings, +110 °C, must not be exceeded.
The designed maximum speed of the motor must
not be exceeded.
Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings, lubrication intervals in duty hours
112 10 all 10 000 13 000 all 18 000 21 000 all 2 5 000 all 28 000
132 15 all 9 000 11 000 all 17 000 19 000 all 23 000 all 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 all 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 all 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 all 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 all 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 all 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 all 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 all 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 all 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 all 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 all 7 000
2801) 60 all 2 000 3 500 - - - - - - -
2801) 60 - - - all 8 000 10 500 all 14 000 all 17 000
280 35 all 1 900 3 200 - - - -
280 40 - - all 7 800 9 600 all 13 900 all 15 000
315 35 all 1 900 3 200 - - - -
315 55 - - all 5 900 7 600 all 11 800 all 12 900
355 35 all 1 900 3 200 - - - -
355 70 - - all 4 000 5 600 all 9 600 all 10 700
400 40 all 1 500 2 700 - - - -
400 85 - - all 3 200 4 700 all 8 600 all 9 700
450 40 all 1 500 2 700 - - - -
450 95 - - all 2 500 3 900 all 7 700 all 8 700
Roller bearings, lubrication intervals in duty hours

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 all 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 all 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 all 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 all 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 all 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 all 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 all 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 all 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 all 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 all 3 500
2801) 60 all 1 000 1 750 - - - - - - -
2801) 70 - - - all 4 000 5 250 all 7 000 all 8 500
280 35 all 900 1 600 - - - -
280 40 - - all 4 000 5 300 all 7 000 all 8 500
315 35 all 900 1 600 - - - -
315 55 - - all 2 900 3 800 all 5 900 all 6 500
355 35 all 900 1 600 - - - -
355 70 - - all 2 000 2 800 all 4 800 all 5 400
400 40 all - 1 300 - - - -
400 85 - - all 1 600 2 400 all 4 300 all 4 800
450 40 all - 1 300 - - - -
450 95 - - all 1 300 2 000 all 3 800 all 4 400
1)
M3AA
7.2.4 Lubricants The following greases can be used for high speed cast iron
motors but not mixed with lithium complex greases:
WARNING! - Klüber Klüber Quiet BQH 72-102 (polyurea base)

Do not mix different types of grease. - Lubcon Turmogrease PU703 (polyurea base)
Incompatible lubricants may cause bearing damage.
If other lubricants are used, check with the manufacturer
that the qualities correspond to those of the above
When re-greasing, use only special ball bearing grease with mentioned lubricants. The lubrication intervals are based
the following properties: on the listed high performance greases above. Using other
greases can reduce the interval.
– good quality grease with lithium complex soap and with
mineral- or PAO-oil
– base oil viscosity 100-160 cST at 40 °C
– consistency NLGI grade 1.5 - 3 *)
– temperature range -30 °C - +120 °C, continuously
*) A stiffer end of scale is recommended for vertical

mounted motors or in hot conditions.
The above mentioned grease specification is valid if the

ambient temperature is above -30 °C or below +55 °C,
and the bearing temperature is below 110 °C; otherwise,
consult ABB regarding suitable grease.
Grease with the correct properties is available from all major

lubricant manufacturers.
Admixtures are recommended, but a written guarantee

must be obtained from the lubricant manufacturer,
especially concerning EP admixtures, that admixtures do
not damage bearings or the properties of lubricants at the
operating temperature range.
WARNING!
Lubricants containing EP admixtures are not
recommended in high bearing temperatures in frame
sizes 280 to 450.
The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)
– Mobil Mobilith SHC 100 (lithium complex base)
– Shell Gadus S5 V 100 2 (lithium complex base)
– Klüber Klüberplex BEM 41-132 (special lithium base)
– FAG Arcanol TEMP110 (lithium complex base)
– Lubcon Turmogrease L 802 EP PLUS
(special lithium base)
– Total Multiplex S2 A (lithium complex base)
– Rhenus Rhenus LKZ 2 (lithium complex base)
NOTE!
Always use high speed grease for high speed 2-pole
motors where the speed factor is higher than
480,000 (calculated as Dm x n where Dm = average
bearing diameter, mm; n = rotational speed, r/min).
8. After Sales Support 9. Environmental
requirements
8.1 Spare parts
Most of ABB’s motors have a sound pressure level not
Unless otherwise stated, spare parts must be original parts
exceeding 82 dB (A) (± 3 dB) at 50 Hz.
or approved by ABB.
Values for specific motors can be found in the relevant
When ordering spare parts, the motor serial number, full
product catalogs. At 60 Hz sinusoidal supply, the values are
type designation and product code, as stated on the rating
approximately 4 dB(A) higher compared to 50 Hz values
plate, must be specified.
stated in the product catalogs.
8.2 Dismantling, re-assembly For sound pressure levels at frequency converter supplies,
please contact ABB.
and rewinding When motor(s) need to be scrapped or recycled,
Rewinding should always be carried out by qualified repair appropriate means, local regulations and laws must be
shops. followed.
Smoke venting and other special motors should not be

rewound without first contacting ABB.
8.3 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by heating

or using special tools.
Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.
Any directions placed on the motor, such as labels, must

be followed. The bearing types indicated on the rating plate
must not be changed.
NOTE!
Any repair by the end user, unless expressly
approved by the manufacturer, releases the
manufacturer from responsibility to conformity.
10. Troubleshooting
These instructions do not cover all details or variations
in equipment nor provide information for every possible
condition to be met in connection with installation,
operation or maintenance. Should additional information be
required, please contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be
handled by qualified persons who have the proper tools
and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate
and load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or Indicated by humming sound when switch is closed. Check for loose
control switch wiring connections and ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator
Poor stator coil connection Indicated by blown fuses. Motor must be rewound.
Remove end shields and locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown. Check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, fuses and control.
then dies down
Motor does not Not applied properly Consult equipment supplier for proper type.
accelerate up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load.
nominal speed because of line drop Check connections. Check conductors for proper size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as
repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
TROUBLE CAUSE WHAT TO DO
Motor takes too Excessive load Reduce load.
long to accelerate Low voltage during start Check for high resistance. Make sure that an adequate cable size
and/or draws high is used.
current
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
Motor overheats Overload Reduce load.
while running Frame or ventilation openings may be Open vent holes and check for a continuous stream of air
full of dirt and prevent proper ventilation from the motor.
of motor
Motor may have one phase open Check to make sure that all leads and cables are well connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor
Balancing weights shifted Rebalance rotor.
Contradiction between balancing of Rebalance coupling or rotor.
rotor and coupling (half key - full key)
Poly phase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene and
contaminated replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.
Niederspannungsmotoren
Montage-, Betriebs-, Wartungs- und Sicherheitsanleitung
Inhalt
1. Einführung .................................................................................................................................23
1.1 Konformitätserklärung........................................................................................................23
1.2 Gültigkeit ...........................................................................................................................23
2. Sicherheitshinweise ..................................................................................................................23
3. Handhabung ..............................................................................................................................24
3.1 Eingangsprüfung ...............................................................................................................24
3.2 Transport und Lagerung ....................................................................................................24
3.3 Heben ...............................................................................................................................24
3.4 Motorgewicht ....................................................................................................................24
4. Installation und Inbetriebnahme der Maschine .....................................................................25
4.1 Allgemeines .......................................................................................................................25
4.2 Motoren mit anderen als Kugellagern .................................................................................25
4.3 Prüfung des Isolationswiderstandes ...................................................................................25
4.4 Fundament ........................................................................................................................25
4.5 Auswuchten und Anbau von Kupplungshälften und Riemenscheiben ................................26
4.6 Einbau und Ausrichtung des Motors ..................................................................................26
4.7 Radialkräfte und Riemenantriebe .......................................................................................26
4.8 Motoren mit Kondenswasser-Ablaufstopfen .......................................................................26
4.9 Kabel und elektrische Anschlüsse ......................................................................................27
4.9.1 Anschlüsse für unterschiedliche Startmethoden ...................................................28
4.9.2 Anschlüsse von Zubehör ......................................................................................28
4.10 Anschlussklemmen und Drehrichtung ................................................................................28
5. Betriebsbedingungen ..............................................................................................................29
5.1 Allgemeines .......................................................................................................................29
Anleitung für Niederspannungsmotoren, 3GZF500730-85 Änd. F 02-2015 | ABB Motoren und Generatoren 21
6. Drehzahlgeregelte Niederspannungsmotoren ......................................................................30
6.1 Einführung .........................................................................................................................30
6.2 Wicklungsisolierung ...........................................................................................................30
6.2.1 Auswahl der Wicklungsisolierung für ABB-Frequenzumrichter ...............................30
6.2.2 Auswahl der Wicklungsisolierung aller übrigen Frequenzumrichter .......................30
6.3 Thermoisolierung der Wicklung .........................................................................................30
6.4 Lagerströme ......................................................................................................................31
6.4.1 Verhindern von Lagerströmen bei ABB-Frequenzumrichtern .................................31
6.4.2 Verhindern von Lagerströmen bei allen anderen Umrichtern ..................................31
6.5 Verkabelung, Erdung und EMV ..........................................................................................31
6.6 Betriebsdrehzahl ................................................................................................................31
6.7 Motoren mit drehzahlgeregelten Anwendungen .................................................................31
6.7.1 Allgemeines ..........................................................................................................31
6.7.2 Motorbelastbarkeit mit Frequenzumrichterantrieben
der Baureihe AC_8_ _ mit DTC-Regelung .............................................................31
6.7.3 Motorbelastbarkeit mit Frequenzumrichterantrieben der Baureihe AC_5_ _ ...........32
6.7.4 Motorbelastbarkeit mit PWM-Frequenzumrichtern
mit anderen Spannungsquellen .............................................................................32
6.7.5 Kurzzeitige Überlasten ..........................................................................................32
6.8 Leistungsschilder ...............................................................................................................32
6.9 Inbetriebnahme des drehzahlgeregelten Antriebs ...............................................................32
7. Wartung......................................................................................................................................33
7.1 Allgemeine Kontrolle ..........................................................................................................33
7.1.1 Standbymotoren ..................................................................................................33
7.2 Schmierung .......................................................................................................................33
7.2.1 Motoren mit dauergeschmierten Lagern ...............................................................33
7.2.2 Motoren mit nachschmierbarem Lager..................................................................34
7.2.3 Schmierintervalle und -mengen .............................................................................35
7.2.4 Schmiermittel........................................................................................................37
8. Kundendienst ............................................................................................................................38
8.1 Ersatzteile ..........................................................................................................................38
8.2 Demontage und Neueinbau sowie Neuwicklung ................................................................38
8.3 Lager .................................................................................................................................38
9. Umweltanforderungen ..............................................................................................................38
10. Motor-Störungssuchtabelle .....................................................................................................39
22 ABB Motoren und Generatoren | Anleitung für Niederspannungsmotoren, 3GZF500730-85 Änd. F 02-2015
1. Einführung 2. Sicherheitshinweise
Die Montage und der Betrieb des Motors darf nur durch
HINWEIS!
hierfür qualifiziertes Fachpersonal erfolgen, das mit den
Die nachstehenden Anweisungen sind genau zu
Arbeitsschutz- und Sicherheitsvorschriften und den
befolgen, um die Sicherheit bei der Installation,
gesetzlichen Bestimmungen des jeweiligen Landes vertraut
beim Betrieb und bei der Wartung des Motors zu
ist.
gewährleisten. Jede/r Mitarbeiter/in, der/die an der
Montage, am Betrieb oder an der Wartung des Zur Unfallverhütung sind entsprechend den im betreffenden
Motors oder dessen Zubehör beteiligt ist, sollte von Land geltenden Gesetzen und Bestimmungen bei
diesen Anweisungen in Kenntnis gesetzt werden. Die der Montage und beim Betrieb des Motors geeignete
Montage und der Betrieb des Motors darf nur durch Sicherheitseinrichtungen zu verwenden.
hierfür qualifiziertes Fachpersonal erfolgen, das mit
den Arbeitsschutz- und Sicherheitsvorschriften und
den gesetzlichen Bestimmungen des jeweiligen WARNUNG!
Landes vertraut ist. Nichtbefolgung der Anweisungen Notstopp-Bedienelemente müssen mit
kann zum Verlust aller geltenden Gewährleistungen Wiedereinschaltsperren versehen sein. Nach
führen. einem Notstopp kann ein Wiedereinschaltbefehl
nur ausgeführt werden, nachdem die
Wiedereinschaltsperre vorsätzlich zurückgesetzt
1.1 Konformitätserklärung wurde.
Wenn der Motor in ein Gerät eingebaut wird, muss

die Konformität des Endprodukts mit der Richtlinie
2006/42/EG (Maschinen) durch die entsprechende Partei Die folgenden Warnhinweise sind zu beachten:
sichergestellt werden. 1. Sich nicht auf den Motor stellen.
2. Vorsicht: Auch im normalen Betrieb und besonders
1.2 Gültigkeit nach dem Ausschalten können an der Oberfläche des
Motors hohe Temperaturen auftreten!
Diese Anleitung gilt für die folgenden elektrischen 3. Einige Anwendungen erfordern möglicherweise
ABB-Maschinentypen, sowohl im Motoren- als auch eine spezielle Anleitung (z.B. bei Versorgung durch
Generatorbetrieb: Frequenzumrichter).
4. Auf rotierende Teile des Motors achten.
Baureihe MT*, MXMA,
Baureihe M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/ 5. Unter Spannung stehende Klemmenkästen nicht öffnen.
M3C*, M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*,
M2R*/M3R*, M2V*/M3V*
bei Baugrößen 56 - 450.
Es gibt separate Handbücher, z.B. für 'Niederspannungs-

motoren in explosionsgefährdeten Bereichen: Montage-,
Betriebs-, Wartungs- und Sicherheitsanleitung,
(3GZF500730-47)
Für Sonderausführungen oder spezielle Anwendungen

werden gegebenenfalls zusätzliche Hinweise benötigt.
Für folgende Motoren sind zusätzliche Handbücher

verfügbar:
– Rollgangsmotoren
– Wassergekühlte Motoren
– Brandgas-Entlüftungsmotoren
– Bremsmotoren
– Motoren für hohe Umgebungstemperaturen
– Motoren in Schiffsanwendungen zur Montage
auf offenem Deck von Schiffen und Offshore-Einheiten
3. Handhabung Ösenschrauben vor dem Anheben festziehen. Die Position
der Ösenschraube kann bei Bedarf mit Hilfe geeigneter
Distanzstücke wie Unterlegscheiben justiert werden.
3.1 Eingangsprüfung
Es dürfen nur geeignete Hebeeinrichtungen und Haken in
Der Motor ist bei Empfang unverzüglich auf äußere für die jeweiligen Hebeösen geeigneter Größe verwendet
Beschädigungen (z.B. Wellenenden, Flansche und werden.
Lackierung) zu untersuchen und der Spediteur ggf. sofort
zu verständigen. Es ist darauf zu achten, dass Zusatzgeräte und am Motor
angeschlossene Kabel nicht beschädigt werden.
Alle Leistungsschilddaten überprüfen, insbesondere
Spannung und Wicklungsanschlüsse (Stern oder Dreieck). Eventuelle Transportvorrichtungen, die den Motor an der
Der Lagertyp ist auf dem Leistungsschild aller Motoren mit Palette befestigen, sind zu entfernen.
Ausnahme der kleinsten Baugrößen angegeben.
Spezifische Hebeanleitungen sind über ABB verfügbar.
Bei Drehzahlregelung maximal zulässige Belastbarkeit
entsprechend der auf dem zweiten Leistungsschild des
Motors angegebenen Frequenz überprüfen. WARNUNG!
Bei Hebe-, Montage- oder Wartungsarbeiten
müssen alle erforderlichen Sicherheitsvorrichtungen
3.2 Transport und Lagerung an Ort und Stelle sein, und es ist besonders
Der Motor muss in einem Gebäude (über –20°C) trocken darauf zu achten, dass sich niemand unter der
sowie schwingungs- und staubfrei gelagert werden. Beim angehobenen Last aufhält.
Transport sind Erschütterungen, Stürze und Feuchtigkeit zu
vermeiden. Wenn andere Bedingungen vorliegen, wenden
Sie sich bitte an ABB. 3.4 Motorgewicht
Ungeschützte bearbeitete Oberflächen (Wellenenden Das Gesamtgewicht des Motors kann innerhalb der
und Flansche) sollten mit einem Korrosionsschutzmittel gleichen Baugröße (mittige Höhe) je nach den Ausgängen,
behandelt werden. Einbauarrangements und Zusatzeinrichtungen schwanken.
Für eine gleichmäßige Schmierung wird empfohlen, Die folgende Tabelle zeigt die anhand des Rahmenmaterials
die Welle regelmäßig von Hand zu drehen. vorauss. Höchstgewichte für Motoren in der Grundaus-
stattung.
Falls vorhanden, sollten Standheizungen verwendet
werden, um Kondensation im Motor zu verhindern. Das tatsächliche Gewicht aller ABB Motoren ist mit
Ausnahme der kleinsten Baugrößen (56 und 63) auf dem
Zur Vermeidung von Lagerschäden darf der Motor im Leistungsschild angegeben.
Stillstand keinen äußeren Erschütterungen ausgesetzt
werden. Baugröße Aluminium Grauguss Zusätzl.
für Bremse
Motoren mit Zylinderrollen- oder Schrägkugellagern Gewicht kg Gewicht kg
müssen beim Transport mit Sperrvorrichtungen gesichert 56 4,5 - -
werden. 63 6 - -
71 8 13 5
3.3 Heben 80 14 20 8
90 20 30 10
Alle ABB-Motoren über 25 kg haben Hebeösen oder 100 32 40 16
Ösenschrauben. 112 36 50 20
132 93 90 30
Zum Anheben des Motors nur die Hebeösen oder
160 149 130 30
Ösenschrauben des Motors verwenden. Es ist nicht
180 162 190 45
zulässig, den Motor anzuheben, während er an andere
200 245 275 55
Komponenten gekoppelt ist.
225 300 360 75
Hebeösen für Zubehör (z. B. Bremsen, separate 250 386 405 75
280 425 800 -
Kühlgebläse) oder Verteilerkästen dürfen nicht zum
315 - 1.700 -
Heben des Motors verwendet werden. Motoren mit
355 - 2.700 -
gleichem Gehäuse können durch unterschiedliche
400 - 3.500 -
Leistungen, Bauanordnung und Zusatzgeräte verschiedene
450 - 4.500 -
Schwerpunkte haben.
Beschädigte Hebeösen dürfen nicht verwendet werden.

Falls der Motor mit separatem Lüfter ausgestattet ist, bitten
Vor dem Heben Ösenschrauben oder feste Hebeösen auf
Sie ABB um die Gewichtsangaben.
Beschädigung prüfen.
4. Installation und Inbetriebnahme der Maschine
WARNUNG! 4.3 Prüfung des Isolations-

Vor Beginn von Arbeiten am Motor oder an widerstandes
den angetriebenen Komponenten ist der Motor
abzuschalten und zu blockieren. Vor der Inbetriebnahme oder bei Verdacht auf erhöhte
Feuchtigkeit vorliegen ist der Isolationswiderstand zu
prüfen.
4.1 Allgemeines Der Isolationswiderstand, gemessen bei 25°C, liegt
Alle auf dem Leistungsschild angegebenen Werte müssen eventuell nicht in allen Fällen unter 1 MΩ (gemessen mit
sorgfältig geprüft werden, um sicherzustellen, dass 500 oder 1000 VDC). Für jeweils 20°C erhöhte Temperatur
Motorschutz und Anschlüsse korrekt hergestellt werden. ist der Wert des Isolationswiderstandes zu halbieren.
Abbildung 1 kann zur Korrektur der Isolierung auf die
gewünschte Temperatur verwendet werden.
4.2 Motoren mit anderen
als Kugellagern WARNUNG!
Um die Gefahr eines elektrischen Schlages
Die Transportverriegelung, falls vorhanden, entfernen. Falls
auszuschließen, ist das Motorgehäuse zu erden und
möglich, drehen Sie die Motorwelle mit der Hand und
die Wicklungen sind unmittelbar nach der Messung
überprüfen sie auf freies Rotieren.
gegen das Gehäuse zu entladen.
Motoren mit Zylinderrollenlagern:

Der Betrieb der Motoren ohne ausreichende Radialkraft auf Wenn der Bezugswert nicht erreicht wird, ist die Feuchte
die Welle führt aufgrund von "Rutschen" zur Beschädigung innerhalb der Wicklung zu groß und eine Ofentrocknung
des Rollenlagers. wird erforderlich. Die Ofentemperatur sollte für 12-16
Stunden bei 90 °C liegen, danach für 6-8 Stunden bei
105 °C.
Motoren mit Schrägkugellagern:
Der Betrieb des Motors ohne ausreichende Axialkraft auf Falls vorhanden, müssen während der Wärmebehandlung
die Welle führt zur Beschädigung des Schrägkugellagers. die Kondenswasserloch-Stopfen entfernt und die
Sperrventile geöffnet werden. Nach der Wärmebehandlung
die Verschlüsse wieder einsetzen. Auch bei eingesetzten
WARNUNG! Kondenswasserloch-Stopfen sollten die Lagerschild- und
Bei Motoren mit Schrägkugellagern darf sich die Klemmenkasten-Abdeckungen für den Trocknungsvorgang
Richtung der Axialkraft unter keinen Umständen abgenommen werden.
ändern.
Salzwassergetränkte Wicklungen müssen in der Regel
erneuert werden.
Die Lagertypbezeichnungen sind auf dem Leistungsschild
zu ersehen. 4.4 Fundament
Motoren mit Nippel zum Nachschmieren: Der Betreiber trägt die volle Verantwortung für die
Bei Inbetriebnahme des Motors oder nach längerer Bereitstellung des Fundaments.
Lagerung ist die angegebene Fettmenge aufzufüllen. Metallfundamente müssen einen Korrosionsschutzanstrich
Näheres hierzu siehe Abschnitt „7.2.2 Motoren mit erhalten.
nachschmierbarem Lager“. Die Fundamente sind eben und hinreichend steif
Wird ein Motor senkrecht, mit nach unten zeigender Welle auszuführen, um den erhöhten Kräften im Kurzschlussfall
montiert, so ist der Motor durch eine Schutzabdeckung standzuhalten.
gegen herabfallende Gegenstände und gegen das
Eindringen von Flüssigkeiten in die Lüfteröffnungen zu
schützen. Dies kann auch durch eine separate Abdeckung
erfolgen, die nicht am Motor befestigt ist. In diesem Fall
muss am Motor ein Warnschild angebracht sein.
Sie müssen so ausgelegt und bemessen sein, dass Den Motor mit geeigneten Methoden ausrichten.
Resonanzschwingungen vermieden werden. Siehe dazu
Abbildung unten. Gegebenenfalls die Positionsbohrungen durchführen und
die Positionsbolzen an ihren Positionen befestigen.
Richtscheit mit Wasserwaage Montagegenauigkeit von Kupplungshälften: Stellen Sie

sicher, dass sowohl der Freiraum b als auch die Differenz
zwischen a1 und a2 jeweils kleiner als 0,05 mm sind.
Beachten Sie hierzu auch die Angaben auf dem Bild 2.
Hinweis! Der Höhenunterschied
zwischen den Flächen darf
Ausrichtung nach endgültigem Festziehen der Bolzen oder
± 0,1 mm nicht überschreiten. Ankerschrauben erneut prüfen.
Die in den Produktkatalogen angegebenen zulässigen

max. Radial- bzw. Axialkräfte der Lager dürfen nicht
überschritten werden.
Fußposition Es ist zu überprüfen, ob am Motor eine ausreichende

Luftströmung vorhanden ist. Außerdem muss sichergestellt
werden, dass in der Nähe befindliche Anlagen, Oberflächen
oder direkte Sonneneinstrahlung keine zusätzliche
Wärmebelastung für den Motor darstellen.
4.5 Auswuchten und Anbau Bei Motoren mit Flanschanbau (z. B. B5, B35, V1)
sicherstellen, dass die Konstruktion eine ausreichende
von Kupplungshälften Luftströmung an der Außenfläche des Flansches zulässt.
und Riemenscheiben
Das Auswuchten des Motors erfolgte standardgemäß mit 4.7 Radialkräfte
halber Passfeder.
und Riemenantriebe
Kupplungshälften oder Riemenscheiben müssen nach
dem Einfräsen der Passfedernut ausgewuchtet werden. Riemen müssen gemäß der Anleitung des Lieferanten
Das Auswuchten muss entsprechend der für den Motor der angetriebenen Komponente gespannt werden.
angegebenen Auswuchtmethode erfolgen. Beachten Sie jedoch die maximal zulässigen Riemenkräfte
(bzw. Radialkraftbelastungen der Lager), die Sie den
Kupplungshälften und Riemenscheiben dürfen nur mit entsprechenden Produktkatalogen entnehmen können.
geeigneter Ausrüstung und Werkzeug auf der Welle
montiert werden, damit die Lager und Dichtungen nicht
beschädigt werden. WARNUNG!
Übermäßige Riemenspannung führt zur
Montieren Sie niemals eine Kupplungshälfte oder Beschädigung der Lager und kann den Bruch der
Riemenscheibe durch Schläge mit dem Hammer. Bei der Welle zur Folge haben!
Demontage darf nie ein Hebel gegen das Motorgehäuse
angesetzt werden.
4.8 Motoren mit Kondenswasser-

4.6 Einbau und Ausrichtung
Ablaufstopfen
des Motors
Sicherstellen, dass Kondenswasseröffnungen und
Stellen Sie sicher, dass um den Motor genügend Kondenswasserstopfen nach unten zeigen. Bei in vertikaler
Abstand für eine ungehinderte Luftströmung vorhanden Position montierten Motoren können die Ablaufstopfen
ist. Es wird empfohlen, zwischen der Lüfterhaube und waagrecht liegen.
der Wand usw. einen Zwischenraum von mindestens
der Hälfte des Lufteinlasses der Lüfterhaube zu lassen. Motoren mit verschließbaren Ablauföffnungen aus
Weitere Informationen sind im Produktkatalog oder in den Kunststoff werden in geöffnetem Zustand geliefert.
Maßzeichnungen angegeben, die auf unseren Webseiten In sehr staubhaltigen Umgebungen müssen alle
verfügbar sind: www.abb.com/motors&generators. Kondenswasserlöcher verschlossen werden.
Die sorgfältige Ausrichtung ist von entscheidender

Bedeutung für das Vermeiden von Lagerschäden,
Schwingungen und möglichen Brüchen der Wellenenden.
Den Motor mit geeigneten Bolzen oder Ankerschrauben

montieren und zwischen Fundament und Füßen
Distanzscheiben einsetzen.
4.9 Kabel und elektrische Mindestquerschnitt von Schutzleitern
Anschlüsse Querschnitt von Außenleitern

der Installation, S, [mm2]
Mindestquerschnitt des
entsprechenden Schutzleiters,
SP, [mm2]
Der Verteilerkasten von eintourigen Standardmotoren
enthält in der Regel sechs Anschlussklemmen und 4 4
zumindest eine Erdungsklemme. 6 6
10 10
Zusätzlich zu den Klemmen der Hauptwicklung und der 16 16
Erdung kann der Klemmenkasten auch Anschlüsse für 25 25
Kaltleiter, Heizelemente oder anderes Zubehör enthalten. 35 25
50 25
Für die Anschlüsse aller Hauptkabel sind geeignete 70 35
Kabelschuhe zu verwenden. Kabel für Zubehör können 95 50
ohne weitere Vorrichtungen an den entsprechenden 120 70
Klemmenleisten angeschlossen werden. 150 70
Die Motoren sind nur für ortsfeste Installation 185 95
vorgesehen. Sofern nicht anders angegeben, weisen 240 120
300 150
Kabeleinführungsgewinde metrische Maße auf. Die IP-
400 185
Klasse der Kabelverschraubung muss mindestens der
IP-Klasse des Klemmenkastens entsprechen. Zusätzlich müssen die Erdungs- oder Masseanschlüsse an
der Außenseite des elektrischen Geräts über Klemmen für
Bei der Installation müssen zertifizierte Kanal-Hubs oder
einen Leiter mit einem Querschnitt von mindestens 4 mm2
Kabelverbinder verwendet werden.
verfügen.
Die Kabelverbindung zwischen Netz und Motorklemmen

HINWEIS!
muss die Anforderungen der in dem jeweiligen Land
Im Hinblick auf die Einhaltung von IEC/EN 60079-0
gültigen Normen für Motoreneinbau oder der Norm
sowie nationaler Montagenormen sind die Kabel
EN 60204-1 in Übereinstimmung mit dem auf dem
nahe dem Klemmenkasten mit einem mechanischen
Leistungsschild angegebenen Bemessungsstrom erfüllen.
Schutz und mit einer Zugentlastungsvorrichtung zu
versehen.
HINWEIS!
Nicht benutzte Kabeleinführungen sind entsprechend IP- Wenn die Umgebungstemperatur 50 °C
Klasse des Klemmenkastens mit Verschlusselementen zu übersteigt, müssen Kabel mit einer zulässigen
versehen. Betriebstemperatur von mindestens 90 °C
verwendet werden. Bei der Dimensionierung der
Schutzart und Durchmesser sind in den Unterlagen zur Kabel müssen je nach Einbaubedingungen auch
Kabelverschraubung spezifiziert. alle anderen Umrechnungsfaktoren berücksichtigt
werden.
WARNUNG!
Stellen Sie sicher, dass der Motorschutz den jeweiligen
Geeignete Kabelverschraubungen und Dichtungen
Umgebungs- und Witterungsbedingungen entspricht.
in den Kabeleinführungen entsprechend Typ und
Stellen Sie z. B. sicher, dass kein Wasser in den Motor oder
Durchmesser des Kabels verwenden.
die Klemmenkästen eindringen kann.
Zur Gewährleistung der richtigen IP-Klasse müssen

Die Erdung sollte vor dem Anschließen des Motors mit der
die Dichtungen von Klemmenkästen sorgfältig in die
Versorgungsspannung im Einklang mit den jeweils gültigen
hierfür vorgesehenen Schlitze eingesetzt werden.
Vorschriften erfolgen.
Undichte Stellen können das Eindringen von Staub oder
Die Erdungsklemme am Gehäuse muss mit einem Wasser ermöglichen und bergen somit das Risiko eines
Kabel gemäß Tabelle 5 von IEC/EN 60034-1 an die PE Funkenüberschlags zu spannungsführenden Teilen in sich.
(Schutzerde) angeschlossen werden.
4.9.1 Anschlüsse für unterschiedliche 4.10 Anschlussklemmen
Startmethoden
und Drehrichtung
Der Verteilerkasten von eintourigen Standardmotoren
enthält in der Regel sechs Anschlussklemmen und Von der Wellenstirnfläche auf das Antriebsende des
zumindest eine Erdungsklemme. Dies ermöglicht Starts mit Motors gesehen dreht die Welle im Uhrzeigersinn, und die
Netzbetrieb oder Stern-/Dreieckanlauf. Schaltphasensequenz - L1, L2, L3 - wird an die Klemmen
angeschlossen wie in Abb. 3 gezeigt.
Bei polumschaltbaren und Spezialmotoren sind die
entsprechenden Angaben im Klemmenkasten oder im Durch Umpolen der Zuleitungskabel kann die Drehrichtung
Motorhandbuch zu beachten. geändert werden.
Spannung und Anschlussart sind auf dem Typenschild Falls der Motor einen Ein-Weg-Lüfter hat, sicherstellen,
angegeben. dass er in Pfeilrichtung dreht (Pfeil am Motor angebracht).
Direktanlauf (DOL):
Y- oder D-Wicklungsanschlüsse können benutzt werden.
Zum Beispiel 690 VY, 400 VD bedeutet ein Y-Anschluss für

690 V und ein D-Anschluss für 400 V.
Stern-/Dreieckanlauf (Wye/Delta, Y/D):

Bei Verwendung eines D-Anschlusses muss die
Versorgungsspannung die gleiche wie die Nennspannung
des Motors sein.
Alle Verbindungslaschen an der Klemmenleiste sind zu

entfernen.
Andere Startverfahren und widrige Startbedingungen:

In Fällen, in denen in den Betriebsarten S1 und S2 andere
Startmethoden verwendet werden, z.B. Konverter oder
Softstarter, wird davon ausgegangen, dass das Gerät "vom
Netz getrennt ist, wenn die elektrische Maschine läuft", wie
in der Norm IEC 60079-0 verlangt, und Wärmeschutz ist
optional.
4.9.2 Anschlüsse von Zubehör

Wenn ein Motor mit Kaltleitern oder anderen WDFs
(Pt100, Thermorelais usw.) und Zubehör ausgestattet ist,
müssen diese mit geeigneten Methoden verwendet und
angeschlossen werden. Für bestimmte Schutzarten ist ein
Wärmeschutz obligatorisch. Nähere Informationen finden
Sie in den mit dem Motor gelieferten Dokumenten. Auf
der Innenseite des Klemmenkastens befinden sich die
Anschlussschaltbilder für die Hilfselemente.
Die maximale Messspannung für die Kaltleiter beträgt 2,5 V.

Der maximale Messstrom für Pt100 beträgt 5 mA. Die
Verwendung einer höheren Messspannung oder eines
höheren Messstroms kann zu beschädigten Temperatur-
fühlern führen.
Die Isolierung der Wärmesensoren erfüllt die Anforderungen

einer Basisisolierung.
5. Betriebsbedingungen
5.1 Allgemeines
Sofern auf dem Leistungsschild nicht anders angegeben,
sind die Motoren für folgende Bedingungen ausgelegt:
- Die Motoren sind nur für ortsfeste Installation

vorgesehen.
- Die Umgebungstemperatur liegt im Bereich von
–20 °C bis +40 °C.
- Die maximal zulässige Aufstellungshöhe liegt bei
1.000 m über dem Meeresspiegel.
- Die Abweichung von Netzspannung und Frequenz darf
die in einschlägigen Normen genannten Grenzwerte
nicht überschreiten. Die Toleranz beträgt gemäß
Abbildung 4 (EN/IEC 60034-1, Abschnitt 7.3, Zone A)
für die Versorgungsspannung ±5 % und für die
Frequenz ±2 %. Beide Extremwerte sollen nicht zur
gleichen Zeit auftreten.
Der Motor darf nur für zweckbestimmte Anwendungen

eingesetzt werden. Die Nennwerte und Betriebsbe-
dingungen werden auf den Motorleistungsschildern
angegeben. Zudem müssen alle Anforderungen in diesem
Handbuch und weitere entsprechende Anweisungen und
Normen erfüllt und befolgt werden.
Werden diese Grenzen überschritten, müssen Motor-

und Konstruktionsdaten überprüft werden. Für weitere
Informationen wenden Sie sich bitte an ABB.
WARNUNG!
Die Nichteinhaltung von Anweisungen oder der
Wartung des Geräts kann die Sicherheit und damit
den Einsatz des Motors gefährden.
6. Drehzahlgeregelte Niederspannungsmotoren
6.1 Einführung 6.2.1 Auswahl der Wicklungsisolierung

für ABB-Frequenzumrichter
Dieser Teil des Handbuchs enthält zusätzliche Anlei-
tungen für Motoren, die in Bereichen mit Frequenzum- Bei ABB-Frequenzumrichtern z.B. der Baureihe AC_8_ _
richterspeisung verwendet werden. Der Motor ist dazu und AC_5_ _ mit Dioden-Einspeisungseinheit (ungesteuerte
bestimmt, von einem einzigen Frequenzumformer versorgt DC-Spannung) können Wicklungsisolierung und Filter
zu werden, und Motoren dürfen nicht parallel von einem gemäß Tabelle 6.1 ausgewählt werden.
Frequenzumrichter betrieben werden. Die Anweisungen
des Umrichterherstellers sind zu beachten. 6.2.2 Auswahl der Wicklungsisolierung aller
ABB behält sich vor, zusätzliche Informationen anzufordern übrigen Frequenzumrichter
zwecks Prüfung der Eignung für bestimmte Motortypen,
Die Spannungsbelastungen sind auf Werte unter den
die bei speziellen Anwendungen oder mit speziellen
zulässigen Grenzen zu begrenzen. Wenden Sie sich
Konstruktionsänderungen zum Einsatz kommen.
an den Lieferanten des Systems, um die Sicherheit der
Anwendung zu gewährleisten. Bei der Dimensionierung des
Motors ist der Einfluss möglicher Filter zu berücksichtigen.
6.2 Wicklungsisolierung
Drehzahlgeregelte Antriebe erzeugen an der Motorwicklung
höhere Spannungsbelastungen als die sinusförmige 6.3 Thermoisolierung
Versorgung. Daher muss die Wicklungsisolierung
des Motors sowie der Filter am Umrichterausgang
der Wicklung
entsprechend der folgenden Angaben dimensioniert sein. Die meisten Motoren, die in diesem Handbuch behandelt
werden, sind mit PTC-Thermistoren oder anderen RTDs
in den Ständerwicklungen ausgestattet. Diese müssen an
den Frequenzumrichter angeschlossen werden. Mehr dazu
erfahren Sie in Kapitel 4.9.2.
PN < 100 kW PN ≥ 100 kW oder PN ≥ 350 kW oder

IEC315 ≤ Baugröße ≤ IEC355 IEC400 ≤ Baugröße ≤ IEC450
UN ≤ 500 V Standardmotor Standardmotor Standardmotor
+ Isoliertes N-Lager + Isoliertes N-Lager
+ Gleichtaktfilter
500V >UN ≤ 600V Standardmotor Standardmotor Standardmotor
+ dU/dt-Filter (Reaktor) + dU/dt-Filter (Reaktor) + Isoliertes N-Lager
ODER + Isoliertes N-Lager + dU/dt-Filter (Reaktor)
Verstärkte Isolierung ODER + Gleichtaktfilter
Verstärkte Isolierung ODER
+ Isoliertes N-Lager Verstärkte Isolierung
+ Isoliertes N-Lager
+ Gleichtaktfilter
500V >UN ≤ 600V Standardmotor Standardmotor Standardmotor
(Kabellänge > 150 m) + Isoliertes N-Lager + Isoliertes N-Lager
+ Gleichtaktfilter
600V >UN ≤ 690V Verstärkte Isolierung Verstärkte Isolierung Verstärkte Isolierung

+ dU/dt-Filter (Reaktor) + dU/dt-Filter (Reaktor) + Isoliertes N-Lager
+ Isoliertes N-Lager + dU/dt-Filter (Reaktor)
+ Gleichtaktfilter
600V >UN ≤ 690V Verstärkte Isolierung Verstärkte Isolierung Verstärkte Isolierung
(Kabellänge > 150 m) + Isoliertes N-Lager + Isoliertes N-Lager
+ Gleichtaktfilter
Tabelle 6.1 Auswahl der Wicklungsisolierung für ABB-Frequenzumrichter
Für weitere Informationen zu Frequenzumrichtern mit gesteuerten Einspeiseeinheiten oder Widerstandsbremsung wenden
Sie sich bitte an ABB.
6.4 Lagerströme Bei Motoren ab Baugröße 280 ist ein zusätzlicher Potenzial-
ausgleich zwischen Motorgehäuse und angetriebenen
Es sind isolierte Lager oder Lagerkonstruktionen, Komponenten erforderlich, sofern nicht beide auf einem
Gleichtaktfilter und geeignete Verkabelungs- und gemeinsamen Stahlfundament montiert sind. In diesem
Erdungsverfahren gemäß der folgenden Anweisungen und Fall muss die Leitfähigkeit bei hoher Frequenz der über
Tabelle 6.1 zu verwenden. das Stahlfundament vorhandenen Verbindung überprüft
werden, indem z. B. die Potentialdifferenz zwischen den
Komponenten gemessen werden.
6.4.1 Verhindern von Lagerströmen bei
ABB-Frequenzumrichtern Weitere Informationen über die Erdung und Verkabelung
Bei ABB-Frequenzumrichtern z.B. der Baureihe AC_8_ _ bei drehzahlgeregelten Antrieben finden Sie im Handbuch
und AC_5_ _ mit Dioden-Einspeisungseinheit, sind „Erdung und Verkabelung des Antriebssystems“ (Code:
Verfahren gemäß Tabelle 6.1 zu verwenden, um schädliche 3AFY 61201998).
Lagerströme in den Motoren zu verhindern.
6.6 Betriebsdrehzahl
HINWEIS!
Es werden isolierte Lager mit aluminiumoxid- Für Drehzahlen über der auf dem Leistungsschild des
beschichteten Innen- und/oder Außenringen Motors angegebenen Nenndrehzahl sicherstellen, dass die
oder Keramikwälzkörpern empfohlen. Aluminium- höchste zulässige Drehzahl des Motors oder die kritische
oxidbeschichtungen werden außerdem mit einem Drehzahl der gesamten Anwendung nicht überschritten
Dichtungsmittel behandelt, um das Eindringen wird.
von Schmutz und Feuchtigkeit in die poröse
Beschichtung zu verhindern. Genaue Angaben
zum Typ der Lagerisolierung finden Sie auf dem 6.7 Motoren mit drehzahl-
Leistungsschild des Motors. Das Ändern des
Lagertyps oder der Isolierungsmethode ohne die geregelten Anwendungen
Genehmigung von ABB ist untersagt.
6.7.1 Allgemeines
6.4.2 Verhindern von Lagerströmen Bei Frequenzumrichtern von ABB kann das Dimensionieren
bei allen anderen Umrichtern mithilfe des Dimensionierungsprogramms DriveSize von
ABB erfolgen. Das Tool kann von der ABB Website (www.
Der Betreiber ist für den Schutz des Motors und
abb.com/motors&generators) heruntergeladen werden.
der angetriebenen Komponenten vor schädlichen
Lagerströmen verantwortlich. Die Anweisungen in Kapitel Für Anwendungen, die durch andere Frequenzumrichter
6.4.1 können als Richtlinie verwendet werden, doch kann gestützt werden, muss die Dimensionierung manuell
ihre Wirksamkeit nicht in allen Fällen gewährleistet werden. erfolgen. Für weitere Informationen wenden Sie sich bitte
an ABB.
6.5 Verkabelung, Erdung Die Belastbarkeitskurven basieren auf der Nennver-
und EMV sorgungsspannung. Der Betrieb bei Unter- oder Über-
spannung kann die Leistung der Anwendung beeinflussen.
Um eine korrekte Erdung und Übereinstimmung mit allen
EMV-Richtlinien zu gewährleisten, müssen an 6.7.2 Motorbelastbarkeit mit Frequenz-
Motoren über 30 kW abgeschirmte symmetrische Kabel umrichterantrieben der Baureihe
angeschlossen und EMV-Kabelverschraubungen, d.
h. Verschraubungen mit 360°-Schirmkontaktierung, AC_8_ _ mit DTC-Regelung
verwendet werden. Die Belastbarkeitskurven in Abb. 5a - 5d gelten für
ABB-Frequenzumrichter der Baureihe AC_8_ _ mit
Für kleinere Motoren werden symmetrische abgeschirmte ungesteuerter DC-Spannung und DTC-Steuerung. Die
Kabel dringend empfohlen. Die 360°-Erdung an allen Abbildungen stellen das ungefähre maximal zulässige
Kabeleinführungen wie in den Anweisungen für die dauerhafte Ausgangsdrehmoment der Motoren als
Kabelverschraubungen vornehmen. Kabelabschirmungen Funktion der Versorgungsspannungsfrequenz dar.
zu Bündeln verdrillen und an die nächste Das Ausgangsdrehmoment wird als Prozentsatz des
Erdungsklemme/Sammelschiene im Klemmenkasten, Nenndrehmoments des Motors angegeben. Die Werte sind
Frequenzumwandlerschrank usw. anschließen. nur indikativ, genaue Werte sind auf Anfrage erhältlich.
HINWEIS! HINWEIS!
An allen Endpunkten, z. B. Motor, Frequenz- Die Höchstdrehzahl des Motors und der Anwendung
umrichter, ggf. Sicherheitsschalter usw., müssen darf nicht überschritten werden!
ordnungsgemäße Kabelverschraubungen mit
360°-Masseverbindung verwendet werden.
6.7.3 Motorbelastbarkeit mit Frequenz- 6.9 Inbetriebnahme des
umrichterantrieben der Baureihe
AC_5_ _
drehzahlgeregelten Antriebs
Die Belastbarkeitskurven in Abb. 6a - 6d gelten für Die Inbetriebnahme des drehzahlgeregelten Motors muss
ABB-Frequenzumrichter der Baureihe AC_5_ _. Die gemäß den Anweisungen für den Frequenzumrichter und
Abbildungen stellen das ungefähre maximal zulässige den lokalen Gesetzen und Vorschriften erfolgen. Die durch
dauerhafte Ausgangsdrehmoment der Motoren als die Anwendung gesetzten Anforderungen und Grenzen
Funktion der Versorgungsspannungsfrequenz dar. sind ebenfalls zu berücksichtigen.
Das Ausgangsdrehmoment wird als Prozentsatz des
Nenndrehmoments des Motors angegeben. Die Werte sind Alle zum Einrichten des Frequenzumrichters erforderlichen
nur indikativ, genaue Werte sind auf Anfrage erhältlich. Parameter müssen den Motorleistungsschildern
entnommen werden. Die am häufigsten benötigten
Parameter lauten:
HINWEIS!
Die Höchstdrehzahl des Motors und der Anwendung
- Nennspannung
darf nicht überschritten werden!
- Nennstrom
- Nennfrequenz
6.7.4 Motorbelastbarkeit mit PWM- - Nenndrehzahl
Frequenzumrichtern mit anderen - Nennleistung
Spannungsquellen
Für andere Frequenzumrichter mit ungesteuerter Gleich-
HINWEIS!
spannung und einer Mindestschaltfrequenz von 3 kHz
Bei fehlenden oder ungenauen Daten den Motor
(200…500 V) kann die Dimensionierungsanleitung gemäß
nicht in Betrieb nehmen, bevor die korrekten
Kapitel 6.7.3 als Richtlinie verwendet werden. Es sollte aber
Einstellungen gewährleistet sind.
beachtet werden, dass die tatsächliche Wärmebelastbarkeit
auch niedriger sein kann. Wenden Sie sich an den
Hersteller des Frequenzumrichters oder den Lieferanten
ABB empfiehlt die Verwendung aller geeigneten
des Systems.
Schutzfunktionen des Frequenzumrichters, um die
Sicherheit der Anwendung zu erhöhen. Frequenzumrichter
HINWEIS! bieten in der Regel z. B. folgende Funktionen (Namen und
Die tatsächliche Wärmebelastbarkeit eines Motors Verfügbarkeit der Funktionen hängen von Hersteller und
kann geringer als durch die Richtlinienkurven Modell des Frequenzumrichters ab):
angegeben sein.
- Mindestdrehzahl
- Höchstdrehzahl
6.7.5 Kurzzeitige Überlasten - Zeit für Beschleunigung und Abbremsung
ABB-Motoren können normalerweise kurzfristig überlastet - Maximaler Strom
und im Aussetzbetrieb verwendet werden. Die bequemste - Maximales Drehmoment
Art der Dimensionierung solcher Anwendungen ist die - Blockierschutz
Verwendung des Tools DriveSize.
6.8 Leistungsschilder
Die Verwendung von ABB-Motoren mit drehzahlgeregelten
Anwendungen erfordert gewöhnlich keine zusätzlichen
Leistungsschilder. Die Parameter zur Inbetriebnahme des
Frequenzumrichters sind auf dem Hauptleistungsschild
enthalten. Für einige Spezialanwendungen können
Motoren jedoch mit zusätzlichen Leistungsschildern für
drehzahlgeregelte Anwendungen ausgestattet sein. Diese
enthalten folgende Informationen:
- Drehzahlbereich
- Leistungsbereich
- Spannungs- und Strombereich
- Drehmomenttyp (konstant oder quadratisch)
- Frequenzumrichtertyp und erforderliche Mindest-
schaltfrequenz
7. Wartung 1. Die Welle muss regelmäßig alle 2 Wochen durch
Starten des Systems (berichtspflichtig) gedreht werden.
Ist ein Start aus irgendeinem Grund nicht möglich,
WARNUNG! muss die Welle pro Woche mindestens einmal mit der
Auch bei Stillstand des Motors können gefährliche Hand gedreht werden, um so eine andere Position zu
Spannungen für die Versorgung von Heizelementen erreichen. Durch andere Behälterausrüstung verursachte
oder für eine direkte Wicklungsheizung anliegen. Vibrationen führen zu einer Korrosion des Lagers, was
durch regelmäßigen Betrieb oder durch Handbewegung
minimiert wird.
2. Das Lager muss einmal pro Jahr während des Drehens

7.1 Allgemeine Kontrolle der Welle geschmiert werden (berichtspflichtig).
1. Untersuchen Sie den Motor in regelmäßigen Verfügt der Motor am angetriebenen Ende über ein
Abständen, mindestens einmal pro Jahr. Die Häufigkeit Zylinderrollenlager, muss vor dem Drehen der Welle die
der Kontrollen hängt z. B. von der Feuchtigkeit der Transportverriegelung entfernt werden. Im Falle eines
Umgebungsluft und von den lokalen Wetterverhältnissen Transports muss die Transportverriegelung wieder
ab. Sie sind auf experimentellem Wege zu ermitteln und angebracht werden.
dann genau einzuhalten. 3. Vibrationen müssen vermieden werden, um ein
2. Halten Sie den Motor sauber und sorgen Sie für einen Nichtfunktionieren des Lagers zu verhindern. Die
freien Kühlluftstrom. Beim Einsatz des Motors in Anweisungen der Betriebsanleitung des Motors für
einer staubigen Umgebung ist es zu empfehlen, das Inbetriebnahme und Wartung müssen ebenfalls genau
Belüftungssystem regelmäßig zu überprüfen und zu befolgt werden. Werden diese Anweisungen nicht
reinigen. befolgt, sind Wicklungs- und Lagerschäden nicht von
der Garantie abgedeckt.
3. Den Zustand der Wellendichtungen untersuchen
(z. B. V-Ring oder Radialdichtung); bei Bedarf neue
Dichtungen einsetzen.
7.2 Schmierung
4. Überprüfen Sie den Zustand aller Verbindungen und
Verbindungselemente (z. B. Schrauben).
5. Den Lager-Zustand untersuchen: auf ungewöhnliche WARNUNG!
Geräusche achten, Schwingung und Lagertemperatur Vorsicht bei allen rotierenden Teilen!
messen, Kontrolle des verbrauchten Schmierfetts
oder Lager-Überwachung über SPM. Die Lager
erfordern eine besondere Aufmerksamkeit, wenn deren
Nennlebensdauer abläuft. WARNUNG!
Viele Fette können Hautreizungen sowie
Wenn Anzeichen von Abnutzung festgestellt werden, Entzündungen des Auges verursachen. Befolgen Sie
den Motor auseinanderbauen, die Teile kontrollieren und alle Sicherheitshinweise des Schmierfett-Herstellers.
erforderlichenfalls auswechseln. Die Originallager dürfen
nur durch Lager gleichen Typs ersetzt werden. Desgleichen
müssen neue Wellendichtungen von derselben Qualität sein Lagertypen sind in den entsprechenden Produktkatalogen
und die gleichen Eigenschaften wie die Originaldichtungen spezifiziert und auf dem Leistungsschild aller unserer
aufweisen. Motoren mit Ausnahme der Motoren mit den kleinsten
Baugrößen angegeben.
Wenn ein IP 55-Motor mit geschlossenem
Kondenswasserloch-Stopfen geliefert wurde, sollten Für Lagerschmierintervalle ist Zuverlässigkeit von
die Kondenswasserloch-Stopfen in regelmäßigen entscheidender Bedeutung. ABB verwendet für die
Abständen geöffnet werden, um sicherzustellen, Schmierung das L1-Prinzip (d. h. dass 99 % der Motoren
dass der Kondenswasserabfluss nicht blockiert ist die Nennlebensdauer erreichen).
und das Kondensat entweichen kann. Dies muss aus
Sicherheitsgründen bei abgestelltem Motor durchgeführt 7.2.1 Motoren mit dauergeschmierten
werden. Lagern
Lager sind im Allgemeinen dauergeschmierte Lager vom
7.1.1 Standbymotoren Typ 1Z, 2Z, 2RS oder äquivalentem Typ.
Befindet sich der Motor über einen längeren Zeitraum Als Faustregel kann eine angemessene Schmierung
in Standby und auf einem Schiff oder in einer anderen für Größen bis zu 250 gemäß L1 für die folgende Dauer
vibrierenden Umgebung, müssen die folgenden erreicht werden. Für Informationen über den Betrieb bei
Maßnahmen ergriffen werden: höherer Umgebungstemperatur bitte an ABB wenden. Die
informative Faustformel zum Ändern der L1-Werte in L10-
Werte: L10 = 2,0 x L1.
Betriebsstunden für dauergeschmierte Lager bei einer Nachschmieren bei stillstehendem Motor
Umgebungstemperatur von 25 °C und 40 °C: Falls es nicht möglich ist, die Lager bei laufendem Motor
nachzuschmieren, kann auch bei stillstehendem Motor
Betriebs- Betriebs- geschmiert werden.
stunden stunden – In diesem Fall nur die Hälfte der Fettmenge benutzen,
Baugröße Pole bei 25° C bei 40° C anschließend den Motor für einige Minuten bei voller
56 2 52.000 33.000 Drehzahl laufen lassen.
56 4-8 65.000 41.000 – Nachdem der Motor abgestellt ist, den Rest der
63 2 49.000 31.000 vorgesehenen Fettmenge in das Lager drücken.
63 4-8 63.000 40.000 – Nach 1-2 Stunden Durchlauf die Fett-Auslassöffnung
71 2 67.000 42.000 verschließen oder das Sperrventil, falls vorhanden,
71 4-8 100.000 56.000 schließen.
80-90 2 100.000 65.000
B. Automatische Schmierung
80-90 4-8 100.000 96.000
100-112 2 89.000 56.000 Bei automatischer Schmierung muss die Fett-Auslass-
100-112 4-8 100.000 89.000 öffnung beständig offen sein, bzw. das Sperrventil, falls
132 2 67.000 42.000 vorhanden, geöffnet sein.
132 4-8 100.000 77.000
160 2 60.000 38.000
ABB empfiehlt dringend den Einsatz elektromechanischer
Anlagen.
160 4-8 100.000 74.000
180 2 55.000 34.000 Bei Benutzung eines zentralen Schmiersystems sind die
180 4-8 100.000 70.000 in der Tabelle angegebenen Werte für Schmierfett pro
200 2 41.000 25.000 Schmierintervall zu verdreifachen. Bei Verwendung eines
200 4-8 95.000 60.000 kleineren automatischen Nachschmiersystems (eine oder
225 2 36.000 23.000 zwei Patronen pro Motor), kann die normale Menge an Fett
225 4-8 88.000 56.000 verwendet werden.
250 2 31.000 20.000
Wenn 2-polige Motoren automatisch nachgeschmiert
250 4-8 80.000 50.000
werden, befolgen Sie bitte die entsprechenden
Daten gelten für Werte von bis zu 60 Hz. Schmierempfehlungen im Kapitel über Schmiermittel.
Das verwendete Schmierfett sollte für automatische

7.2.2 Motoren mit nachschmierbarem Schmierung geeignet sein. Der Lieferant des
Lager automatischen Schmiersystems und die Empfehlungen des
Schmiermittelherstellers sollten überprüft werden.
Informationsschild für Schmierung und allgemeiner
Ratgeber zur Schmierung Berechnungsbeispiel für die benötigte Menge an
Ist der Motor mit einem Informationsschild für Schmierung Schmierfett für ein automatisches Schmiersystem
versehen, sind die dort angegebenen Werte zu befolgen. Zentrales Schmiersystem: Motor IEC M3_P 315_ 4-polig in
50 Hz-Netzwerk, Schmierintervall entsprechend Tabelle ist
Auf dem Schild sind die Schmierintervalle bezüglich Einbau,
7600 h/55g (DE) und 7600 h/40g (NDE):
Umgebungstemperatur und Drehzahl angegeben.
Beim ersten Start oder nach einer Lagerschmierung (DE) RLI = 55 g/7600h*3*24 = 0,52 g/Tag
kann für ca. 10 bis 20 Stunden ein temporärer (NDE) RLI = 40 g/7600*3*24 = 038 g/Tag
Temperaturanstieg auftreten.
Einige Motoren sind mit einem Sammler für Altfett Berechnungsbeispiel für die benötigte Menge an
ausgerüstet. Entsprechend die Anweisung für diese Schmierfett für eine automatische Schmiereinheit
Einrichtung befolgen. (Patrone)
(DE) RLI = 55 g/7600h*24 = 0,17 g/Tag
A. Manuelle Schmierung
(NDE) RLI = 40 g/7600*24 = 0,13 g/Tag
Nachschmieren bei laufendem Motor
– Den Stopfen der Schmiermittel-Auslassöffnung RLI = Schmierintervall, DE = Antriebsseite,
abnehmen oder das Sperrventil öffnen, falls vorhanden. NDE = Nichtantriebsseite
– Sicherstellen, dass der Schmierkanal offen ist.
– Die vorgesehene Menge Schmierfett in das Lager
einspritzen.
– Den Motor 1-2 Stunden laufen lassen, um sicher-
zustellen, dass sämtliches überschüssiges Schmiermittel
aus dem Lager gedrückt ist. Den Stopfen der Fett-
Auslassöffnung oder ggf. Sperrventil schließen.
7.2.3 Schmierintervalle und -mengen
Für vertikal montierte Motoren sind die
Nachschmierintervalle in der folgenden Tabelle zu halbieren.
Als Faustregel kann eine angemessene Schmierung gemäß

L1 für die folgende Dauer erreicht werden. Für Informationen
über den Betrieb bei höherer Umgebungstemperatur bitte
an ABB wenden. Die Faustformel zum Ändern der L1-Werte
in L10-Werte ist L10 = 2,0 x L1.
Die Schmierintervalle basieren auf einer Lager-Betriebs-

temperatur von 80 °C (Umgebungstemperatur +25 °C).
HINWEIS!
Ein Anstieg der Umgebungstemperatur lässt die
Temperatur der Lager entsprechend ansteigen.
Bei einem Anstieg der Lager-Temperatur von 15 °C
sollten die Werte halbiert, bei einem Absinken
um 15 °C können sie verdoppelt werden.
Höhere Drehzahlen, z. B. bei Frequenzumrichterbetrieb,

oder niedrige Drehzahlen unter hoher Belastung erfordern
kürzere Nachschmierintervalle.
WARNUNG!
Die zulässigen Höchsttemperaturen für Lager und
Schmierfett, +110 °C,dürfen nicht überschritten
werden.
Die Höchstdrehzahl, für die der Motor ausgelegt ist,
darf nicht überschritten werden.
Fett-
Bau- 3600 3000 1800 1500 1000 500-900
menge kW kW kW kW
größe U/min U/min U/min U/min U/min U/min
g/Lager
Kugellager, Nachschmierintervalle in Betriebsstunden
112 10 alle 10.000 13.000 alle 18.000 21.000 alle 25.000 alle 28.000
132 15 alle 9.000 11.000 alle 17.000 19.000 alle 23.000 alle 26.500
160 25 ≤ 18,5 9.000 12.000 ≤ 15 18.000 21.500 ≤ 11 24.000 alle 24.000
160 25 > 18,5 7.500 10.000 > 15 15.000 18.000 > 11 22.500 alle 24.000
180 30 ≤ 22 7.000 9.000 ≤ 22 15.500 18.500 ≤ 15 24.000 alle 24.000
180 30 > 22 6.000 8.500 > 22 14.000 17.000 > 15 21.000 alle 24.000
200 40 ≤ 37 5.500 8.000 ≤ 30 14.500 17.500 ≤ 22 23.000 alle 24.000
200 40 > 37 3.000 5.500 > 30 10.000 12.000 > 22 16.000 alle 20.000
225 50 ≤ 45 4.000 6.500 ≤ 45 13.000 16.500 ≤ 30 22.000 alle 24.000
225 50 > 45 1.500 2.500 > 45 5.000 6.000 > 30 8.000 alle 10.000
250 60 ≤ 55 2.500 4.000 ≤ 55 9.000 11.500 ≤ 37 15.000 alle 18.000
250 60 > 55 1.000 1.500 > 55 3.500 4.500 > 37 6.000 alle 7.000
2801) 60 alle 2.000 3.500 - - - - - - -
2801) 60 - - - alle 8.000 10.500 alle 14.000 alle 17.000
280 35 alle 1.900 3.200 - - - -
280 40 - - alle 7.800 9.600 alle 13.900 alle 15.000
315 35 alle 1.900 3.200 - - - -
315 55 - - alle 5.900 7.600 alle 11.800 alle 12.900
355 35 alle 1.900 3.200 - - - -
355 70 - - alle 4.000 5.600 alle 9.600 alle 10.700
400 40 alle 1.500 2.700 - - - -
400 85 - - alle 3.200 4.700 alle 8.600 alle 9.700
450 40 alle 1.500 2.700 - - - -
450 95 - - alle 2.500 3.900 alle 7.700 alle 8.700
Rollenlager, Nachschmierintervalle in Betriebsstunden

160 25 ≤ 18,5 4.500 6.000 ≤ 15 9.000 10.500 ≤ 11 12.000 alle 12.000
160 25 > 18,5 3.500 5.000 > 15 7.500 9.000 > 11 11.000 alle 12.000
180 30 ≤ 22 3.500 4.500 ≤ 22 7.500 9.000 ≤ 15 12.000 alle 12.000
180 30 > 22 3.000 4.000 > 22 7.000 8.500 > 15 10.500 alle 12.000
200 40 ≤ 37 2.750 4.000 ≤ 30 7.000 8.500 ≤ 22 11.500 alle 12.000
200 40 > 37 1.500 2.500 > 30 5.000 6.000 > 22 8.000 alle 10.000
225 50 ≤ 45 2.000 3.000 ≤ 45 6.500 8.000 ≤ 30 11.000 alle 12.000
225 50 > 45 750 1.250 > 45 2.500 3.000 > 30 4.000 alle 5.000
250 60 ≤ 55 1.000 2.000 ≤ 55 4.500 5.500 ≤ 37 7.500 alle 9.000
250 60 > 55 500 750 > 55 1.500 2.000 > 37 3.000 alle 3.500
2801) 60 alle 1.000 1.750 - - - - - - -
2801) 70 - - - alle 4.000 5.250 alle 7.000 alle 8.500
280 35 alle 900 1.600 - - - -
280 40 - - alle 4.000 5.300 alle 7.000 alle 8.500
315 35 alle 900 1.600 - - - -
315 55 - - alle 2.900 3.800 alle 5.900 alle 6.500
355 35 alle 900 1.600 - - - -
355 70 - - alle 2.000 2.800 alle 4.800 alle 5.400
400 40 alle - 1.300 - - - -
400 85 - - alle 1.600 2.400 alle 4.300 alle 4.800
450 40 alle - 1.300 - - - -
450 95 - - alle 1.300 2.000 alle 3.800 alle 4.400
1)
M3AA
7.2.4 Schmiermittel
HINWEIS!
Stets Hochgeschwindigkeitsfette verwenden für
WARNUNG! 2-polige Maschinen mit hoher Drehzahl, bei denen
Verschiedene Fetttypen nicht miteinander der Drehzahlfaktor höher als
vermischen. 480.000 ist (berechnet als Dm x n, wobei
Ungeeignete Schmiermittel können die Lager Dm = durchschnittlicher Lagerdurchmesser in mm;
beschädigen. n = Drehzahl U/min).
Für die Nachschmierung darf nur ein speziell auf die Folgende Schmierfette können mit Graugussmotoren mit
Schmierung von Kugellagern abgestimmtes Fett mit den hoher Drehzahl verwendet werden, dürfen jedoch nicht mit
folgenden Eigenschaften verwendet werden: Schmierfetten auf Lithiumkomplex-Basis gemischt werden:
– Hochwertiges Fett mit Lithiumkomplexseife und Mineral- - Klüber Klüber Quiet BQH 72-102 (Polyuretan-Basis)
oder PAO-Öl - Lubcon Turmogrease PU703 (Polyuretan-Basis)
– Viskosität des Grundöls 100-160 cST bei 40 °C
– Konsistenz NLGI Bereich 1,5 - 3 *) Falls andere Schmiermittel verwendet werden, erkundigen
– Dauergebrauchstemperatur -30° C bis +120° C Sie sich bitte beim Hersteller, ob die Qualität derjenigen der
oben aufgeführten Fette entspricht. Die Schmierintervalle
*) Für vertikal montierte Motoren und unter heißen basieren auf den oben aufgeführten hochwertigen
Betriebsbedingungen ist ein steiferer NLGI-Grad zu Schmierfetten. Bei Verwendung anderer Schmierfette
empfehlen. können sich die Intervalle verringern.
Die oben angegebene Schmierfettspezifikation gilt für
Umgebungstemperaturen über -30 °C oder unter +55 °C
und Lagertemperaturen unter 110 °C. Wenden Sie sich
andernfalls an ABB für Informationen über geeignetes
Schmierfett.
Geeignete Fette mit den geforderten Eigenschaften sind bei

allen größeren Schmiermittelherstellern erhältlich.
Beimengungen werden empfohlen, doch sollte man

eine schriftliche Garantie vom Schmiermittelhersteller
besonders für EP-Zusätze erhalten, dass diese
nicht die Lager beschädigen oder innerhalb des
Betriebstemperaturbereichs die Eigenschaften der
Schmiermittel beeinträchtigen.
WARNUNG!
Schmiermittel, denen EP-Zusätze beigemengt sind,
sind unter hohen Lager-Temperaturen bei Baugrößen
von 280 bis 450 nicht zu empfehlen.
Folgende hochwertige Schmierfette können benutzt

werden:
– Mobil Unirex N2 oder N3 (Lithiumkomplex-Basis)
– Mobil Mobilith SHC 100 (Lithiumkomplex-Basis)
– Shell Gadus S5 V 100 2 (Lithiumkomplexbasis)
– Klüber Klüberplex BEM 41-132 (Spezielle Lithiumbasis)
– FAG Arcanol TEMP110 (Lithiumkomplex-Basis)
(Spezielle Lithiumbasis)
– Total Multiplex S2 A (Lithiumkomplexbasis)
– Rhenus Rhenus LKZ 2 (Lithiumkomplexbasis)
8. Kundendienst 9. Umweltanforderungen
Die meisten ABB Motoren haben einen Schalldruckpegel,
8.1 Ersatzteile der 82 dB(A) (± 3 dB) bei 50 Hz nicht überschreitet.
Sofern nicht anders angegeben, dürfen als Ersatzteile nur Konkrete Werte für die einzelnen Motoren sind dem
von ABB gelieferte und geprüfte Teile eingesetzt werden. jeweiligen Produktkatalog zu entnehmen. Bei 60 Hz
Bei der Bestellung von Ersatzteilen sollte die sinusförmige Versorgung sind die Werte ca. 4 dB(A) höher
Motorseriennummer, die vollständige Typenbezeichnung als die 50 Hz-Werte in den Produktkatalogen.
und der Produktkode (siehe Leistungsschild) angegeben Bzgl. des Schalldruckpegels bei Frequenzumrichter-
werden. speisung setzen Sie sich bitte mit ABB in Verbindung.
Wenn Motoren ausgesondert oder recycelt werden

8.2 Demontage und Neueinbau müssen, sind die geeigneten Methoden sowie die lokalen
sowie Neuwicklung Vorschriften und Gesetze zu beachten.
Neuwicklungen dürfen nur in autorisierten Werkstätten

durchgeführt werden.
Brandgas-Entlüftungsmotoren und andere Spezialmotoren

sollten nicht ohne Rücksprache mit ABB neugewickelt
werden.
8.3 Lager
Die Lager sind mit besonderer Sorgfalt zu behandeln.
Die Lager dürfen nur mit Hilfe von Ausziehwerkzeugen

demontiert und in erwärmtem Zustand oder unter
Verwendung von Spezialwerkzeug eingebaut werden.
Der Austausch von Lagern wird in einer eigenen

Hinweisschrift von ABB ausführlich beschrieben.
Auf dem Motor, z. B. auf Schildern, angebrachte

Anweisungen sind zu befolgen. Die auf dem
Leistungsschild angegebenen Lagertypen dürfen nicht
geändert werden.
HINWEIS!
Jegliche vom Endanwender durchgeführte
Reparatur, sofern diese nicht ausdrücklich vom
Hersteller genehmigt worden ist, enthebt den
Hersteller seiner Haftung für Normenkonformität der
Ausrüstung.
10. Motor-Störungssuchtabelle
In den folgenden Anleitungen kann nicht auf sämtliche Motor-Fehlersuchtabelle
technische Einzelheiten oder Unterschiede zwischen den
verschiedenen Motoren oder alle bei der Installation, beim Wartungs- und etwaige Fehlersuchmaßnahmen am Motor
Betrieb oder bei der Wartung möglicherweise auftretenden dürfen nur von hierfür qualifiziertem Personal und mit
Situationen eingegangen werden. Anfragen bezüglich geeigneten Werkzeugen und Hilfsmitteln durchgeführt
weitergehender Informationen richten Sie bitte an die werden.
nächste ABB-Vertriebsstelle.
FEHLER URSACHE MASSNAHMEN

Motor startet nicht Sicherungen durchgebrannt Neue Sicherungen des richtigen Typs und mit entsprechenden
Bemessungsdaten einsetzen.
Überlastauslösung Überlast in Anlasser prüfen und zurücksetzen.
Fehlerhafte Stromversorgung Überprüfen, ob die Stromversorgung den Angaben auf dem
Motorleistungsschild entspricht und für den jeweiligen Lastfaktor
geeignet ist.
Fehlerhafte Netzanschlüsse Anschlüsse anhand des mit dem Motor gelieferten Schaltplans
überprüfen.
Stromkreisunterbrechung in Erkennbar an einem Summen bei Einschalten des Schalters.
Wicklung oder Steuerschalter Verdrahtung auf lockere Anschlüsse überprüfen und kontrollieren,
ob alle Kontakte schließen.
Mechanischer Fehler Überprüfen, ob Motor und Antrieb frei drehen.
Lager und Schmierung kontrollieren.
Ständerkurzschluss
Schlechter Anschluss an Erkennbar an durchgebrannten Sicherungen. Motor muss neu
Ständerwicklung gewickelt werden.
Lagerschilde abnehmen; Fehler lokalisieren.
Defekter Rotor Auf gebrochene Stäbe oder Endringe kontrollieren.
Motor überlastet Last reduzieren.
Motor läuft nicht Phasenausfall Leitungen auf offene Phase kontrollieren.
Falsche Anwendung Nach Rücksprache mit dem Anbieter des Geräts geeigneten Typ
bzw. geeignete Baugröße verwenden.
Überlast Last reduzieren.
Niederspannung Kontrollieren, ob die auf dem Leistungsschild angegebene Spannung
eingehalten wird. Anschluss überprüfen.
Offener Stromkreis Durchgebrannte Sicherungen. Überlastrelais, Ständer und Drucktasten
prüfen.
Motor läuft nur für Netzausfall Auf lose Anschlüsse zu Netz, Sicherungen und Steuerung überprüfen.
kurzen Zeitraum
Motor läuft nicht Falsche Anwendung Durch Rücksprache mit dem Lieferanten des Geräts geeigneten Typ
hoch bestimmen.
Unterspannung an Motorklemmen Höhere Spannung oder höhere Transformatorstufe verwenden oder
durch Netzspannungsabfall Last reduzieren.
Anschlüsse überprüfen. Leitungen auf angemessenen Querschnitt
überprüfen.
Anlauflast zu hoch Auslegung des Motors bezüglich Leerlauf überprüfen.
Gebrochene Rotorstäbe oder lockerer Kontrollieren, ob in der Nähe der Ringe Risse vorhanden sind.
Rotor Möglicherweise wird ein neuer Rotor benötigt, da eine dauerhafte
Reparatur in diesem Fall meist nicht möglich ist.
Offener Primärkreis Fehler mit Prüfgerät lokalisieren und beheben.
FEHLER URSACHE MASSNAHMEN
Motor läuft zu Last zu hoch Last reduzieren.
langsam hoch Spannung beim Anlauf zu niedrig Auf zu hohen Widerstand überprüfen.
und/oder zieht zu Angemessenen Leitungsquerschnitt verwenden.
starken Strom
Defekter Käfigrotor Neuen Rotor einbauen.
Netzspannung zu niedrig Spannungsversorgung klären.
Falsche Falsche Phasenfolge Anschlüsse am Motor bzw. an der Schalttafel vertauschen.
Drehrichtung
Motor überhitzt bei Überlast Last reduzieren.
Betrieb unter Last Belüftungsöffnungen sind möglicher- Belüftungsöffnungen säubern und kontrollieren,
weise durch Schmutz verstopft und ob ein kontinuierlicher Luftstrom den Motor kühlt.
verhindern eine ordnungsgemäße
Kühlung des Motors
Eine Motorphase ist möglicherweise Kontrollieren, ob alle Anschlussleitungen richtig angeschlossen sind.
ausgefallen
Erdschluss Motor muss neu gewickelt werden.
Unsymmetrische Klemmenspannung Anschlussleitungen, Anschlüsse und Transformatoren
auf Fehler überprüfen.
Motor- Motor schlecht ausgerichtet Motor nachrichten.
schwingungen Mangelnde Stabilität des Unterbaus Unterbau verstärken.
Unwucht in Kupplung Kupplung auswuchten.
Unwucht in getriebener Anlage Getriebene Anlage neu auswuchten.
Defekte Lager Lager austauschen.
Lager schlecht ausgerichtet Motor reparieren.
Auswuchtgewichte verschoben Rotor neu auswuchten.
Wuchtung von Rotor und Kupplung Kupplung oder Rotor neu auswuchten.
nicht aufeinander abgestimmt
(Halbkeil- bzw. Vollkeilwuchtung)
Mehrphasenmotor läuft einphasig Auf offenen Stromkreis überprüfen.
Axialspiel zu groß Lager nachstellen oder Feder-Ausgleichsscheibe einlegen.
Geräusche Lüfter reibt an Lüfterkappe Lüftermontage korrigieren.
Lockerer Sitz auf Grundplatte Fußschrauben anziehen.
Betriebsgeräusch Luftspalt nicht gleichmäßig Lagerschildbefestigung bzw. Lager überprüfen und
zu laut entsprechend korrigieren.
Unwucht im Rotor Rotor neu auswuchten.
Lagertemperatur Welle verbogen oder beschädigt Welle richten oder austauschen.
zu hoch Riemenzug zu stark Riemenspannung reduzieren.
Riemenscheiben zu weit Riemenscheibe näher am Motorlager anordnen.
von Wellenschulter entfernt
Durchmesser der Riemenscheiben Größere Riemenscheiben verwenden.
zu klein
Schlechte Ausrichtung Durch Nachrichten des Antriebs korrigieren.
Unzureichendes Schmierfett Angemessene Qualität des im Lager vorhandenen
Schmierfetts sicherstellen.
Qualität des Schmierfetts beeinträchtigt Altes Schmierfett entfernen. Lager gründlich in Kerosin waschen
oder Schmiermittel verschmutzt und mit neuem Fett schmieren.
Überschüssiges Schmiermittel Schmiermittelmenge verringern; das Lager sollte maximal
zur Hälfte gefüllt sein.
Lager überlastet Ausrichtung, Radial- und Axialschub überprüfen.
Defekte Kugel oder raue Laufbahnen Lager austauschen; vor dem Einbau des neuen Lagers
das Lagergehäuse gründlich reinigen.
Moteurs basse tension
Manuel d'installation, d'exploitation, de maintenance et de sécurité
Sommaire
1. Introduction ...............................................................................................................................43
1.1 Déclaration de Conformité .................................................................................................43
1.2 Validité ...............................................................................................................................43
2. Sécurité ......................................................................................................................................43
3. Manutention ..............................................................................................................................44
3.1 Contrôle à la réception.......................................................................................................44
3.2 Transport et entreposage ...................................................................................................44
3.3 Levage ..............................................................................................................................44
3.4 Poids du moteur ................................................................................................................44
4. Installation et mise en service .................................................................................................45
4.1 Généralités ........................................................................................................................45
4.2 Moteurs non équipés de roulements à bille ........................................................................45
4.3 Mesure de la résistance de l'isolation .................................................................................45
4.4 Fondations ........................................................................................................................45
4.5 Équilibrage et mise en place des demi-accouplements et des poulies ...............................46
4.6 Montage et alignement du moteur .....................................................................................46
4.7 Forces radiales et entraînements à courroie .......................................................................46
4.8 Moteurs avec trous de purge des eaux de condensation ...................................................46
4.9 Câblage et connexions électriques ....................................................................................46
4.9.1 Couplages pour les différentes méthodes de démarrage ....................................47
4.9.2 Couplages des éléments auxiliaires ....................................................................48
4.10 Bornes et sens de rotation .................................................................................................48
5. Conditions d'exploitation ........................................................................................................49
5.1 Généralités ........................................................................................................................49
Manuel des moteurs basse tension, 3GZF500730-85 Rév. F 02-2015 | Moteurs et alternateurs ABB 41
6. Moteurs basse tension à vitesse variable .............................................................................50
6.1 Introduction .......................................................................................................................50
6.2 Isolation du bobinage ........................................................................................................50
6.2.1 Sélection de l'isolation du bobinage pour les convertisseurs ABB .......................50
6.2.2 Sélection de l'isolation du bobinage avec tous les autres convertisseurs ............50
6.3 Protection thermique ........................................................................................................50
6.4 Courants des roulements...................................................................................................51
6.4.1 Élimination des courants des roulements avec les convertisseurs ABB ...............51
6.4.2 Élimination des courants des roulements avec les autres convertisseurs.............51
6.5 Câblage, mise à la terre et CEM ........................................................................................51
6.6 Vitesse de fonctionnement.................................................................................................51
6.7 Moteurs utilisés dans des variateurs de vitesse ..................................................................51
6.7.1 Généralités .........................................................................................................51
6.7.2 Capacité de charge moteur avec les convertisseurs série AC_8__
à contrôle DTC ...................................................................................................52
6.7.3 Capacité de charge moteur avec les convertisseurs série AC_5__ ......................52
6.7.4 Capacité de charge moteur avec d’autres convertisseurs PWM
de source de tension ..........................................................................................52
6.7.5 Surcharges de courte durée ...............................................................................52
6.8 Plaques signalétiques ........................................................................................................52
6.9 Mise en service de l'application avec variateur ...................................................................52
7. Maintenance ..............................................................................................................................53
7.1 Entretien ............................................................................................................................53
7.1.1 Moteurs en attente ............................................................................................53
7.2 Lubrification .......................................................................................................................53
7.2.1 Moteurs avec roulements graissés à vie..............................................................53
7.2.2 Moteurs avec roulements regraissables ..............................................................54
7.2.3 Intervalles de lubrification et quantités de lubrifiant ..............................................55
7.2.4 Lubrifiants...........................................................................................................57
8. Service après vente ..................................................................................................................58
8.1 Pièces détachées ..............................................................................................................58
8.2 Démontage, remontage et rembobinage............................................................................58
8.3 Roulements .......................................................................................................................58
9. Contraintes d'environnement ..................................................................................................58
10. Dépannage ................................................................................................................................59
42 Moteurs et alternateurs ABB | Manuel des moteurs basse tension 3GZF500730-85 Rév. F 02-2015
1. Introduction 2. Sécurité
Le moteur doit être installé et exploité par un personnel
REMARQUE !
qualifié, connaissant les règles de protection et de sécurité,
Seul le respect des consignes de cette notice
ainsi que la réglementation en vigueur.
garantira une installation, une exploitation et
une maintenance sûres et appropriées de votre Les dispositifs de sécurité obligatoires pour la prévention
moteur. Le personnel chargé de l'installation, des accidents sur les sites d'installation et d'exploitation
l'exploitation ou la maintenance du moteur ou de doivent être mis à disposition, conformément à la
l'équipement associé devra en être informé. Le réglementation en vigueur.
moteur doit être installé et exploité par un personnel
qualifié, connaissant les règles de protection et de
sécurité, ainsi que la réglementation en vigueur. AVERTISSEMENT !
Le non-respect de ces instructions peut entraîner Les commandes d'arrêt d'urgence doivent être
l'annulation des garanties applicables. équipées de dispositifs anti-redémarrage. Suite
à un arrêt d'urgence, une nouvelle commande
de démarrage ne peut prendre effet qu'après
1.1 Déclaration de Conformité réinitialisation intentionnelle du dispositif anti-
redémarrage.
La conformité du produit final à la Directive 2006/42/CE
(Machines) doit être établie par la partie chargée de la mise Points à respecter :
en service lorsque le moteur est monté dans la machine. 1. Ne marchez pas sur le moteur.
2. Au toucher, la température de l'enveloppe extérieure
1.2 Validité du moteur fonctionnant normalement, et en particulier
après son arrêt, peut être très élevée.
Cette notice technique s'applique aux machines électriques
3. Certaines applications spécifiques du moteur peuvent
ABB de types suivants, utilisées en modes moteur et
nécessiter des instructions complémentaires (par ex. en
générateur.
cas d'alimentation par un convertisseur de fréquence).
séries MT*, MXMA, 4. Prenez garde aux pièces du moteur en rotation.
séries M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*, 5. N'ouvrez pas les boîtes à bornes lorsqu'elles sont sous
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, tension.
M2V*/M3V*
en hauteurs d'axe 56 - 450.
Une notice technique séparée existe pour les autres

types de moteurs, comme par exemple les moteurs de
sécurité Ex : « Moteurs basse tension pour atmosphères
explosives : Manuel d'installation, d'exploitation, de
maintenance et de sécurité » (3GZF500730-47)
Des consignes supplémentaires sont nécessaires pour

certains types de machine en raison de spécificités
d'application et/ou de considérations de conception.
Des manuels supplémentaires sont disponibles pour les

moteurs suivants :
– moteurs pour table à rouleaux
– moteurs refroidis à l'eau
– moteurs de désenfumage
– moteurs freins
– moteurs pour températures ambiantes élevées
– moteurs pour applications marines avec montage
sur pont ouvert de navires ou plates-formes offshore
3. Manutention Les anneaux de levage endommagés ne doivent pas être
utilisés. Vérifiez que les boulons à œil ou anneaux de levage
intégrés ne sont pas endommagés avant le levage.
3.1 Contrôle à la réception
Les boulons à œil de levage doivent être serrés avant
À la réception, vérifiez l'état du moteur (par ex. extrémités le levage. Au besoin, la position de chaque boulon sera
d'arbres, brides et surfaces peintes) ; tout dommage doit ajustée au moyen de rondelles (entretoises) appropriées.
être signalé immédiatement au transporteur.
Vérifiez la compatibilité de l'engin de levage et de la taille
Vérifiez toutes les données de la plaque signalétique, plus des crochets avec les anneaux de levage.
particulièrement la tension et le mode de couplage des
enroulements (étoile ou triangle). Le type de roulement Veillez à ne pas endommager les équipements auxiliaires et
est spécifié sur la plaque signalétique des moteurs, à les câbles raccordés au moteur.
l'exception de ceux de faible hauteur d'axe.
Retirez les éventuelles broches de transport fixant le
En cas d'utilisation d'un variateur de vitesse, vérifiez la moteur à la palette.
capacité de charge maximale autorisée en fonction de la
fréquence indiquée sur la plaque signalétique auxiliaire du Des instructions particulières relatives au levage sont
moteur. disponibles auprès d'ABB.
3.2 Transport et entreposage AVERTISSEMENT !

Pendant les opérations de levage, de montage ou
Le moteur doit toujours être entreposé dans un local fermé de maintenance, toutes les précautions de sécurité
(température ambiante supérieure à –20 °C), à l'abri de nécessaires doivent être mises en œuvre. Veillez
l'humidité et de la poussière, et exempt de vibrations. Lors notamment à ce que personne ne se trouve sous les
du transport, tout choc, chute et présence d'humidité charges levées.
doivent être évités. En présence d'autres conditions, prière
de contacter ABB.
Les surfaces usinées non protégées (bouts d'arbre 3.4 Poids du moteur
et brides) doivent être recouvertes d'une protection
anticorrosion. La masse totale des moteurs de même hauteur d'axe peut
varier selon leur puissance, leur disposition de montage et
Nous préconisons de tourner l'arbre à la main à intervalles les auxiliaires montés.
réguliers pour prévenir tout écoulement de graisse.
Le tableau suivant donne la masse maximale approximative
L'utilisation de chauffages anti-condensation est des machines en exécution de base et en fonction du
recommandée afin d'éviter toute condensation d'eau dans matériau du châssis.
le moteur.
La masse réelle de tous les moteurs ABB (à l'exception
Le moteur ne doit pas être soumis à des vibrations des moteurs dotés des plus petits châssis – 56 et 63) est
supérieures à 0,5 mm/s à l'arrêt afin d'éviter tout indiquée sur leur plaque signalétique.
endommagement des roulements.
Hauteur d'axe Aluminium Fonte Ajouter
Pendant le transport ou tout déplacement, le rotor des Masse en kg Masse en kg pour le frein
moteurs dotés de roulements à rouleaux cylindriques et/ 56 4,5 - -
ou à contact oblique doit être immobilisé par un dispositif 63 6 - -
adéquat. 71 8 13 5
80 14 20 8
3.3 Levage 90 20 30 10
100 32 40 16
Tous les moteurs ABB dont le poids est supérieur à 25 kg 112 36 50 20
sont équipés d'anneaux de levage. 132 93 90 30
160 149 130 30
Seuls les anneaux de levage ou boulons à œil principaux 180 162 190 45
du moteur doivent être utilisés pour son levage. Ils ne 200 245 275 55
doivent en aucun cas servir à soulever le moteur lorsque 225 300 360 75
celui-ci est fixé à un autre équipement. 250 386 405 75
280 425 800 -
Les anneaux de levage pour éléments auxiliaires (freins,
315 - 1700 -
ventilateurs de refroidissement séparés) ou boîtes à
355 - 2700 -
bornes ne doivent pas être utilisés pour lever le moteur.
400 - 3500 -
Du fait des différentes formes de sorties, de montages et
450 - 4500 -
d'équipements auxiliaires, des moteurs avec un même
châssis peuvent avoir un centre de gravité différent. Si le moteur est équipé d'un ventilateur séparé, demandez-
en la masse à ABB.
4. Installation et mise en service
AVERTISSEMENT ! 4.3 Mesure de la résistance

Avant toute intervention, débranchez et de l'isolation
désaccouplez le moteur ou la machine entraînée.
La résistance de l'isolation du moteur doit être mesurée
avant sa mise en service et en particulier si les bobinages
4.1 Généralités sont susceptibles d'être humides.
Vérifiez soigneusement toutes les valeurs de la plaque La résistance de l'isolation, corrigée à 25 °C, ne doit
signalétique afférentes à la certification pour vous assurer en aucun cas être inférieure à 1 MΩ (mesure à 500 ou
que les branchements et la protection du moteur sont 1000 VCC). La valeur de résistance de l'isolation est
réalisés correctement. divisée par deux pour chaque augmentation de 20 °C
de la température. La Figure 1 peut être utilisée pour la
correction de l'isolation à la température voulue.
4.2 Moteurs non équipés
de roulements à bille AVERTISSEMENT !
Afin d'éviter tout risque de choc électrique, le
Le cas échéant, retirez le dispositif d'immobilisation utilisé
châssis du moteur doit être mis à la terre et les
pour le transport. Si possible, tournez l'arbre du moteur à
bobinages doivent être déchargés sur le châssis
la main pour vérifier que sa rotation s'effectue sans entrave.
immédiatement après chaque mesure.
Moteurs dotés de roulements à rouleaux :

La rotation du moteur sans charge radiale appliquée à Si vous n'obtenez pas la valeur de résistance de référence,
l'arbre est susceptible d'endommager le roulement à les bobinages sont trop humides et doivent être séchés
rouleaux par « glissement ». en étuve. L'étuve doit être portée à une température de
90 °C pendant 12 à 16 heures, puis à 105 °C pendant 6 à
8 heures.
Moteurs dotés de roulements à contact oblique :
La rotation du moteur, sans charge axiale appliquée Pendant le séchage, vous devez retirer les obturateurs
sur l'arbre dans la direction adéquate, est susceptible des trous de purge et ouvrir les valves de fermeture, si le
d'endommager le roulement à contact oblique. moteur en est doté. N'oubliez pas de les refermer après le
séchage. Même si les bouchons de purge sont fixés, il est
recommandé de démonter les flasques et couvercles de
AVERTISSEMENT ! boîtes à bornes pour l'opération de séchage.
Pour les moteurs dotés de roulements à rouleaux
cylindriques, la force axiale ne doit en aucun cas Les bobinages imprégnés d'eau de mer doivent
changer de direction. normalement être rembobinés.
Le type de roulement est spécifié sur la plaque signalétique 4.4 Fondations

du moteur. La préparation du support de fixation (fondations) du
moteur incombe entièrement à l'utilisateur final.
Moteurs dotés de graisseurs :
Lors du démarrage du moteur pour la première fois ou Les supports métalliques doivent être traités contre la
après un entreposage de longue durée, appliquez la corrosion.
quantité de graisse spécifiée. Les fondations doivent être de niveau et suffisamment
Pour de plus amples informations, consultez la section rigides pour encaisser les éventuelles forces liées à un
« 7.2.2 Moteurs dotés de roulements regraissables ». court-circuit.
Un moteur monté en position verticale avec l'arbre dirigé Elles doivent être d'une conception et de dimensions
vers le bas doit être doté d'un capot de protection contre la permettant d'éviter tout transfert de vibration au moteur,
chute de corps étrangers et la pénétration de fluides via les ainsi que toute vibration provoquée par résonance. Voir la
ouvertures de ventilation. Cette mesure de protection peut figure ci-dessous.
également être assurée par l'emploi d'un capot séparé,
non fixé au moteur. Dans ce cas, le moteur doit porter une
étiquette d'avertissement.
Précision de montage du demi-accouplement : vérifiez que
Règle le jeu b est inférieur à 0,05 mm et que l'écart entre a1 et a2
est également inférieur à 0,05 mm. Consultez la figure 2.
Remarque ! La différence de Revérifiez l'alignement après le serrage final des boulons et
niveau maximale entre les
emplacements des pattes goujons.
du moteur ne doit pas
excéder ± 0,1 mm. Ne dépassez pas les valeurs de charge admissibles des
roulements spécifiées dans les catalogues de produits.
Vérifiez que le moteur est correctement refroidi. Assurez-

vous qu'aucun objet ne se trouve à proximité ou qu'aucun
rayonnement direct du soleil ne chauffe le moteur.
Emplacement des pieds
Pour les moteurs montés sur bride (par ex., B5, B35, V1),
assurez-vous que la structure permet un passage d'air
suffisant au niveau de la surface extérieure de la bride.
4.5 Équilibrage et mise en place
des demi-accouplements et 4.7 Forces radiales et
des poulies entraînements à courroie
En configuration standard, l'équilibrage du moteur est
Les courroies doivent être tendues conformément
réalisé à l'aide d'une demi-clavette.
aux instructions du fournisseur ou de l'équipement
Les demi-accouplements ou poulies doivent être équilibrés d'entraînement. Ne dépassez cependant pas les valeurs de
après usinage des rainures de clavette. L'équilibrage doit tension maximales des courroies (c'est-à-dire, les efforts
être effectué conformément aux instructions d'équilibrage radiaux maximaux admissibles par les roulements) figurant
du moteur. dans les catalogues de produits correspondants.
Les demi-accouplements et les poulies doivent être

montés sur l'arbre à l'aide de dispositifs et d'outils adaptés AVERTISSEMENT !
pour ne pas endommager les roulements et les éléments Une courroie trop tendue peut endommager les
d'étanchéité. roulements et l'arbre.
N'utilisez jamais de marteau pour mettre en place un demi-

accouplement ou une poulie, et ne les démontez jamais en
utilisant un levier appuyé sur le châssis du moteur. 4.8 Moteurs avec trous de purge
des eaux de condensation
4.6 Montage et alignement Vérifiez que les trous et bouchons de purge sont orientés
vers le bas. Sur les moteurs montés en position verticale,
du moteur les trous de purge peuvent se trouver en position
horizontale.
Veillez à laisser un espace libre suffisant autour du moteur
pour permettre le passage d'air. Il est recommandé de Les moteurs équipés de trous de purge plastiques à
laisser un dégagement d'au moins la moitié de la largeur obturateurs sont livrés en position ouverte. Dans les
de l'admission d'air du capot de ventilateur entre ce dernier environnements très poussiéreux, tous les trous de purge
et le mur ou la paroi. Des informations supplémentaires doivent être fermés.
sont disponibles dans le catalogue du produit ou sur les
schémas dimensionnels disponibles dans nos pages Web :
www.abb.com/motors&generators.
4.9 Câblage et connexions
L'alignement doit être parfait pour éviter toute détérioration
des roulements, les vibrations et les ruptures éventuelles
électriques
des arbres. La boîte à bornes des moteurs monovitesse standard
comporte normalement six bornes pour le bobinage et au
Montez le moteur sur ses fondations à l'aide des boulons moins une borne de terre.
et goujons appropriés, et placez des cales entre les
fondations et les pieds. Outre les bornes des bobinages principaux et de mise à
la terre, la boîte à bornes peut également contenir des
Alignez le moteur à l'aide de la méthode appropriée. raccordements pour des thermistances, des éléments de
Le cas échéant, forez des trous de positionnement et fixez réchauffage ou des équipements auxiliaires.
des goupilles de positionnement.
Des anneaux de câble appropriés doivent être utilisés pour De plus, les connexions à la terre ou de raccordement à
la connexion de tous les câbles principaux. Les câbles l'extérieur de l'appareil électrique peuvent représenter une
pour éléments auxiliaires peuvent être connectés tels quels connexion efficace pour un conducteur doté d'une section
dans leurs boîtes à bornes. d'au moins 4 mm2.
Les moteurs sont uniquement destinés à une installation Le raccordement des câbles entre le réseau et les bornes
fixe. Sauf indication contraire, les filetages des entrées de du moteur doit satisfaire aux règles d'installation des
câble sont au pas métrique. La classe IP du presse-étoupe normes nationales ou de la norme EN 60204-1 pour ce
doit être au moins identique à celle des boîtes à bornes. qui concerne le courant nominal figurant sur la plaque
signalétique.
Un concentrateur de conduit ou un connecteur de câble
certifié doit être utilisé au moment de l'installation.
REMARQUE !
Lorsque la température ambiante dépasse +50 °C,
REMARQUE ! des câbles ayant une température d'utilisation
Les câbles doivent être protégés mécaniquement et autorisée d'au moins +90 °C doivent être utilisés.
fixés au plus près de la boîte à bornes pour satisfaire En outre, tous les autres facteurs de conversion
aux exigences correspondantes de la norme CEI/ dépendant des conditions d'installation doivent
EN 60079-0 et aux règles d'installation des normes être pris en compte lors du dimensionnement des
nationales. câbles.
Assurez-vous que la protection du moteur correspond

Les entrées de câble inutilisées doivent être fermées à
à l'environnement et aux conditions climatiques. Par
l'aide d'éléments étanches conformes à la classe IP de la
exemple, assurez-vous que l'eau ne peut pénétrer dans le
boîte à bornes.
moteur ou les boîtes à bornes.
L'indice de protection et le diamètre sont spécifiés dans la
Les éléments d'étanchéité des boîtes à bornes doivent être
documentation technique du presse-étoupe.
placés correctement dans les fentes prévues à cet effet afin
de respecter la classe IP. Tout interstice est susceptible de
AVERTISSEMENT ! favoriser la pénétration de poussières ou d'eau, avec risque
Utilisez des presse-étoupes et joints appropriés dans d'amorçage des éléments sous tension.
les entrées de câble, conformément au type et au
diamètre du câble. 4.9.1 Couplages pour les différentes
méthodes de démarrage
La mise à la terre doit être réalisée conformément à la
La boîte à bornes des moteurs monovitesse standard
réglementation en vigueur avant raccordement du moteur
comporte normalement six bornes pour le bobinage et
au réseau.
au moins une borne de terre. Cela permet d'utiliser le
La borne de masse du châssis doit être raccordée à la démarrage DOL ou Y/D.
terre de protection (PE) par un câble, comme indiqué dans
Pour les moteurs bivitesse et les moteurs spéciaux, les
le tableau 5 de la norme CEI/EN 60034-1 :
raccordements électriques doivent être effectués selon les
Section minimale des conducteurs de protection instructions figurant à l'intérieur de la boîte à bornes ou
dans le manuel d'utilisation du moteur.
Section des conducteurs de Section minimale du conducteur
phase de l'installation, de protection correspondant, La tension et le mode de couplage sont indiqués sur la
S [mm2] SP, [mm2] plaque signalétique du moteur.
4 4
6 6
Démarrage direct sur le réseau :
10 10 Possibilité de couplage Y ou D.
16 16
25 25
Ex., 690 VY, 400 VD désigne un couplage Y pour 690 V et
35 25
un couplage D pour 400 V.
50 25 Démarrage étoile/triangle (Y/D) :
70 35
95 50 Lorsqu'un couplage D est utilisé, la tension d'alimentation
120 70 doit être égale à la tension nominale du moteur.
150 70
Vous devez retirer toutes les barrettes de connexion situées
185 95
sur la plaque à bornes.
240 120
300 150
400 185
Autres modes de démarrage et démarrages en
conditions difficiles :
4.10 Bornes et sens de rotation
En cas d'utilisation d'autres méthodes de démarrage (par L'arbre tourne dans le sens horaire, vu du côté
ex. convertisseur ou démarreur progressif) pour les types accouplement du moteur, pour un ordre de phases – L1,
d'applications S1 et S2, on considère que le dispositif L2, L3 – aux bornes tel qu'illustré à la figure 3.
est « isolé du système de puissance lorsque la machine
Pour inverser le sens de rotation, permutez les deux
électrique est en fonctionnement », comme indiqué par
raccordements des câbles d'alimentation, au choix.
la norme CEI 60079-0, et que la protection thermique est
optionnelle. Si le moteur est doté d'un ventilateur unidirectionnel,
vérifiez que celui-ci tourne effectivement dans le sens
4.9.2 Couplages des éléments auxiliaires indiqué par la flèche figurant sur le moteur.
Si un moteur est équipé de thermistances ou autres RTD

(Pt100, relais thermiques, etc.) et équipement auxiliaires,
il est recommandé de les utiliser et de les connecter selon
des moyens appropriés. Pour certaines applications,
l'utilisation d'une protection thermique est obligatoire.
De plus amples informations sont accessibles via la
documentation accompagnant le moteur. Les schémas
de raccordement des dispositifs auxiliaires et pièces de
raccordement se trouvent dans la boîte à bornes.
La tension de mesure maximale pour les thermistances est

de 2,5 V. La tension de mesure maximale pour le Pt100 est
de 5 mA. L'application d'une tension ou d'un courant de
mesure supérieur(e) peut provoquer des erreurs de lecture
ou endommager le capteur de température.
L'isolation des capteurs thermiques répond aux exigences

d'isolation de base.
5. Conditions d'exploitation
5.1 Généralités
Les moteurs sont conçus pour les conditions d'utilisation
suivantes, sauf indication contraire sur la plaque
signalétique :
- Les moteurs sont uniquement destinés à une installation

fixe.
- Plage normale de températures ambiantes : –20 °C à
+40 °C.
- Altitude maximale : 1 000 m au-dessus du niveau de la
mer.
- La variation de la tension et de la fréquence
d'alimentation ne peut dépasser les limites définies
dans les normes applicables. La tolérance pour la
tension d'alimentation est de ±5 % et de ±2 % pour
la fréquence, conformément à la figure 4 (norme
EN/CEI 60034-1, paragraphe 7.3, zone A). Les deux
valeurs extrêmes ne sont pas supposées se présenter
au même instant.
Le moteur ne peut être utilisé que dans les applications

pour lesquelles il est prévu. Les valeurs nominales et
conditions d'exploitation sont indiquées sur les plaques
signalétiques du moteur. En outre, toutes les exigences
du présent manuel, autres instructions et normes annexes
doivent être respectées.
En cas de non-respect de ces limitations, les données du

moteur et de la structure doivent être vérifiées. Veuillez
contacter ABB pour de plus amples informations.
AVERTISSEMENT !
Le fait d'ignorer toute instruction ou maintenance
de l'appareil peut en compromettre la sécurité,
empêchant l'utilisation du moteur.
6. Moteurs basse tension à vitesse variable
6.1 Introduction 6.2.1 Sélection de l'isolation du bobinage
pour les convertisseurs ABB
Cette partie du manuel fournit des instructions
supplémentaires pour les moteur utilisés avec une Dans le cas des systèmes d'entraînement uniques de
alimentation par convertisseur de fréquence. Le moteur séries ABB AC_8__ et AC_5__ avec unité d'alimentation à
est conçu pour fonctionner en étant alimenté par un seul diode (tension CC non contrôlée), la sélection de l'isolation
convertisseur de fréquence et non pour des applications du bobinage et des filtres peut se faire en fonction du
de moteurs tournant en parallèle à partir d'un seul tableau 6.1.
convertisseur de fréquence. Les instructions fournies par le
fabricant du convertisseur doivent être respectées. 6.2.2 Sélection de l'isolation du bobinage
Des informations supplémentaires peuvent être requises avec tous les autres convertisseurs
par ABB quant à l'adéquation de certains types de moteurs
Les surtensions ne doivent pas excéder certaines limites
utilisés pour certaines applications spécifiques ou de
acceptables. Veuillez contacter le concepteur du système
conception spécialement modifiée.
pour garantir la sécurité de l'application. L'influence
des filtres éventuels doit être prise en compte lors du
dimensionnement du moteur.
6.2 Isolation du bobinage
Les variateurs de vitesse engendrent des contraintes
de tension plus élevées qu'une alimentation sinusoïdale 6.3 Protection thermique
sur le bobinage du moteur. Par conséquent, l'isolation
La plupart des moteurs décrits dans ce manuel sont
du bobinage, ainsi que le filtre au niveau de la sortie
équipés de thermistances PTC ou d'autres types de RTD
du convertisseur, doivent être dimensionnés selon les
dans les bobinages du stator. Il est recommandé de les
instructions suivantes.
connecter au convertisseur de fréquence. Pour en savoir
plus, se reporter au chapitre 4.9.2.
PN < 100 kW PN ≥ 100 kW ou PN ≥ 350 kW ou

CEI315 ≤ Hauteur d'axe ≤ CEI355 CEI400 ≤ Hauteur d'axe ≤ CEI450
UN ≤ 500 V Moteur standard Moteur standard Moteur standard
+ N-roulement isolé + N-roulement isolé
+ Filtre mode courant
500 V > UN ≤ 600 V Moteur standard Moteur standard Moteur standard
+ dU/dt – filtre (réacteur) + dU/dt – filtre (réacteur) + N-roulement isolé
OU + N-roulement isolé + dU/dt – filtre (réacteur)
Isolation renforcée OU + Filtre mode courant
Isolation renforcée OU
+ N-roulement isolé Isolation renforcée
+ N-roulement isolé
500 V > UN ≤ 600 V Moteur standard Moteur standard Moteur standard
(longueur de câble > 150 m) + N-roulement isolé + N-roulement isolé
600 V > UN ≤ 690 V Isolation renforcée Isolation renforcée Isolation renforcée

+ dU/dt – filtre (réacteur) + dU/dt – filtre (réacteur) + N-roulement isolé
+ N-roulement isolé + dU/dt – filtre (réacteur)
600 V > UN ≤ 690 V Isolation renforcée Isolation renforcée Isolation renforcée
(longueur de câble > 150 m) + N-roulement isolé + N-roulement isolé
Tableau 6.1 Sélection de l'isolation du bobinage pour les convertisseurs ABB
Pour de plus amples informations concernant le freinage à résistance et les convertisseurs avec unités d'alimentation
contrôlées, contactez ABB.
6.4 Courants des roulements REMARQUE !
Il faut utiliser des roulements et structures de roulement Des presse-étoupes appropriés assurant une
isolées, des filtres en mode courant et un câblage continuité de masse sur 360° doivent être utilisés
approprié, ainsi que des méthodes de mise à la terre au niveau de tous les points de raccordement, par
adéquates, conformément aux instructions suivantes et en exemple au niveau du moteur, du convertisseur, de
se reportant au tableau 6.1. l'éventuel commutateur de sécurité, etc.
6.4.1 Élimination des courants des Pour les moteurs d'une hauteur d'axe supérieure ou égale
roulements avec les convertisseurs à CEI 280, il est nécessaire de procéder à une égalisation
ABB supplémentaire du potentiel entre le châssis du moteur et
Dans le cas des convertisseurs de fréquence ABB l'équipement entraîné, sauf si le moteur et l'équipement
(par exemple des séries AC_8__ et AC_5__ avec unité sont montés sur un même socle d'acier. Dans ce cas, la
d'alimentation à diode), les méthodes présentées dans le conductivité haute fréquence de la connexion fournie par le
tableau 6.1 doivent être utilisées afin d'éviter tout courant socle en acier doit être vérifiée, par exemple, en mesurant
dangereux dans les roulements des moteurs. la différence de potentiel entre les composants.
De plus amples informations concernant la mise à la

terre et le câblage des variateurs de vitesse peuvent être
REMARQUE ! consultées dans le manuel « Mise à la terre et câblage du
Il est recommandé d'utiliser des roulement système d'entraînement » (code : 3AFY 61201998).
isolés dotés d'alésages intérieur et/ou extérieur
revêtus d'oxyde d'aluminium ou d'éléments de
roulement en céramique. Les revêtements d'oxyde
d'aluminium sont également traités à l'aide d'un 6.6 Vitesse de fonctionnement
produit d'étanchéité qui empêche la pénétration Pour les vitesses supérieures à la vitesse nominale inscrite
des impuretés et de l'humidité à travers le sur la plaque signalétique du moteur ou dans le catalogue
revêtement poreux. Pour connaître le type exact produit correspondant, vérifiez l'absence de dépassement
d'isolation de roulement, reportez-vous à la plaque de la vitesse de rotation la plus élevée autorisée ou de la
signalétique du moteur. Il est interdit de modifier le vitesse critique de l'ensemble de l'application.
type de roulement ou la méthode d'isolation sans
l'autorisation préalable d'ABB.
6.7 Moteurs utilisés dans
6.4.2 Élimination des courants des
roulements avec les autres des variateurs de vitesse
convertisseurs
L'utilisateur est responsable de la protection du moteur 6.7.1 Généralités
et de l'équipement d'entraînement contre les courants Avec les convertisseurs de fréquence ABB, les moteurs
de roulements dangereux. Les instructions décrites au peuvent être dimensionnés en utilisant le programme
chapitre 6.4.1 peuvent être suivies, mais leur efficacité ne de dimensionnement DriveSize d'ABB. L'outil est
peut être garantie dans tous les cas de figure. téléchargeable sur le site Web d'ABB (www.abb.com/
motors&generators).
6.5 Câblage, mise à la terre Pour les applications fournies avec d'autres convertisseurs,
les moteurs devront être dimensionnés manuellement. Pour
et CEM plus d'informations, contactez ABB.
Pour assurer une mise à la terre correcte et garantir la Les courbes de capacité de charge sont basées sur la
conformité avec toutes les normes CEM applicables, les tension d'alimentation nominale. Le fonctionnement dans
moteurs d'une puissance supérieure à 30 kW doivent être des conditions de sous-tension ou de surtension peut
câblés à l'aide de câbles symétriques blindés et de presse- influencer les performances de l'application.
étoupe CEM assurant une continuité de masse sur 360°.
Des câbles symétriques blindés sont également hautement

recommandés pour les moteurs plus petits. Procédez à
la disposition de mise à la terre pour toutes les entrées
de câble en suivant les instructions relatives aux presse-
étoupes. Torsadez les blindages de câble en faisceaux et
connectez-les à la borne/barre omnibus de terre la plus
proche à l'intérieur de la boîte à bornes, de l'armoire du
convertisseur, etc.
6.7.2 Capacité de charge moteur avec 6.8 Plaques signalétiques
les convertisseurs série AC_8__
L'utilisation des moteurs ABB dans les applications à
à contrôle DTC
vitesse variable ne nécessitent habituellement aucune
Les courbes de capacité de charge présentées dans plaque signalétique supplémentaire. Les paramètres
les figures 5a - 5d sont valables pour les convertisseurs nécessaires à la mise en service du convertisseur se
ABB série AC_8__ avec une tension en courant continu trouvent sur la plaque signalétique principale. Cependant,
non contrôlée et un contrôle DTC. Les figures présentent dans certaines applications spéciales, les moteurs peuvent
le couple de sortie continu maximum approximatif être dotés de plaques signalétiques supplémentaires pour
des moteurs, en tant que fonction de la fréquence les applications à vitesse variable. Ces plaques contiennent
d'alimentation. Le couple de sortie est fourni en tant que les informations suivantes :
pourcentage du couple nominal du moteur. Les valeurs
sont fournies à titre indicatif. Les valeurs exactes sont - plage de vitesses
disponibles sur demande. - plage de puissances
- plage de tensions et de courants
REMARQUE ! - type de couple (constant ou quadratique)
Les vitesses maximum du moteur et de l'application - type de convertisseur et fréquence de commutation
ne doivent pas être dépassées ! minimale requise
6.7.3 Capacité de charge moteur avec 6.9 Mise en service de

les convertisseurs série AC_5__ l'application avec variateur
Les courbes de capacité de charge présentées dans les
figures 6a - 6d sont valables pour les convertisseurs de La mise en service de l'application avec variateur doit
série AC_5__. Les figures présentent le couple de sortie être effectuée conformément aux instructions d'utilisation
continu maximum approximatif des moteurs, en tant que du convertisseur de fréquence et en respect des lois et
fonction de la fréquence d'alimentation. Le couple de sortie réglementations. Les exigences et limitations associées à
est fourni en tant que pourcentage du couple nominal l'application doivent également être prises en compte.
du moteur. Les valeurs sont fournies à titre indicatif. Les
valeurs exactes sont disponibles sur demande. Tous les paramètres nécessaires au réglage du
convertisseur doivent être associés aux éléments des
plaques signalétiques du moteur. Les paramètres les plus
REMARQUE ! fréquemment requis sont les suivants :
Les vitesses maximum du moteur et de l'application
ne doivent pas être dépassées ! - tension nominale
- courant nominal
6.7.4 Capacité de charge moteur avec - fréquence nominale
d’autres convertisseurs PWM de - vitesse nominale
- puissance nominale
source de tension
Pour les autres convertisseurs qui présentent une tension
en courant continu non contrôlée et une fréquence REMARQUE !
de commutation minimale de 3 kHz (200-500 V), les En cas d'absence d'information ou d'imprécision,
instructions de dimensionnement mentionnées au chapitre n'utilisez le moteur qu'une fois vérifiée l'exactitude
6.7.3 peuvent être utilisées comme ligne directrice. Notez des paramètres !
cependant que la capacité de charge thermique réelle peut
également être plus faible. Veuillez contacter le fabricant du
convertisseur ou le fournisseur du système. ABB recommande l'utilisation de l'ensemble des
fonctionnalités proposées par le convertisseur afin
d'optimiser la sécurité de l'application. Les convertisseurs
REMARQUE !
offrent généralement les fonctionnalités suivantes (les noms
La capacité de charge thermique réelle d'un moteur
et disponibilité des fonctionnalités dépendent du fabricant
peut être inférieure à celle indiquée par les courbes
et du modèle de convertisseur) :
de capacité de charge de référence.
- vitesse minimum
6.7.5 Surcharges de courte durée - vitesse maximum
Les moteurs ABB peuvent généralement être surchargés - temps d'accélération et de décélération
de façon temporaire, ou bien être exploités de façon - courant maximum
intermittente. La méthode la plus adaptée pour - couple maximum
dimensionner ces applications est d'utiliser l'utilitaire - protection contre le calage
DriveSize.
7. Maintenance 1. L’arbre doit être tourné régulièrement, toutes les
2 semaines (à rapporter), en effectuant un démarrage du
système. Au cas où il ne soit pas possible d’effectuer de
AVERTISSEMENT ! démarrage pour une raison quelconque, il faudra tourner
Même avec le moteur à l'arrêt, la boîte à bornes peut l’arbre à la main afin de lui faire adopter une position
être sous tension pour les résistances de réchauffage différente une fois par semaine. Les vibrations causées
ou le réchauffage direct des enroulements. par le reste de l’équipement du vaisseau entraînent une
usure en cratères au niveau des roulements, que cette
mise en marche ou ce déplacement manuel peut limiter.
2. Le roulement doit être graissé chaque année, à un

7.1 Entretien moment où l’on fait tourner l’arbre (à rapporter). Si
1. Vérifiez l'état du moteur à intervalles réguliers, au moins le moteur a été équipé d’un roulement à rouleaux
une fois par an. La fréquence des contrôles dépend, par côté entraînement, il convient de retirer le verrou de
exemple, du degré d'humidité de l'air ambiant et des transport avant de faire tourner l’arbre. Le dispositif
conditions climatiques spécifiques. La périodicité devra d’immobilisation utilisé pour le transport doit être
donc être établie de manière empirique, pour ensuite remonté en cas de transport.
être respectée rigoureusement. 3. Toute vibration doit être évitée, pour éviter qu’un
2. Le moteur doit toujours être propre et correctement roulement ne se rompe. Toutes les instructions
ventilé. En cas d'utilisation dans un environnement données dans le manuel d’instructions du moteur,
poussiéreux, le système de ventilation doit être vérifié et tant celles concernant la mise en service que celles
nettoyé à intervalles réguliers. de la maintenance, doivent être suivies. La garantie ne
couvrira pas les dommages subis par les bobinages et
3. Vérifiez l'état des joints de l'arbre (ex., joint trapézoïdal les roulements si ces instructions n’ont pas été suivies.
ou radial) et remplacez-les au besoin.
4. Vérifiez l'état des raccordements et du montage ainsi
que les vis de fixation. 7.2 Lubrification
5. Vérifiez l'état des roulements : bruit anormal, vibrations,
température, aspect de la graisse souillée (utilisation
éventuelle d'un dispositif de type SPM de surveillance AVERTISSEMENT !
en continu de l'état des roulements et du comportement Attention à toutes les pièces en rotation !
vibratoire des machines). Faites particulièrement
attention aux roulements lorsque le calcul de la durée de
vie estimée approche de l'échéance.
AVERTISSEMENT !
En cas de signes d'usure, démontez le moteur, vérifiez Le lubrifiant peut provoquer une irritation de la
l'état des pièces et remplacez les pièces défectueuses. peau et une inflammation des yeux. Respectez les
Lors du remplacement des roulements, les roulements précautions d'utilisation du fabricant de la graisse.
de rechange doivent être d'un type identique à celui des
roulements placés à l'origine. Les joints de l'arbre doivent
être remplacés par des joints de qualité et caractéristiques Les types de roulements sont spécifiés dans les catalogues
identiques aux roulements d'origine lors du remplacement de produits correspondants et sur la plaque signalétique
de ceux-ci. des moteurs, à l'exception de ceux de faibles hauteurs
d'axe.
Dans le cas du moteur IP 55 et lorsque ce dernier a
été livré avec un bouchon fermé, il est conseillé d'ouvrir La fiabilité est un point crucial pour les intervalles de
périodiquement les bouchons de vidange afin de s'assurer lubrification des roulements. ABB utilise principalement le
que le passage pour la condensation n'est pas bloqué et principe L1 (99 % des moteurs sont donc garantis en terme
que la condensation est libre de s'échapper du moteur. de durée de vie optimale) pour la lubrification.
Cette opération doit être effectuée lorsque le moteur est à
l'arrêt et a été préparé pour pouvoir y effectuer le travail en 7.2.1 Moteurs avec roulements
toute sécurité. graissés à vie
Les roulements sont généralement des roulements graissés
7.1.1 Moteurs en attente à vie de type 1Z, 2Z, 2RS ou équivalent.
Si le moteur reste en veille sur une longue période, à bord En règle générale, une lubrification adéquate pour les
d’un bateau ou de tout autre environnement en vibration, il tailles allant jusqu'à 250 peut être obtenue pour la durée
convient de prendre les mesures suivantes : suivante, conformément à L1. Lorsque le travail doit être
effectué à des températures ambiantes supérieures, prière
de contacter ABB. La formule d'information brute de
conversion des valeurs L1 en L10 est : L10 = 2,0 x L1.
Les heures de fonctionnement pour les roulements graissés Regraissage avec le moteur à l'arrêt
à vie à des températures de 25 °C et 40 °C sont : Il est impossible de regraisser les roulements si le moteur
ne tourne pas ; quant à la lubrification, elle peut être opérée
Heures de Heures de lorsque le moteur est à l'arrêt.
Hauteur fonctionne- fonctionne- – Dans ce cas, commencez en injectant la moitié de la
d'axe Pôles ment à 25 °C ment à 40 °C quantité de graisse et faites tourner le moteur à vitesse
56 2 52 000 33 000 maximale pendant quelques minutes.
56 4-8 65 000 41 000 – Après avoir arrêté le moteur, injectez le reste de graisse
63 2 49 000 31 000 dans le roulement.
63 4-8 63 000 40 000 – Après avoir fait tourner le moteur pendant 1 à 2 heures,
71 2 67 000 42 000 refermez le bouchon d'orifice d'évacuation de la graisse
71 4-8 100 000 56 000 ou la valve de fermeture si le moteur en est doté.
80-90 2 100 000 65 000
B. Lubrification automatique
80-90 4-8 100 000 96 000
100-112 2 89 000 56 000 En cas de lubrification automatique, le bouchon de l'orifice
100-112 4-8 100 000 89 000 d'évacuation de la graisse doit être retiré ou la valve de
132 2 67 000 42 000 fermeture doit être ouverte, si le moteur en est doté.
132 4-8 100 000 77 000
160 2 60 000 38 000
ABB recommande l'utilisation de systèmes
électromécaniques uniquement.
160 4-8 100 000 74 000
180 2 55 000 34 000 La quantité de graisse par intervalle de lubrification
180 4-8 100 000 70 000 indiquée dans le tableau doit être multipliée par trois si un
200 2 41 000 25 000 système de lubrification centralisé est utilisé. Lorsqu'une
200 4-8 95 000 60 000 unité de regraissage automatique plus petite (une ou deux
225 2 36 000 23 000 cartouches par moteur) est utilisée, la quantité normale de
225 4-8 88 000 56 000 graisse peut être utilisée.
250 2 31 000 20 000
Pour les moteurs à 2 pôles avec lubrification automatique,
250 4-8 80 000 50 000
la note relative aux recommandations de lubrification des
Les données sont valides jusqu'à 60 Hz. moteurs à 2 pôles figurant au paragraphe « Lubrifiants »
doit être observée.
7.2.2 Moteurs avec roulements La graisse utilisée doit convenir à la lubrification
regraissables automatique. Les recommandations du fournisseur du
système de lubrification automatique et celles du fabricant
Plaque de lubrification et procédure générale de
de la graisse doivent être respectées.
lubrification
Si le moteur est doté d'une plaque de lubrification, Exemple de calcul de la quantité de graisse pour le
respectez les valeurs indiquées. système de lubrification automatique
Système de lubrification centralisé : L'intervalle de
Les intervalles de graissage pour les roulements, la
regraissage du moteur CEI M3_P 315_ à 4 pôles dans un
température ambiante et la vitesse de rotation sont définis
réseau 50 Hz, selon le tableau, est de 7 600 h/55 g (DE) et
sur la plaque de lubrification.
7 600 h/40 g (NDE) :
Lors du premier démarrage ou après une lubrification de
roulement, une hausse de température temporaire peut se (DE) RLI = 55 g/7 600 h*3*24 = 0,52 g/jour
produire pendant environ 10 à 20 heures. (NDE) RLI = 40 g/7 600*3*24 = 0,38 g/jour
Certains moteurs peuvent être équipés d'un collecteur de
graisse usagée. Consultez les consignes spéciales fournies Exemple de calcul de la quantité de graisse
avec l'équipement. pour l'unité de lubrification automatique unique
(cartouche)
A. Lubrification manuelle (DE) RLI = 55 g/7 600 h*24 = 0,17 g/jour
Regraissage avec le moteur en marche (NDE) RLI = 40 g/7 600*24 = 0,13 g/jour
– Ôtez le bouchon de l'orifice d'évacuation de la graisse ou
ouvrez la valve de fermeture si le moteur en est doté. RLI = Intervalle de relubrification, DE = Côté entraînement,
– Assurez-vous que le conduit de lubrification est ouvert NDE = Côté non-entraînement
– Injectez la quantité spécifiée de graisse dans le
roulement.
– Faites tourner le moteur pendant 1 à 2 heures pour
évacuer le trop-plein de graisse du roulement. Refermez
les orifices d'évacuation de la graisse si le moteur en est
doté.
7.2.3 Intervalles de lubrification et Un fonctionnement à grande vitesse (ex., alimentation par
quantités de lubrifiant convertisseur de fréquence) ou à petite vitesse avec une
charge élevée impose des intervalles de lubrification plus
Pour les intervalles de lubrification des moteurs verticaux, rapprochés.
les valeurs du tableau ci-dessous doivent être divisées par
deux.
AVERTISSEMENT !
En règle générale, une lubrification adéquate peut être Ne pas dépasser la température maximum de
obtenue pour la durée suivante, conformément à L1. fonctionnement de la graisse et des roulements
Lorsque le travail doit être effectué à des températures (+110 °C).
ambiantes supérieures, prière de contacter ABB. La La vitesse maximale assignée au moteur ne doit pas
formule indicative de conversion des valeurs L1 en L10 est : être dépassée.
L10 = 2,0 x L1 avec lubrification manuelle.
Les intervalles de lubrification s'entendent pour une

température de fonctionnement des roulements de 80 °C
(température ambiante de +25 °C).
REMARQUE !
Toute augmentation de la température ambiante
augmente d'autant la température des roulements.
Les intervalles seront réduits de moitié pour chaque
augmentation de 15 °C de la température des
roulements et doublés pour chaque réduction de
15 °C de la température des roulements.
Quantité
Hauteur de graisse 3 600 3 000 1 800 1 500 1 000 500-900
kW kW kW kW
d'axe g/ tr/min tr/min tr/min tr/min tr/min tr/min
roulement
Roulements à billes, intervalles de lubrification en heures de fonctionnement
112 10 toutes 10 000 13 000 toutes 18 000 21 000 toutes 25 000 toutes 28 000
132 15 toutes 9 000 11 000 toutes 17 000 19 000 toutes 23 000 toutes 26 500
160 25 ≤ 18,5 9 000 12 000 ≤ 15 18 000 21 500 ≤ 11 24 000 toutes 24 000
160 25 > 18,5 7 500 10 000 > 15 15 000 18 000 > 11 22 500 toutes 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 toutes 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 toutes 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 toutes 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 toutes 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 toutes 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 toutes 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 toutes 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 toutes 7 000
2801) 60 toutes 2 000 3 500 - - - - - - -
2801) 60 - - - toutes 8 000 10 500 toutes 14 000 toutes 17 000
280 35 toutes 1 900 3 200 - - - -
280 40 - - toutes 7 800 9 600 toutes 13 900 toutes 15 000
315 35 toutes 1 900 3 200 - - - -
355 35 toutes 1 900 3 200 - - - -
400 40 toutes 1 500 2 700 - - - -
450 40 toutes 1 500 2 700 - - - -
Roulements à rouleaux, intervalles de lubrification en heures de fonctionnement

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 toutes 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 toutes 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 toutes 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 toutes 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 toutes 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 toutes 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 toutes 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 toutes 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 toutes 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 toutes 3 500
2801) 60 toutes 1 000 1 750 - - - - - - -
2801) 70 - - - toutes 4 000 5 250 toutes 7 000 toutes 8 500
280 35 toutes 900 1 600 - - - -
315 35 toutes 900 1 600 - - - -
355 35 toutes 900 1 600 - - - -
400 40 toutes - 1 300 - - - -
450 40 toutes - 1 300 - - - -
1)
M3AA
7.2.4 Lubrifiants
REMARQUE !
Pour les moteurs à 2 pôles tournant à grande vitesse
AVERTISSEMENT ! pour lesquels le facteur de vitesse est supérieur à
Ne mélangez pas différents types de graisse. 480 000 (obtenu par Dm x n, où Dm = diamètre
Des lubrifiants non miscibles peuvent endommager moyen du roulement en mm ; n = vitesse de rotation
les roulements. en tr/min), vous devez utiliser des graisses grande
vitesse.
Pour le regraissage, seules les graisses spéciales pour
roulements à billes présentant les propriétés suivantes Les graisses suivantes peuvent être utilisées pour les
doivent être utilisées : moteurs en fonte tournant à grande vitesse, sans être
- graisse de qualité supérieure à base de savon lithium mélangées à des graisses au lithium complexe :
complexe et d'huile minérale ou huile synthétique
(ex., PAO) - Klüber Klüber Quiet BQH 72-102
- viscosité de l'huile de base entre 100 et 160 cST à 40 °C (savon polycarbamide)
- consistance (échelle NLGI 1,5–3*) - Lubcon Turmogrease PU703 (savon polycarbamide)
- températures d'utilisation : -30 °C à +120 °C, Si d'autres lubrifiants sont utilisés, vérifiez auprès du
en continu. fabricant que la qualité correspond aux lubrifiants
*) Une consistance supérieure est préconisée pour les mentionnés précédemment. Les intervalles de lubrification
moteurs à arbre vertical ou exploités en ambiance chaude. sont basés sur les graisses à hautes performances
présentées ci-dessus. L'utilisation d'autres graisses peut
Les caractéristiques de la graisse mentionnées ci-dessus sont réduire l'intervalle.
applicables si la température ambiante est comprise entre
-30 °C et +55 °C, et la température des roulements inférieure
à 110 °C. Si les conditions sont différentes, prière de consulter
ABB pour en savoir plus concernant la graisse applicable.
Des graisses aux propriétés énoncées sont proposées par les

principaux fabricants de lubrifiants.
Des additifs sont recommandés, mais une garantie écrite

doit être obtenue auprès du fabricant de lubrifiants, tout
particulièrement pour ce qui concerne les additifs EP, stipulant
que les additifs n'endommagent pas les roulements ou les
propriétés des lubrifiants à la températures de fonctionnement.
AVERTISSEMENT !
Les lubrifiants contenant des additifs EP sont
déconseillés pour les températures de roulements
élevées, pour les hauteurs d'axe de 280 à 450.
Les graisses hautes performances suivantes peuvent être

utilisées :
– Mobil Unirex N2 ou N3 (savon lithium complexe)
– Mobil Mobilith SHC 100 (savon lithium complexe)
– Shell Gadus S5 V 100 2 (savon lithium complexe)
– Klüber Klüberplex BEM 41-132 (savon lithium spécial)
– FAG Arcanol TEMP110 (savon lithium complexe)
(savon lithium spécial)
– Total Multiplex S2 A (savon lithium complexe)
– Rhenus Rhenus LKZ 2 (savon lithium complexe)
8. Service après vente 9. Contraintes d'environnement
La plupart des moteurs ABB présentent un niveau de
8.1 Pièces détachées pression acoustique n'excédant pas 82 dB(A) (± 3 dB) à
Sauf indication contraire, les pièces de rechange doivent 50 Hz.
être des pièces d'origine approuvées par ABB. Les valeurs spécifiques à chaque moteur figurent dans
Lors de toute commande de pièces de rechange, vous les catalogues de produits correspondants. Lorsqu'une
devez fournir le numéro de série, la référence complète et alimentation sinusoïdale de 60 Hz est appliquée, les valeurs
toutes les spécifications du moteur figurant sur sa plaque sont de 4 dB(A) supérieures env. aux valeurs associées à
signalétique. une alimentation de 50 Hz dans les catalogues de produits.
Pour les niveaux de pression acoustique au niveau des

8.2 Démontage, remontage alimentations des convertisseurs de fréquence, prière de
contacter ABB.
et rembobinage
Lors de la mise au rebut ou du recyclage des moteurs,
Le rembobinage doit toujours être réalisé dans un atelier les moyens adéquats doivent être employés et les
spécialisé. réglementations et législations locales respectées.
Les moteurs de désenfumage et autres moteurs spéciaux
ne doivent pas être rebobinés sans avoir au préalable
contacté ABB.
8.3 Roulements
Les roulements du moteur doivent faire l'objet d'une
attention particulière.
Ils doivent être démontés avec un extracteur et remontés à

chaud ou avec des outils spécialisés.
Le remplacement des roulements fait l'objet d'une notice à

part, disponible auprès d'ABB.
Toute consigne particulière figurant sur le moteur (ex.,

étiquette) doit être respectée. Les types de roulements
indiqués sur la plaque signalétique doivent être respectés.
REMARQUE !
Sauf autorisation spécifique du constructeur,
toute réparation réalisée par l'exploitant annule
l'engagement de conformité du constructeur.
10. Dépannage
Ces instructions ne couvrent pas toutes les variantes ou Tableau de dépannage du moteur
exécutions des machines et ne permettent pas de résoudre
tous les problèmes d'installation, d'exploitation ou de L'entretien et la maintenance du moteur doivent être
maintenance. Pour toute information complémentaire, nous réalisés par un personnel qualifié disposant des outils et
vous invitons à contacter votre correspondant ABB. des instruments adéquats.
PROBLÈME ORIGINE INTERVENTION

Le moteur ne Fusibles fondus Remplacez les fusibles par des éléments de mêmes type et calibre
démarre pas Déclenchements de surcharge Vérifiez et réinitialisez la surcharge dans le démarreur.
Alimentation électrique inappropriée Vérifiez que l'alimentation fournie correspond aux indications de la
plaque
signalétique et du facteur de charge du moteur.
Branchements inappropriés Vérifiez les connexions en vous reportant au schéma qui accompagne
le moteur.
Circuit ouvert dans le bobinage ou Indiqué par un bourdonnement lorsque l'interrupteur est fermé Vérifiez
l'interrupteur de commande que tous les câbles de raccordement sont serrés et assurez-vous que
tous les contacts de commande se ferment correctement.
Dysfonctionnement mécanique Vérifiez que le moteur et l'entraînement tournent librement.
Vérifiez les roulements et la lubrification.
Court-circuit au niveau du stator
Mauvaise connexion de la bobine du Indiqué par des fusibles fondus. Le moteur doit être rembobiné
stator Retirez les flasques et localisez la défaillance.
Rotor défectueux Vérifiez l'absence de barres et bagues d'extrémité fissurées.
Il se peut que le moteur soit surchargé Réduisez la charge.
Calage du moteur Il se peut qu'une phase soit ouverte Vérifiez l'absence de phase ouverte au niveau des lignes.
Application erronée Modifiez le type ou la taille. Consultez le fabricant de l'équipement.
Surcharge Réduisez la charge.
Basse tension Assurez-vous que la tension de la plaque signalétique est respectée.
Vérifiez la connexion.
Circuit ouvert Fusibles fondus. Vérifiez le relais de surcharge, le stator et les boutons
poussoirs
Le moteur tourne, Alimentation défectueuse Vérifiez le bon serrage des raccordements au niveau de la ligne, des
puis ralentit et fusibles et de la commande.
s'arrête
Le moteur Application incorrecte Consultez le fabricant de l'équipement pour le type adéquat.
est incapable Tension trop basse au niveau des Utilisez une tension plus élevée au niveau des bornes du
d'accélérer jusqu'à bornes du moteur du fait d'une perte transformateur ou réduisez la charge
la vitesse nominale de ligne Vérifiez les connexions. Vérifiez que la taille des conducteurs est
correcte.
Charge de démarrage trop élevée Vérifiez que le moteur démarre au niveau de « pas de charge ».
Barres de rotor fissurées ou rotor Vérifiez l'absence de fissures à proximité des anneaux. Il se peut qu'un
desserré nouveau rotor soit nécessaire, les réparations étant généralement
provisoires.
Circuit primaire ouvert Identifiez le dysfonctionnement à l'aide d'un appareil d'essai et opérez
la réparation.
PROBLÈME ORIGINE INTERVENTION
Le moteur prend Charge excessive Réduisez la charge.
trop de temps Basse tension lors du démarrage Vérifiez la présence de résistance élevée. Assurez-vous que la
à accélérer et/ dimension du câble utilisé est correcte.
ou présente un
courant trop élevé Rotor à cage d'écureuil défectueux Remplacement par un nouveau rotor.
Application d'une tension trop basse Corrigez l'alimentation.
Sens de rotation Séquence de phases erronée Inversez les connexions au niveau du moteur et du tableau de
erroné commande.
Surchauffe du Surcharge Réduisez la charge.
moteur lorsqu'il Il se peut que les ouvertures du châssis Ouvrez les trous de ventilation et vérifiez que l'air passe de façon
tourne ou de ventilation soit obstruées par des continue
impuretés, ce qui rend impossible la depuis le moteur.
ventilation adéquate du moteur
Possibilité de phase ouverte au niveau Vérifiez que tous les fils et câbles sont correctement connectés.
du moteur
Bobine mise à la terre Le moteur doit être rembobiné
Déséquilibre de tension de borne Vérifiez la présence de câbles, connexions et transformateurs
défaillants.
Le moteur vibre Désalignement du moteur Réalignez-le.
Support faible Renforcez la base.
Couplage déséquilibré Équilibrez le couplage.
Équipement entraîné déséquilibré Rééquilibrez l'équipement entraîné.
Roulements défectueux Remplacez les roulements.
Roulements désalignés Réparez le moteur.
Poids d'équilibrage mal positionnés Rééquilibrez-le.
Contradiction entre l'équilibrage du Rééquilibrez le couplage ou le rotor.
rotor et le couplage (demi-clavette -
clavette)
Moteur polyphasé tournant en phase Vérifiez l'absence de circuit ouvert.
unique
Jeu axial excessif Ajustez le roulement ou ajoutez une cale.
Bruit de raclement Flasque frottant contre le ventilateur ou Corrigez le positionnement du ventilateur.
le couvercle du ventilateur
Plaque de base desserrée Serrez les boulons de maintien.
Fonctionnement Passage d'air non uniforme Vérifiez et corrigez les fixations des flasques et des roulements.
bruyant Rotor déséquilibré Rééquilibrez-le.
Roulements Arbre plié ou détendu Redressez ou remplacez l'arbre.
chauds Tension de courroie excessive Réduisez la tension de la courroie.
Poulies trop éloignées de l'épaulement Rapprochez la poulie du roulement du moteur.
d'arbre
Diamètre de poulie trop petit Utilisez des poulies plus larges.
Désalignement Corrigez l'alignement de l'entraînement.
Quantité de graisse insuffisante Veillez à maintenir la qualité et la quantité de graisse appropriées dans
le roulement.
Détérioration de la graisse ou lubrifiant Vidangez la graisse usagée, nettoyez à fond les roulements au
contaminé kérosène et appliquez de la graisse neuve.
Excès de lubrifiant Réduisez la quantité de graisse ; le roulement ne doit être rempli qu'à
moitié.
Roulement surchargé Vérifiez l'alignement, la poussée latérale et la poussée axiale
Bille fissurée ou courses fissurées Remplacez le roulement ; nettoyez d'abord le logement à fond.
Motores de baja tensión
Manual de instalación, funcionamiento, mantenimiento y seguridad
Contenido
1. Introducción ..............................................................................................................................63
1.1 Declaración de conformidad ..............................................................................................63
1.2 Validez ...............................................................................................................................63
2. Consideraciones de seguridad ................................................................................................63
3. Manipulación .............................................................................................................................64
3.1 Comprobación de recepción .............................................................................................64
3.2 Transporte y almacenaje ....................................................................................................64
3.3 Elevación ...........................................................................................................................64
3.4 Peso del motor ..................................................................................................................64
4. Instalación y puesta en servicio ..............................................................................................65
4.1 Generalidades ...................................................................................................................65
4.2 Motores con rodamientos distintos de los de bolas ...........................................................65
4.3 Comprobación de la resistencia de aislamiento..................................................................65
4.4 Anclajes .............................................................................................................................65
4.5 Equilibrado y montaje de acoplamientos y poleas ..............................................................66
4.6 Montaje y alineación del motor ..........................................................................................66
4.7 Fuerzas radiales y accionamientos por correas ..................................................................66
4.8 Motores con tapones de drenaje para condensación.........................................................66
4.9 Cableado y conexiones eléctricas ......................................................................................66
4.9.1 Conexiones para distintos métodos de arranque ................................................67
4.9.2 Conexión de elementos auxiliares .......................................................................68
4.10 Bornes y sentido de giro ....................................................................................................68
5. Operación .................................................................................................................................69
5.1 General..............................................................................................................................69
Manual de motores de baja tensión, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 61
6. Motores de baja tensión alimentados por variadores de velocidad ...................................70
6.1 Introducción ......................................................................................................................70
6.2 Aislamiento del devanado ..................................................................................................70
6.2.1 Selección del aislamiento de devanado para convertidores ABB ........................70
6.2.2 Selección del aislamiento del devanado con todos los demás convertidores .....70
6.3 Protección por temperatura ..............................................................................................70
6.4 Corrientes a través de los rodamientos ..............................................................................71
6.4.1 Eliminación de las corrientes en los rodamientos con convertidores ABB ...........71
6.4.2 Eliminación de las corrientes en los rodamientos
con todos los demás convertidores ....................................................................71
6.5 Cableado, conexión a tierra y compatibilidad electro-magnética ........................................71
6.6 Velocidad de funcionamiento .............................................................................................71
6.7 Motores en aplicaciones con variador de velocidad ...........................................................71
6.7.1 General ..............................................................................................................71
6.7.2 Capacidad de carga del motor con la serie de convertidores AC_8_ _
con control de DTC ............................................................................................72
6.7.3 Capacidad de carga del motor con la serie de convertidores AC_5_ _................72
6.7.4 Capacidad de carga del motor con otros convertidores
de fuente de tensión de tipo PWM......................................................................72
6.7.5 Sobrecargas breves............................................................................................72
6.8 Placas de características ...................................................................................................72
6.9 Puesta en funcionamiento de la aplicación de velocidad variable .......................................72
7. Mantenimiento ..........................................................................................................................73
7.1 Inspección general.............................................................................................................73
7.1.1 Motores en reposo ............................................................................................73
7.2 Lubricación ........................................................................................................................73
7.2.1 Motores con rodamientos lubricados de por vida ...............................................74
7.2.2 Motores con rodamientos reengrasables ............................................................74
7.2.3 Intervalos de lubricación y cantidades de grasa ..................................................75
7.2.4 Lubricantes ........................................................................................................77
8. Servicio postventa ....................................................................................................................78
8.1 Piezas de repuesto ............................................................................................................78
8.2 Desmontaje, ensamblaje y rebobinado ..............................................................................78
8.3 Rodamientos .....................................................................................................................78
9. Requisitos medioambientales .................................................................................................78
10. Resolución de problemas ........................................................................................................79
62 ABB Motors and Generators | Manual de motores de baja tensión, 3GZF500730-85 Rev F 02-2015
1. Introducción 2. Consideraciones
de seguridad
¡ATENCIÓN!
Debe seguir estas instrucciones para garantizar una El motor debe ser instalado y utilizado por personal
instalación, un funcionamiento y un mantenimiento cualificado y familiarizado con los requisitos de salud y
seguros y correctos del motor. Cualquiera que seguridad y la legislación nacional.
instale, maneje o realice el mantenimiento del motor
o los equipos asociados debe tenerlas en cuenta. Deben existir los equipos de seguridad necesarios para la
El motor debe ser instalado y utilizado por personal prevención de accidentes en el lugar de la instalación, y el
cualificado y familiarizado con los requisitos de lugar de funcionamiento debe respetar la normativa local.
salud y seguridad y la legislación nacional. No tener
en cuenta estas instrucciones puede suponer la
anulación de todas las garantías aplicables. ¡ADVERTENCIA!
Los controles de parada de emergencia deben
estar dotados de elementos de bloqueo del
1.1 Declaración de conformidad rearranque. Tras una parada de emergencia, un
comando de rearranque sólo puede funcionar tras
La conformidad del producto final con la Directiva el restablecimiento intencionado del bloqueo de
2006/42/CE (Máquinas) debe ser determinada por la parte rearranque.
encargada de la puesta en servicio en el momento del
montaje del motor en la maquinaria.
Puntos que deben respetarse:

1.2 Validez 1. No pise el motor.
Estas instrucciones son válidas para los siguientes tipos 2. La temperatura de la cubierta externa del motor puede
de máquinas eléctricas de ABB, funcionando tanto en el llegar a ser caliente al tacto durante su funcionamiento
modo de motor como el de generador: normal y, especialmente, tras una parada.
3. Algunas aplicaciones especiales del motor pueden
Serie MT*, MXMA, requerir instrucciones adicionales (p. ej., cuando son
Serie M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*, alimentadas por un convertidor de frecuencia).
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, 4. Tenga en cuenta las partes giratorias del motor.
M2V*/M3V*
5. No abra las cajas de bornes mientras haya tensión
Con tamaños de carcasa 56 - 450.
aplicada.
Existe un manual separado para, por ejemplo, los motores
Ex, Motores de baja tensión para áreas peligrosas: Manual
de instalación, funcionamiento, mantenimiento y seguridad
(3GZF500730-47)
En el caso de algunos tipos de máquinas, puede requerirse

información adicional debido a sus aplicaciones y/o
consideraciones de diseño especiales.
Existe un manual adicional para los siguientes motores:

– Motores para caminos de rodillos
– Motores refrigerados por agua
– Motores de extracción de humos
– Motores con freno
– Motores para temperaturas ambiente elevadas
– Motores de aplicaciones marinas para su montaje sobre
cubierta abierta de buques o unidades de alta mar
3. Manipulación Debe apretar las argollas antes de la elevación. Si es
necesario, puede ajustar la posición de la argolla, usando
arandelas adecuadas como espaciadores.
3.1 Comprobación de recepción
Asegúrese de que utiliza el equipo de elevación adecuado
A su recepción, verifique inmediatamente si el motor y de que los tamaños de los ganchos son los adecuados
presenta daños externos (por ejemplo en las salidas de eje, para los cáncamos de elevación.
las bridas y las superficies pintadas) y, en tal caso, informe
inmediatamente al agente de ventas correspondiente. Tenga cuidado para no dañar los equipos auxiliares ni los
cables que estén conectados al motor.
Compruebe los datos de la placa de características,
especialmente la tensión y las conexiones del devanado Retire las posibles fijaciones de transporte que sujeten el
(estrella o triángulo). El tipo de rodamiento se especifica en motor al palé.
la placa de características de todos los motores, excepto
en los tamaños de carcasa más pequeños. ABB puede proporcionarle instrucciones de elevación
específicas.
En el caso de las aplicaciones con convertidor de
frecuencia, compruebe la capacidad máxima de carga
permitida de acuerdo con la frecuencia marcada en la ¡ADVERTENCIA!
segunda placa de características del motor. Durante los trabajos de elevación, montaje o
mantenimiento, deben tenerse en cuenta todas
las consideraciones de seguridad necesarias
3.2 Transporte y almacenaje y prestarse especial atención a que nadie esté
El motor debe almacenarse siempre en interior (por encima expuesto a una carga elevada.
de los –20 °C), en ambientes secos, sin vibraciones y sin
polvo. Durante el transporte, deben evitarse los golpes,
las caídas y la humedad. En presencia de cualquier otra 3.4 Peso del motor
situación, póngase en contacto con ABB.
El peso total del motor puede variar dentro de un mismo
Las superficies mecanizadas sin protección (salidas de eje tamaño de carcasa (altura de eje), en función de la poten-
y bridas) deben ser tratadas con un anticorrosivo. cia, la disposición de montaje y los elementos auxiliares.
Se recomienda hacer girar los ejes periódicamente con la La tabla siguiente muestra los pesos estimados para los
mano para evitar migraciones de grasa. motores en su versión básica, en función del material de la
carcasa.
Se recomienda el uso de las resistencias anti condensa-
ción, si las tiene, para evitar la condensación de agua en El peso real de todos los motores ABB, excepto el de los
el motor. tamaños de carcasa más pequeños (56 y 63) se indica en
la placa de características.
El motor no debe ser sometido a vibraciones externas en
reposo, para evitar daños en los rodamientos. Tamaño de Aluminio Hierro fundido Además
carcasa para el freno
Los motores equipados con rodamientos de rodillos Peso kg Peso kg
cilíndricos y/o de bolas de contacto angular deben llevar 56 4,5 - -
dispositivos de bloqueo durante el transporte. 63 6 - -
71 8 13 5
3.3 Elevación 80 14 20 8
90 20 30 10
Todos los motores ABB con peso superior a los 25 kg 100 32 40 16
están equipados con cáncamos de elevación. 112 36 50 20
132 93 90 30
A la hora de elevar el motor sólo deben usarse los
160 149 130 30
cáncamos de elevación principales del propio motor. No
180 162 190 45
deben usarse para elevar el motor si éste está unido a
200 245 275 55
otros equipos.
225 300 360 75
No deben usarse los cáncamos de elevación de los ele- 250 386 405 75
mentos auxiliares (por ejemplo frenos, ventiladores de refri- 280 425 800 -
geración separados) ni de las cajas de bornes para elevar 315 - 1700 -
el motor. Debido a las distintas potencias, la disposición 355 - 2700 -
de montaje y los equipos auxiliares, motores de la misma 400 - 3500 -
carcasa pueden tener centros de gravedad diferentes. 450 - 4500 -
No deben utilizarse cáncamos de elevación defectuosos.

Antes de la elevación, compruebe que las argollas o los Si el motor está equipado con un motoventilador, póngase
cáncamos de elevación integrados no presenten ningún en contacto con ABB para conocer el peso.
daño.
4. Instalación y puesta en servicio
¡ADVERTENCIA! 4.3 Comprobación de la

Desconecte y bloquee el motor antes de hacer resistencia de aislamiento
cualquier comprobación en él o en el equipo
accionado. Mida la resistencia de aislamiento antes de poner el
motor en servicio o cuando se sospeche la existencia de
humedad en el devanado.
4.1 Generalidades La resistencia de aislamiento, corregida a 25 °C, no
Es necesario comprobar cuidadosamente todos los debe ser en ningún caso inferior a 1 MΩ (medido con
valores de la placa de características con el fin de ejecutar 500 ó 1000 V CC). El valor de resistencia de aislamiento
correctamente la protección y conexión del motor. se reduce a la mitad por cada incremento de 20 °C
en la temperatura. La Figura 1 puede utilizarse para la
corrección del aislamiento a la temperatura deseada.
4.2 Motores con rodamientos
distintos de los de bolas ¡ADVERTENCIA!
Para evitar riesgos de descarga eléctrica, la carcasa
Retire el bloqueo para transporte si está presente. Gire el
del motor debe estar conectada a tierra y los
eje del motor con la mano para comprobar que gira sin
devanados deben ser descargados a la carcasa
dificultad.
inmediatamente después de cada medición.
Motores con rodamientos de rodillos:

Arrancar el motor sin fuerza radial aplicada al eje puede Si no se alcanza el valor de resistencia indicado, el
dañar el rodamiento de rodillos debido al “deslizamiento”. devanado está demasiado húmedo y debe secarse al
horno. La temperatura del horno debe ser de 90 °C
durante un periodo de 12-16 horas y, posteriormente,
Motores con rodamientos de contacto angular:
105 °C durante un periodo de 6-8 horas.
Arrancar el motor sin fuerza axial aplicada en la dirección
correcta respecto del eje puede dañar los rodamientos de Durante el calentamiento, los tapones de los orificios
contacto angular. de drenaje, si los hay, deben ser retirados y las válvulas
de cierre deben estar abiertas. Tras el calentamiento,
asegúrese de volver a colocar los tapones. Incluso si
¡ADVERTENCIA! existen tapones de drenaje, se recomienda desmontar los
En el caso de los motores dotados de rodamientos escudos y las tapas de las cajas de bornes para el proceso
de contacto angular, la fuerza axial no debe cambiar de secado.
de sentido bajo ningún concepto.
Normalmente, si la humedad es causada por agua marina,
debe bobinarse de nuevo el motor.
El tipo de rodamiento se especifica en la placa de
características. 4.4 Anclajes
Motores con engrasadores: El usuario final es el único responsable de la preparación
Al arrancar el motor por primera vez o tras un tiempo de los anclajes.
prolongado en el almacén, aplique la cantidad especificada Los anclajes de metal deben pintarse para evitar la
de grasa. corrosión.
Para obtener más detalles, consulte la sección Los anclajes deben ser lisos y lo suficientemente
“7.2.2 Motores con rodamientos reengrasables”. firmes para resistir las posibles fuerzas causadas por
En el caso de montaje vertical con el eje hacia abajo, cortocircuitos.
el motor debe contar con una cubierta protectora para
impedir la caída de objetos extraños y fluidos en el interior
de las aberturas de ventilación. Este objetivo también
puede conseguirse con una cubierta separada no unida
al motor. En este caso, el motor debe contar con una
etiqueta de advertencia.
Deben diseñarse y dimensionarse adecuadamente para Exactitud de montaje del acoplamiento: compruebe que
evitar la transferencia de vibraciones al motor y la aparición la separación b sea inferior a 0,05 mm y que la diferencia
de vibraciones por resonancia. Consulte la figura que entre a1 y a2 sea también inferior a 0,05 mm. Consulte la
aparece a continuación. Figura 2.
Vuelva a comprobar la alineación tras el apriete final de los

Regla tornillos o pernos.
No sobrepase los valores de carga permitidos para los

rodamientos que se indican en los catálogos de productos.
¡Atención! La diferencia de
altura no debe superar los ± Compruebe que el motor cuenta con un flujo de aire
0,1 mm con respecto a ningún
otro pie del motor.
suficiente. Asegúrese de que ningún objeto cercano ni la
luz solar directa radie calor adicional al motor.
En el caso de los motores montados en brida (por ejemplo

B5, B35, V1), asegúrese de que la construcción permita un
flujo de aire suficiente en la superficie exterior de la brida.
Ubicación de la pata
4.7 Fuerzas radiales y

accionamientos por correas
4.5 Equilibrado y montaje
Debe tensar las correas de acuerdo con las instrucciones
de acoplamientos y poleas del proveedor del equipo accionado. Sin embargo, no
sobrepase las fuerzas máximas de la correa (es decir, la
De serie, el equilibrado del motor ha sido realizado con
carga radial del rodamiento) indicadas en los catálogos de
media chaveta.
producto pertinentes.
Los acoplamientos o las poleas deben ser equilibradas tras
mecanizar los chaveteros. El equilibrado debe ser realizado
¡ADVERTENCIA!
de acuerdo con el método de equilibrado especificado
Una tensión excesiva de la correa dañará los
para el motor.
rodamientos y puede provocar daños en el eje.
Los acoplamientos y las poleas deben fijarse al eje con
ayuda de equipos y herramientas adecuados que no dañen
ni los rodamientos, ni las juntas, ni los retenes.
4.8 Motores con tapones de
No monte en ningún caso un acoplamiento o una polea
con ayuda de un martillo ni los retire haciendo fuerza con
drenaje para condensación
una palanca contra el cuerpo del motor. Compruebe que los orificios y tapones de drenaje queden
orientados hacia abajo. En los motores con montaje
vertical, los tapones de drenaje estarán en posición
4.6 Montaje y alineación horizontal.
del motor Los motores con tapones de drenaje herméticos de
Asegúrese de que haya suficiente espacio para que el plástico se suministran con los tapones en la posición
aire pueda circular libremente alrededor del motor. Se abierta. En ambientes muy polvorientos, todos los orificios
recomienda tener una separación entre la cubierta del de drenaje deben permanecer cerrados.
ventilador y la pared, etc. de al menos ½ de la entrada de
aire de la cubierta del ventilador. Encontrará información
adicional en el catálogo de productos o en los planos de 4.9 Cableado y conexiones
dimensiones disponibles en nuestras páginas web: www. eléctricas
abb.com/motors&generators.
La caja de bornes de los motores estándar de una sola
Una alineación correcta resulta esencial para evitar velocidad tiene normalmente seis bornes de conexión del
vibraciones y averías en los rodamientos y los ejes. devanado y como mínimo un borne de conexión a tierra.
Sujete el motor a los anclajes con los tornillos o pernos Además del devanado principal y los bornes de conexión
adecuados y utilice calces entre los anclajes y las patas. a tierra, la caja de bornes también puede contener
conexiones para termistores, resistencias calefactoras u
Alinee el motor con los métodos adecuados.
otros dispositivos auxiliares.
Si corresponde, perfore orificios de posicionamiento y
sujete los pasadores de posicionamiento en su lugar.
Para la conexión de todos los cables principales deben Además, los medios de conexión a tierra o conexión
usarse terminales de cable adecuados. Los cables de equipotencial del exterior del aparato eléctrico deben
los elementos auxiliares pueden conectarse tal cual a sus permitir la conexión efectiva de un conductor con una
placas de bornes. sección transversal de al menos 4 mm2.
Estos motores son sólo para instalación fija. A no ser que La conexión de cable entre la red y los bornes del motor
se especifique lo contrario, las roscas de las entradas de debe cumplir los requisitos establecidos en las normas
cables son métricas. La clase IP del prensaestopas debe nacionales sobre instalación, o cumplir con la norma
ser al menos la misma que la de las cajas de bornes. IEC/EN 60204-1, según la intensidad nominal indicada en
la placa de características.
En el momento de la instalación, debe usarse un buje de
conducto o un conector de cables certificado.
¡ATENCIÓN!
Si la temperatura ambiente supera los +50 °C,
¡ATENCIÓN! deben utilizarse cables con una temperatura de
Los cables deben estar protegidos mecánicamente funcionamiento permitida de +90 °C como mínimo.
y sujetos cerca de la caja de bornes, para cumplir Al medir los cables, también deben tenerse en
los requisitos adecuados de la norma IEC/EN cuenta todos los demás factores de conversión en
60079-0 y las normas de instalación locales. función de las condiciones de instalación.
Asegúrese de que la protección del motor se corresponde

Las entradas de cable no utilizadas deben cerrarse con con las condiciones ambientales y climáticas. Por ejemplo,
tapones de acuerdo con la clase IP de la caja de bornes. asegúrese de que no pueda penetrar agua en el motor ni
en las cajas de bornes.
El grado de protección y el diámetro se especifican en los
documentos relativos al prensaestopas. Las juntas de las cajas de bornes deben estar colocadas
correctamente en las ranuras correspondientes, para
garantizar una clase IP correcta. Un escape podría
¡ADVERTENCIA!
conducir a una penetración de polvo o de agua, creando
Utilice prensaestopas y juntas adecuados en las
un riesgo de descarga eléctrica entre las partes con
entradas de cable, de acuerdo con el tipo y el
tensión.
diámetro del cable.
4.9.1 Conexiones para distintos métodos

La conexión a tierra debe llevarse a cabo de acuerdo con
de arranque
los reglamentos locales antes de conectar el motor a la
tensión de suministro. La caja de bornes de los motores estándar de una sola
velocidad tiene normalmente seis bornes de conexión del
El borne de conexión a tierra de la carcasa debe estar
devanado y como mínimo un borne de conexión a tierra.
conectado a la
Con ello se permite el uso de los arranques directo e Y/D.
tierra de protección con un cable, de la forma indicada en
la Tabla 5 de la norma IEC/EN 60034-1: En el caso de los motores especiales de dos velocidades,
para su conexión, se deben seguir las instrucciones
Sección transversal mínima de los conductores de
indicadas dentro de la caja de bornes o en el manual del
protección
motor.
Sección transversal Sección transversal mínima
del conductor de protección La tensión y la conexión están indicadas en la placa de
de los conductores de fase
de la instalación, S, [mm2] correspondiente, SP, [mm2] características.
4 4
Arranque directo (DOL):
6 6
10 10
Pueden utilizarse conexiones al devanado en estrella o
16 16
triángulo.
25 25 Por ejemplo, 690 VY, 400 VD indica una conexión en Y
35 25 para 690 V y una conexión en D para 400 V.
50 25
70 35 Arranque en estrella/triángulo (Y/D):
95 50
La tensión de suministro debe ser igual a la tensión nominal
120 70
del motor si se usa una conexión en D.
150 70
185 95 Retire todos los puentes de la placa de bornes.
240 120
300 150
400 185
Otros métodos de arranque y condiciones de
arranque difíciles:
En los casos en los que se utilicen otros métodos de
arranque, como un convertidor o un arrancador suave,
en los tipos de carga de S1 y S2, se considera que el
dispositivo está “aislado de la red eléctrica cuando la
máquina eléctrica está en funcionamiento”, según la norma
IEC 60079-0, y la protección por temperatura es opcional.
4.9.2 Conexión de elementos auxiliares

Si un motor está equipado con termistores u otros RTD
(Pt100, relés térmicos, etc.) y dispositivos auxiliares, se
recomienda usarlos y conectarlos de la forma adecuada.
En determinadas aplicaciones es obligatorio usar una
protección por temperatura. Encontrará información más
detallada en los documentos suministrados con el motor.
Encontrará los diagramas de conexión para elementos
auxiliares y piezas de conexión en el interior de la caja de
bornes.
La tensión de medida máxima para los termistores es de

2,5 V. La intensidad de medida máxima para el Pt100
es de 5 mA. El uso de una tensión o una intensidad de
medida superiores puede dar lugar a errores en las lecturas
o daños en un detector de temperatura.
El aislamiento de los sensores térmicos satisface los

requisitos de aislamiento básico.
4.10 Bornes y sentido de giro

El eje gira en el sentido de las agujas del reloj, visto desde
el lado de acople del motor, si la secuencia de fases de
línea a los bornes es L1, L2, L3, como se muestra en la
figura 3.
Para modificar el sentido de giro, intercambie dos

conexiones cualesquiera de los cables de suministro.
Si el motor tiene un ventilador unidireccional, asegúrese de

que gire en el mismo sentido que el indicado por la flecha
dibujada en el motor.
5. Operación
5.1 General
Estos motores han sido diseñados para las condiciones
siguientes, a no ser que se indique lo contrario en la placa
de características:
- Los motores deben instalarse únicamente en

instalaciones fijas.
- El intervalo normal de temperaturas ambiente es de -20
a +40 °C.
- La altitud máxima es de 1000 m sobre el nivel del mar.
- La variación de la tensión de suministro y la frecuencia
no debe exceder los límites mencionados en las normas
correspondientes. La tolerancia de tensión de suministro
es de ±5% y la de la frecuencia es de ±2% de acuerdo
con la figura 4 (EN / IEC 60034-1, párrafo 7.3, Zona
A). Se supone que ambos valores extremos no deben
producirse al mismo tiempo.
El motor sólo puede ser usado en las aplicaciones a

las que está destinado. Los valores nominales y las
condiciones de funcionamiento se indican en las placas
de características del motor. Además, se deben respetar
todos los requisitos de este manual y demás instrucciones
relacionadas, además de respetar las normas.
Si se sobrepasan estos límites, se deben comprobar lo

datos del motor y los de su diseño. Póngase en contacto
con ABB para más información.
¡ADVERTENCIA!
No tener en cuenta las instrucciones o el
mantenimiento del aparato puede poner en peligro la
seguridad y con ello impedir el uso del motor.
6. Motores de baja tensión alimentados por variadores
de velocidad
6.1 Introducción 6.2.1 Selección del aislamiento de
devanado para convertidores ABB
Esta parte del manual proporciona instrucciones
adicionales para los motores utilizados con alimentación En el caso de los convertidores de frecuencia de, por
a través de un convertidor de frecuencia. El motor ha sido ejemplo, las series AC_8_ _ y AC_5_ _ de ABB con
concebido para su alimentación con un solo convertidor rectificador de diodos (tensión de CC no controlada),
de frecuencia y no para su uso con otros motores la selección del aislamiento de devanado y de los filtros
funcionando en paralelo desde un solo convertidor puede hacerse de acuerdo con la tabla 6.1.
de frecuencia. Deben respetarse las instrucciones
proporcionadas por el fabricante del convertidor. 6.2.2 Selección del aislamiento del
ABB puede necesitar información adicional a la hora de devanado con todos los demás
decidir la idoneidad de algunos tipos de motores concretos convertidores
utilizados en aplicaciones especiales o con modificaciones
de diseño especiales. Los esfuerzos de tensión deben estar limitados por debajo
de los límites aceptados. Póngase en contacto con el
suministrador del sistema para garantizar la seguridad de la
aplicación. La influencia de los posibles filtros debe tenerse
6.2 Aislamiento del devanado en cuenta a la hora de dimensionar el motor.
Los convertidores de frecuencia generan esfuerzos
de tensión mayores en el devanado del motor que
la alimentación sinusoidal. Por ello el aislamiento de 6.3 Protección por temperatura
devanado del motor, así como el filtro de la salida del
convertidor, deben dimensionarse de acuerdo con las La mayoría de los motores tratados en este manual están
instrucciones que aparecen a continuación. equipados con termistores PTC u otro tipo de detector de
temperatura de resistencia en los devanados del estátor.
Se recomienda conectarlos al convertidor de frecuencia.
Para saber más, consulte el capítulo 4.9.2.
PN < 100 kW PN ≥ 100 kW o PN ≥ 350 kW o

IEC315 ≤ Tamaño de carcasa ≤ IEC355 IEC400 ≤ Tamaño de carcasa ≤ IEC450
UN ≤ 500 V Motor estándar Motor estándar Motor estándar
+ rodamiento de lado de acople aislado + rodamiento de lado de acople aislado
+ filtro de modo común
500 V >UN ≤ 600 V Motor estándar Motor estándar Motor estándar
+ filtro dU/dt (reactor) + filtro dU/dt (reactor) + rodamiento de lado de acople aislado
O bien + rodamiento de lado de acople aislado + filtro dU/dt (reactor)
Aislamiento reforzado O bien + filtro de modo común
Aislamiento reforzado O bien
+ rodamiento de lado de acople aislado Aislamiento reforzado
+ rodamiento de lado de acople aislado
500 V >UN ≤ 600 V Motor estándar Motor estándar Motor estándar
(longitud de cable > 150 m) + rodamiento de lado de acople aislado + rodamiento de lado de acople aislado
600 V >UN ≤ 690 V Aislamiento reforzado Aislamiento reforzado Aislamiento reforzado

+ filtro dU/dt (reactor) + filtro dU/dt (reactor) + rodamiento de lado de acople aislado
+ rodamiento de lado de acople aislado + filtro dU/dt (reactor)
600 V >UN ≤ 690 V Aislamiento reforzado Aislamiento reforzado Aislamiento reforzado
(longitud de cable > 150 m) + rodamiento de lado de acople aislado + rodamiento de lado de acople aislado
Tabla 6.1 Selección del aislamiento de devanado para convertidores ABB
Para obtener más información sobre el frenado con resistencias y los convertidores con unidades de suministro
controladas, póngase en contacto con ABB.
6.4 Corrientes a través ¡ATENCIÓN!
de los rodamientos Deben usarse prensaestopas adecuados que
proporcionen una conexión equipotencial de 360°
Deben usarse rodamientos aislados o construcciones de en todos los puntos de terminación, es decir, en
rodamientos aisladas, filtros de modo común y cables y el motor, el convertidor, el posible interruptor de
métodos de conexión a tierra adecuados, de acuerdo con seguridad, etc.
las instrucciones que aparecen a continuación y con la
tabla 6.1.
En el caso de los motores con tamaño de carcasa IEC
6.4.1 Eliminación de las corrientes en los 280 y mayores, se requiere una conexión equipotencial
adicional entre la carcasa del motor y el equipo accionado,
rodamientos con convertidores ABB a no ser que los dos estén montados sobre una base
En el caso de un convertidor de frecuencia de, por común de acero. En este caso, es necesario comprobar
ejemplo, las series AC_8_ _ y AC_5_ _ de ABB con la conductividad de alta frecuencia de la conexión ofrecida
rectificador de diodos, deben usarse los métodos de por la base de acero, por ejemplo midiendo la diferencia de
la tabla 6.1 para evitar la presencia de corrientes de potencial existente entre los componentes.
rodamiento dañinas en los motores.
Encontrará más información sobre la conexión a tierra y el
cableado de los convertidores de frecuencia en el manual
¡ATENCIÓN! “Grounding and cabling of the drive system” (Conexión a
Se recomienda utilizar rodamientos aislados tierra y cableado de un convertidor de frecuencia, código:
que cuenten con aros interiores y/o exteriores 3AFY 61201998).
recubiertos con óxido de aluminio, o elementos
rodantes cerámicos. Los recubrimientos de óxido
de aluminio también deben estar tratados con un 6.6 Velocidad de funcionamiento
sellante para evitar la penetración de suciedad y
humedad en el recubrimiento poroso. Para conocer En el caso de las velocidades superiores a la velocidad
el tipo exacto de aislamiento de los rodamientos, nominal indicada en la placa de características del motor
consulte la placa de características del motor. Se o en el catálogo de productos correspondiente, asegúrese
prohíbe cambiar el tipo de rodamiento o el método de que no se sobrepase la velocidad de rotación máxima
de aislamiento sin la autorización de ABB. permitida en el motor, ni la velocidad crítica de la aplicación
en su conjunto.
6.4.2 Eliminación de las corrientes en los
rodamientos con todos los demás
convertidores
6.7 Motores en aplicaciones
El usuario es responsable de la protección del motor y con variador de velocidad
los equipos accionados frente a corrientes dañinas en los
rodamientos. Puede seguir como directriz las instrucciones 6.7.1 General
del capítulo 6.4.1, pero su eficacia no puede garantizarse
En el caso de los convertidores de frecuencia de ABB, los
en todos los casos.
motores pueden dimensionarse con ayuda del programa
de dimensionamiento DriveSize de ABB. Puede descargar
6.5 Cableado, conexión a tierra esta herramienta desde la página web de ABB (www.abb.
com/motors&generators).
y compatibilidad electro-
En el caso de las aplicaciones alimentadas por otros con-
magnética vertidores, los motores deben dimensionarse manualmen-
te. Para más información, póngase en contacto con ABB.
Para ofrecer una conexión a tierra adecuada y garantizar
el cumplimiento de los requisitos de compatibilidad Las curvas de cargabilidad (o curvas de capacidad de
electromagnética aplicables, los motores de más de carga) se basan en la tensión de suministro nominal. El
30 kW deben estar cableados con cables apantallados funcionamiento en condiciones de tensión insuficiente
simétricos y prensaestopas EMC, es decir, que o sobretensión puede influir en el rendimiento de la
proporcionen una conexión equipotencial en los 360°. aplicación.
Para motores más pequeños, también se recomienda
encarecidamente el uso de cables simétricos y
apantallados. Efectúe la conexión a tierra de 360° en
todas las entradas de cables, de la forma descrita en las
instrucciones relativas a los prensaestopas. Entrelace los
apantallamientos de los cables en haces y conéctelos al
borne o barra de bus de conexión a tierra del interior de la
caja de bornes, el armario del convertidor, etc.
6.7.2 Capacidad de carga del motor con la de velocidad no requiere normalmente placas de
serie de convertidores AC_8_ _ con características adicionales. Los parámetros necesarios
para la puesta en servicio del convertidor pueden
control de DTC encontrarse en la placa de características principal. Sin
Las curvas de capacidad de carga mostradas en las embargo, en algunas aplicaciones especiales los motores
Figuras 5a - 5d son válidas para los convertidores ABB de pueden contar con placas de características adicionales
la serie AC_8_ _ con tensión de CC no controlada y control para las aplicaciones con variador de velocidad. En este
de DTC. Las figuras muestran el par máximo de salida caso, contienen la información siguiente:
continua de los motores en función de la frecuencia de
alimentación. El par de salida se indica como un porcentaje - Rango de velocidades
del par nominal del motor. Los valores son indicativos. Los - Rango de potencias
valores exactos pueden proporcionarse si así se solicita. - Rango de tensiones e intensidades
- Tipo de par (constante o cuadrático)
- Tipo de convertidor y frecuencia de conmutación mínima
¡ATENCIÓN!
necesaria
¡No se debe superar la velocidad máxima del motor
y la aplicación!
6.7.3 Capacidad de carga del motor con 6.9 Puesta en funcionamiento

la serie de convertidores AC_5_ _ de la aplicación de velocidad
Las curvas de capacidad de carga mostradas en las
Figuras 6a - 6d son válidas para los convertidores de la
variable
serie AC_5_ _. Las figuras muestran el par máximo de
La puesta en funcionamiento de la aplicación de velocidad
salida continua de los motores en función de la frecuencia
variable debe realizarse de acuerdo con las instrucciones
de alimentación. El par de salida se indica como un
del convertidor de frecuencia y la normativa y regulaciones
porcentaje del par nominal del motor. Los valores son
locales. También deben tenerse en cuenta los requisitos y
indicativos. Los valores exactos pueden proporcionarse si
las limitaciones establecidos por la aplicación.
así se solicita.
Todos los parámetros necesarios para el ajuste del
¡ATENCIÓN! convertidor deben ser tomados de las placas de
¡No se debe superar la velocidad máxima del motor características del motor. Los parámetros necesitados con
y la aplicación! más frecuencia son:
- tensión nominal
6.7.4 Capacidad de carga del motor con - intensidad nominal
otros convertidores de fuente de - frecuencia nominal
tensión de tipo PWM - velocidad nominal
En el caso de otros convertidores con tensión de CC no - potencia nominal
controlada y una frecuencia de conmutación mínima de
3 kHz (200…500 V), pueden usarse las instrucciones de
dimensionamiento del capítulo 6.7.3 como directrices. ¡ATENCIÓN!
Sin embargo, debe recordarse que la capacidad de ¡Si falta información o es inexacta, no utilice el
carga térmica real puede ser también menor. Póngase motor antes de garantizar que los valores sean los
en contacto con el fabricante del convertidor o el correctos!
suministrador del sistema.
ABB recomienda utilizar todas las características de

¡ATENCIÓN! protección adecuadas que ofrezca el convertidor para
La capacidad de carga térmica real de un motor aumentar la seguridad de la aplicación. Los convertidores
puede ser inferior a la mostrada por las curvas suelen contar con características como las siguientes
indicativas. (la disponibilidad de estas características y sus nombres
varían según el fabricante y el modelo del convertidor):
6.7.5 Sobrecargas breves
- velocidad mínima
Los motores ABB pueden ser sometidos normalmente a - velocidad máxima
sobrecargas además de a un uso con carga intermitente. - tiempos de aceleración y deceleración
La forma más cómoda de dimensionar estas aplicaciones - intensidad máxima
es usar la herramienta DriveSize. - par máximo
- protección contra pérdida de velocidad
6.8 Placas de características
El uso de motores ABB en aplicaciones con variador
7. Mantenimiento 7.1.1 Motores en reposo
Si el motor permanece en reposo durante periodos
prolongados en un buque o en otro entorno con
¡ADVERTENCIA!
vibraciones, se deben tomar las siguientes medidas:
Con el motor parado, el interior de la caja de bornes
puede haber tensión eléctrica usada para alimentar 1. El eje debe ser girado regularmente cada 2 semanas
las resistencias calefactoras o para el calentamiento (deberá documentarse) mediante una puesta en marcha
directo del devanado. del sistema. En el caso de que la puesta en marcha no
sea posible por algún motivo, al menos es necesario
girar el eje con la mano para conseguir una posición
7.1 Inspección general diferente una vez por semana. Las vibraciones causadas
por los demás equipos del buque pueden provocar el
1. Inspeccione el motor a intervalos regulares y al menos
picado de los rodamientos, que debe minimizarse con
una vez al año. La frecuencia de las comprobaciones
un funcionamiento regular o el giro manual.
depende, por ejemplo, del nivel de humedad del aire
y de las condiciones climatológicas locales. Puede 2. El rodamiento debe engrasarse una vez al año mientras
determinarse inicialmente de forma experimental y debe se hace girar el eje (deberá documentarse). Si el motor
ser respetada estrictamente a partir de ese momento. ha sido suministrado con rodamiento de rodillos en el
2. Mantenga el motor limpio y asegúrese de que el aire lado de acople, el bloqueo para transporte debe retirarse
puede fluir libremente. Si se utiliza el motor en un antes de girar el eje. El bloqueo para transporte debe
ambiente polvoriento, es necesario verificar y limpiar volver a montarse en caso de transporte.
periódicamente el sistema de ventilación. 3. Se deben evitar todas las vibraciones para evitar
3. Compruebe el estado de los retenes de eje (por la avería del rodamiento. Deben seguirse todas las
ejemplo, anillo en V o retén radial) y reemplácelos si es instrucciones del manual de instrucciones del motor en
necesario. lo relativo a la puesta en servicio y el mantenimiento.
La garantía no cubrirá los daños en devanados o
4. Compruebe el estado de las conexiones y de los
rodamientos si no se siguen estas instrucciones.
tornillos de montaje y ensamblaje.
5. Compruebe el estado de los rodamientos. Para ello,
escuche para detectar cualquier ruido inusual, mida 7.2 Lubricación
las vibraciones, mida la temperatura del rodamiento,
inspeccione la cantidad de grasa consumida o
monitoree los rodamientos mediante un medidor SPM.
¡ADVERTENCIA!
Preste una atención especial a los rodamientos si están
¡Tenga cuidado con todas las partes giratorias!
cerca del fin de su vida útil nominal calculada.
Cuando aparezcan señales de desgaste, desmonte el

motor, compruebe las piezas y cambie las que sean
¡ADVERTENCIA!
necesarias. Al sustituir los rodamientos, los de repuesto
La grasa puede causar irritación de la piel e
deben ser del mismo tipo que los montados originalmente.
inflamación de los ojos. Siga todas las precauciones
Al sustituir los rodamientos, los retenes de eje deben ser
de seguridad especificadas por el fabricante de la
sustituidos con retenes que presenten la misma calidad y
grasa.
las mismas características que los originales.
En el caso del motor IP 55 y si el motor ha sido

Los tipos de rodamientos se especifican en los
suministrado con un tapón cerrado, es recomendable abrir
catálogos de producto correspondiente y en la placa de
periódicamente los tapones de drenaje para asegurarse de
características de todos los motores, excepto los que
que la salida de condensación no está bloqueada y permitir
tienen los tamaños de carcasa más pequeños.
así que la condensación escape del motor. Esta operación
debe hacerse cuando el motor esté parado y se encuentre La fiabilidad es un asunto vital en cuanto a los
en un estado que permita trabajar en él con seguridad. intervalos de lubricación de los rodamientos. ABB sigue
fundamentalmente el principio L1 (es decir, que el 99% de
los motores alcanzarán con certeza su vida útil) para la
lubricación.
7.2.1 Motores con rodamientos lubricados Algunos motores pueden contar con un colector para
de por vida la grasa utilizada. Siga las instrucciones especiales
entregadas junto con el equipo.
Los rodamientos son normalmente rodamientos lubricados
de por vida y son de los tipos 1Z, 2Z, 2RS o equivalentes. A. Lubricación manual
Como guía, es posible conseguir una lubricación suficiente Reengrase mientras el motor está en funcionamiento
en los tamaños hasta 250 para la duración que se indica – Retire el tapón de salida de grasa o abra la válvula de
posteriormente, de acuerdo con el principio L1. Para cierre si dispone de una.
entornos con temperaturas ambiente mayores, póngase en – Asegúrese de que el canal de lubricación esté abierto.
contacto con ABB. La fórmula informativa para cambiar los – Inyecte la cantidad especificada de grasa hacia el interior
valores L1 aproximadamente a valores L10 es: L10 = 2,0 x L1. del rodamiento.
– Haga funcionar el motor de 1 a 2 horas para garantizar
Las horas de funcionamiento para los rodamientos
que el exceso de grasa sea expulsado del rodamiento.
lubricados de por vida con temperaturas ambiente de 25 y
Cierre el tapón de salida de grasa o la válvula de cierre, si
40 °C son:
dispone de una.
Tamaño Horas de Horas de Reengrase mientras el motor está en reposo
de funcionamiento funcionamiento Si no es posible engrasar los rodamientos con los motores
carcasa Polos a 25 °C a 40 °C
en funcionamiento, la lubricación puede ser realizada
56 2 52 000 33 000
mientras el motor está parado.
56 4-8 65 000 41 000 – En este caso, utilice sólo la mitad de la cantidad de
63 2 49 000 31 000 grasa y haga funcionar el motor durante unos minutos a
63 4-8 63 000 40 000 máxima velocidad.
71 2 67 000 42 000 – Cuando el motor se haya detenido, aplique el resto de la
71 4-8 100 000 56 000 cantidad especificada de grasa al rodamiento.
80-90 2 100 000 65 000 – Tras 1 ó 2 horas de funcionamiento, cierre el tapón de
80-90 4-8 100 000 96 000 salida de grasa o la válvula de cierre, si dispone de una.
100-112 2 89 000 56 000
B. Lubricación automática
100-112 4-8 100 000 89 000
132 2 67 000 42 000 El tapón de salida de grasa debe estar quitado de forma
132 4-8 100 000 77 000 permanente si se utiliza la lubricación automática o si
160 2 60 000 38 000 se deja abierta permanentemente la válvula de cierre, si
160 4-8 100 000 74 000 cuenta con una.
180 2 55 000 34 000
ABB recomienda únicamente el uso de sistemas
180 4-8 100 000 70 000
electromecánicos.
200 2 41 000 25 000
200 4-8 95 000 60 000 La cantidad de grasa por intervalo de lubricación indicada
225 2 36 000 23 000 en la tabla debe multiplicarse por tres si se utiliza un
225 4-8 88 000 56 000 sistema de lubricación central. Si se utiliza una unidad de
250 2 31 000 20 000 reengrase automático más pequeña (uno o dos cartuchos
250 4-8 80 000 50 000 en cada motor), puede usarse la cantidad normal de grasa.
Estos datos son válidos hasta los 60 Hz. Si un motor de 2 polos se reengrasa automáticamente,
debe seguir la nota acerca de las recomendaciones de
7.2.2 Motores con rodamientos lubricantes indicadas para los motores de 2 polos en el
reengrasables capítulo Lubricantes.
Placa de información de lubricación e indicaciones La grasa utilizada debe ser adecuada para la lubricación
generales de lubricación automática. Deben comprobarse las recomendaciones
del proveedor del sistema de lubricación automática y el
Si el motor cuenta con una placa de información de fabricante de grasa.
lubricación, siga los valores indicados.
Ejemplo de cálculo para la cantidad de grasa del
En la placa de información de lubricación se indican los sistema de lubricación automática
intervalos de reengrase en relación con el tipo de montaje,
la temperatura ambiente y la velocidad de giro. Sistema de lubricación central: Motor IEC M3_P 315_ 4
polos en una red a 50 Hz; el intervalo de re-lubricación
Durante la primera puesta en marcha o después de la según la Tabla es 7600 h/55 g (lado de acople) y 7600 h/40
lubricación de los rodamientos, puede producirse un g (lado N):
incremento temporal de la temperatura durante un periodo
de 10 a 20 horas aproximadamente. (LA) RLI = 55 g/7600h*3*24 = 0,52 g/día
(LOA) RLI = 40 g/7600*3*24 = 0,38 g/día
Ejemplo de cálculo de cantidad de grasa de
una unidad de lubricación automática individual
(cartucho)
(LA) RLI = 55 g/7600h*24 = 0,17 g/día
(LOA) RLI = 40 g/7600h*24 = 0,13 g/día

RLI = Intervalo de relubricación, LA = Lado de acople, LOA =
Lado opuesto al acople
7.2.3 Intervalos de lubricación y cantidades

de grasa
En los motores verticales, los intervalos de lubricación
deben reducirse a la mitad de los indicados en la tabla que
aparece a continuación.
Como guía, es posible conseguir una lubricación

suficiente para la duración que se indica posteriormente,
de acuerdo con el principio L1. Para entornos con
temperaturas ambiente mayores, póngase en contacto
con ABB. La fórmula informativa para cambiar los valores
L1 aproximadamente a valores L10 es L10 = 2,0 x L1, con
lubricación manual.
Los intervalos de lubricación se basan en una temperatura

de funcionamiento de los rodamientos de 80 °C
(temperatura ambiente de +25 °C).
¡ATENCIÓN!
Un aumento de la temperatura ambiente eleva
correspondientemente la temperatura de los
rodamientos. Los valores de los intervalos deben
reducirse a la mitad en caso de un aumento de
15 °C en la temperatura de los rodamientos y
pueden doblarse en caso de una reducción de
15 °C en la temperatura de los rodamientos.
En caso de funcionamiento a mayor velocidad, por

ejemplo en las aplicaciones con convertidor de frecuencia,
o velocidades más bajas debidas a la carga elevada, se
necesitarán intervalos de lubricación más cortos.
¡ADVERTENCIA!
No debe sobrepasarse la temperatura máxima de
funcionamiento de la grasa y de los rodamientos,
que es de +110 °C.
No se debe superar la velocidad máxima de diseño
del motor.
Tamaño
Cantidad
de 3600 3000 1800 1500 1000 500-900
de grasa kW kW kW kW
carcasa rpm rpm rpm rpm rpm rpm
g/rodam.
Rodamientos de bolas, intervalos de lubricación por horas de funcionamiento

112 10 Todos 10 000 13 000 Todos 18 000 21 000 Todos 25 000 Todos 28 000
132 15 Todos 9 000 11 000 Todos 17 000 19 000 Todos 23 000 Todos 26 500
160 25 ≤ 18,5 9 000 12 000 ≤ 15 18 000 21 500 ≤ 11 24 000 Todos 24 000
160 25 > 18,5 7 500 10 000 > 15 15 000 18 000 > 11 22 500 Todos 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 Todos 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 Todos 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 Todos 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 Todos 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 Todos 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 Todos 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 Todos 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 Todos 7 000
2801) 60 Todos 2 000 3 500 - - - - - - -
2801) 60 - - - Todos 8 000 10 500 Todos 14 000 Todos 17 000
280 35 Todos 1 900 3 200 - - - -
280 40 - - Todos 7 800 9 600 Todos 13 900 Todos 15 000
315 35 Todos 1 900 3 200 - - - -
355 35 Todos 1 900 3 200 - - - -
400 40 Todos 1 500 2 700 - - - -
450 40 Todos 1 500 2 700 - - - -
Rodamientos de rodillos, intervalos de lubricación por horas de funcionamiento

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 Todos 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 Todos 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 Todos 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 Todos 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 Todos 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 Todos 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 Todos 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 Todos 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 Todos 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 Todos 3 500
2801) 60 Todos 1 000 1 750 - - - - - - -
2801) 70 - - - Todos 4 000 5 250 Todos 7 000 Todos 8 500
280 35 Todos 900 1 600 - - - -
315 35 Todos 900 1 600 - - - -
355 35 Todos 900 1 600 - - - -
400 40 Todos - 1 300 - - - -
450 40 Todos - 1 300 - - - -
1)
M3AA
7.2.4 Lubricantes
¡ATENCIÓN!
Utilice siempre grasa de alta velocidad para los
¡ADVERTENCIA! motores de 2 polos a alta velocidad cuyo factor de
No mezcle diferentes tipos de grasa. velocidad sea superior a 480 000 (calculado como
El uso de lubricantes incompatibles puede dar lugar Dm x n, donde Dm = diámetro del rodamiento en
a daños en los rodamientos. mm; n = velocidad de giro en rpm).
Al re-engrasar, utilice únicamente grasa especial para

rodamientos de bolas y con las propiedades siguientes: Puede usar las grasas siguientes en los motores de hierro
fundido a alta velocidad, pero no puede mezclarlas con
– Grasa de buena calidad de espesante de complejo de grasas con complejo de litio:
litio y aceite mineral o PAO
– Viscosidad del aceite base de 100 a 160 cST a 40 °C - Klüber Klüber Quiet BQH 72-102 (base de poliurea)
– Grado de consistencia NLGI de 1,5 a 3 *) - Lubcon Turmogrease PU703 (base de poliurea)
– Rango de temperaturas de -30 °C a +120 °C, servicio
continuo Si se utilizan otros lubricantes, confirme con el
fabricante que las calidades se corresponden con las
*) En los motores con montaje vertical o en condiciones de los lubricantes mencionados arriba. Los intervalos
con temperaturas elevadas, se recomienda utilizar el de lubricación se basan en los de las grasas de alto
extremo más alto de la escala. rendimiento mencionadas arriba. El uso de otras grasas
Las especificaciones mencionadas arriba para la grasa son puede reducir el intervalo.
válidas si la temperatura ambiente está por encima de los
-30 °C o por debajo de los +55 °C, y la temperatura del
rodamiento está por debajo de los 110 °C. De lo contrario,
consulte a ABB acerca de la grasa adecuada.
Los principales fabricantes de lubricantes ofrecen grasas

con las propiedades adecuadas.
Los aditivos están recomendados, pero debe obtenerse

una garantía por escrito del fabricante de lubricantes,
especialmente en el caso de los aditivos EP, de que éstos
no dañarán los rodamientos ni afectarán a las propiedades
de los lubricantes dentro del rango de temperaturas de
funcionamiento.
¡ADVERTENCIA!
No se recomienda utilizar lubricantes con contenido
de aditivos EP en caso de altas temperaturas de
rodamiento en los tamaños de carcasa del 280 al
450.
Pueden usarse las siguientes grasas de alto rendimiento:

– Mobil Unirex N2 o N3 (base con complejo de litio)
– Mobil Mobilith SHC 100 (base con complejo de litio)
– Shell Gadus S5 V 100 2 (base con complejo de litio)
– Klüber Klüberplex BEM 41-132 (base especial de litio)
– FAG Arcanol TEMP110 (base con complejo de litio)
(base especial de litio)
– Total Multiplex S2 A (base con complejo de litio)
– Rhenus Rhenus LKZ 2 (base con complejo de litio)
8. Servicio postventa 9. Requisitos
medioambientales
8.1 Piezas de repuesto
La mayoría de los motores ABB presentan un nivel de
A no ser que se indique lo contrario, las piezas de repuesto
presión sonora que no sobrepasa los 82 dB(A) (± 3 dB) a
deben ser piezas originales o deben ser autorizadas por
50 Hz.
ABB.
Los valores de los distintos motores aparecen en los
A la hora de pedir piezas de repuesto, es necesario indicar
catálogos de producto pertinentes. Con un suministro
el número de serie del motor, la designación de tipo
sinusoidal a 60 Hz, los valores son aproximadamente 4
completa y el código de producto, indicados en la placa de
dB(A) superiores respecto de los valores de los catálogos
características.
de producto, que corresponden a 50 Hz.
8.2 Desmontaje, ensamblaje En cuanto a los niveles de presión sonora con

alimentaciones con convertidor de frecuencia, póngase en
y rebobinado contacto con ABB.
El rebobinado debe ser realizado siempre por centros de Si es necesario desechar o reciclar los motores, debe
reparación cualificados. hacerse de la forma adecuada y según los reglamentos y
legislación locales.
Ni los motores smoke venting ni otros motores especiales
deben ser rebobinados sin antes ponerse en contacto con
ABB.
8.3 Rodamientos
Se debe prestar una atención especial a los rodamientos.
Deben ser retirados con ayuda de extractores y montarse

con calentamiento o con herramientas especiales.
La sustitución de los rodamientos se describe en detalle en

un folleto de instrucciones separado disponible a través de
las oficinas comerciales de ABB.
Debe seguir todas las indicaciones presentes en el motor,

por ejemplo en las etiquetas. Los tipos de rodamientos
indicados en la placa de características no deben ser
cambiados.
¡ATENCIÓN!
Cualquier reparación realizada por el usuario, a no
ser que sea autorizada por el fabricante, exonera
al fabricante de su responsabilidad sobre la
conformidad.
10. Resolución de problemas
Estas instrucciones no cubren todos los detalles o Tabla de solución de problemas del motor
variaciones del equipo ni proporcionan información acerca
de todas y cada una de las condiciones posibles que El servicio técnico y cualquier actividad de solución de
pueden darse en relación con la instalación, el manejo o el problemas del motor deben ser realizados por personas
mantenimiento. Si fuera necesaria información adicional, cualificadas y dotadas de los equipos y herramientas
póngase en contacto con la oficina comercial de ABB más adecuados.
cercana.
PROBLEMA CAUSA ACCIONES

El motor no Fusibles fundidos Sustituya los fusibles con otros del tipo y los valores nominales
arranca adecuados.
La protección de sobrecarga se Compruebe y rearme la protección de sobrecarga en el arrancador.
dispara
Alimentación de suministro inadecuada Compruebe si la alimentación de suministro concuerda con la placa
de características y el factor de carga del motor.
Conexiones de línea incorrectas Contraste las conexiones con el diagrama suministrado con el motor.
Circuito abierto en el devanado o Se detecta por un zumbido cuando el interruptor está cerrado.
el interruptor de control Compruebe si hay cables mal conectados y asegúrese de que todos
los contactos de control se cierran.
Avería mecánica Compruebe si el motor y el accionamiento giran libremente.
Compruebe los rodamientos y la lubricación.
Cortocircuito en el estátor
Mala conexión de las bobinas del Se detecta porque se funden los fusibles. Se debe rebobinar el motor.
estátor Retire los escudos y localice el fallo.
Rotor defectuoso Localizar barras o anillos de cortocircuito rotos.
Posible sobrecarga del motor Reduzca la carga.
El motor pierde Una fase puede estar abierta Compruebe las líneas para detectar la fase abierta.
velocidad Aplicación incorrecta Cambie el tipo o el tamaño de motor. Pregunte al proveedor del
equipo.
Sobrecarga Reduzca la carga.
Baja tensión Compruebe que se mantenga la tensión indicada en la placa de
características. Compruebe las conexiones.
Circuito abierto Fusibles fundidos. Compruebe el relé de sobrecarga, el estátor y los
pulsadores.
El motor arranca Interrupción del servicio eléctrico Busque conexiones defectuosas a la línea, los fusibles y el control.
pero pierde
velocidad hasta
pararse
El motor no Aplicación incorrecta Consulte el tipo adecuado al proveedor del equipo.
acelera hasta la Tensión insuficiente en los bornes del Utilice una tensión mayor o un transformador o reduzca la carga.
velocidad nominal motor a causa de una caída de la línea Compruebe las conexiones. Compruebe que los conductores sean
del tamaño correcto.
Carga de arranque excesiva Compruebe los arranques de los motores frente a “sin carga”.
Barras de rotor rotas o rotor suelto Busque fisuras cerca de los anillos. Es posible que requiera un nuevo
rotor, dado que las reparaciones sólo duran un tiempo.
Circuito primario abierto Busque la avería con un tester y repárela.
PROBLEMA CAUSA ACCIONES
El motor tarda Carga excesiva Reduzca la carga.
demasiado en Tensión insuficiente durante el arranque Compruebe si la resistencia es excesiva. Asegúrese de utilizar un
acelerar y/o cable de una sección suficiente.
requiere una
intensidad Rotor de jaula de ardilla defectuoso Reemplace el rotor por uno nuevo.
excesiva Tensión aplicada insuficiente Corrija la alimentación de suministro.
Sentido de Secuencia de fases incorrecta Invierta las conexiones en el motor o en el panel de interruptores.
rotación incorrecto
El motor se Sobrecarga Reduzca la carga.
sobrecalienta La carcasa o las aberturas de Abra los orificios de ventilación y compruebe que se produzca un flujo
mientras funciona ventilación pueden estar obstruidas de aire continuo desde el motor.
con suciedad e impedir una ventilación
correcta del motor.
El motor puede tener abierta una fase Compruebe si todos los conductores y cables están bien conectados.
Bobina conectada a masa Se debe rebobinar el motor.
Tensión desequilibrada en los bornes Busque cables, conexiones y transformadores defectuosos.
El motor vibra Motor mal alineado Corrija la alineación.
Apoyo poco resistente Refuerce la base.
Desequilibrio en el acoplamiento Equilibre el acoplamiento.
Desequilibrio en el equipo accionado Corrija el equilibrio del equipo accionado.
Rodamientos en mal estado Sustituya los rodamientos.
Rodamientos mal alineados Repare el motor.
Pesos de equilibrado desplazados Corrija el equilibrio del rotor.
Contradicción entre el equilibrado del Reequilibre el acoplamiento o el rotor.
rotor y el del acoplamiento (media
chaveta - chaveta entera)
Motor polifásico funcionando como Compruebe si existe algún circuito abierto.
monofásico
Juego axial excesivo Ajuste el rodamiento o añada suplementos.
Ruido de Rozamiento del ventilador contra el Corrija el montaje del ventilador.
rozaduras escudo o la cubierta de ventilador
Sujeción incorrecta a la placa de base Apriete los pernos de anclaje.
Funcionamiento Entrehierro no uniforme Compruebe y corrija el ajuste de los escudos o del rodamiento.
ruidoso Desequilibrio del rotor Corrija el equilibrio del rotor.
Rodamientos a Eje doblado o deformado Enderece o sustituya el eje.
alta temperatura Tensión excesiva de la correa Reduzca la tensión de la correa.
Poleas demasiado alejadas del apoyo Sitúe la polea más cerca del rodamiento del motor.
del eje
Diámetro de polea demasiado reducido Utilice poleas más grandes.
Mala alineación Corrija el problema realineando el accionamiento.
Lubricación inadecuada Utilice siempre grasa de la calidad y en la cantidad adecuadas en el
rodamiento.
Deterioro de la grasa o lubricante Elimine la grasa antigua, lave meticulosamente los rodamientos con
contaminado queroseno y rellene con grasa nueva.
Exceso de lubricante Reduzca la cantidad de grasa. El rodamiento no debe llenarse por
encima de la mitad de su capacidad.
Rodamiento sobrecargado Compruebe la alineación y el empuje lateral y axial.
Bola rota o caminos de rodadura Sustituya el rodamiento pero limpie primero el alojamiento
rugosos meticulosamente.
Motori a bassa tensione
Manuale d'installazione, funzionamento e manutenzione
Sommario
1. Introduzione...............................................................................................................................83
1.1 Dichiarazione di conformità ................................................................................................83
1.2 Validità ...............................................................................................................................83
2. Considerazioni riguardanti la sicurezza..................................................................................83
3. Gestione .....................................................................................................................................84
3.1 Controllo al ricevimento .....................................................................................................84
3.2 Trasporto e immagazzinaggio ............................................................................................84
3.3 Sollevamento .....................................................................................................................84
3.4 Peso del motore ................................................................................................................84
4. Installazione e messa in servizio .............................................................................................85
4.1 Informazioni generali ..........................................................................................................85
4.2 Motori senza cuscinetti a sfere ...........................................................................................85
4.3 Controllo della resistenza d'isolamento ..............................................................................85
4.4 Fondazione ........................................................................................................................85
4.5 Bilanciamento e montaggio di semigiunti e pulegge ...........................................................86
4.6 Montaggio e allineamento del motore ................................................................................86
4.7 Forze radiali e accoppiamenti a cinghia..............................................................................86
4.8 Motori con fori di scarico condensa ...................................................................................86
4.9 Cablaggio e collegamenti elettrici .......................................................................................86
4.9.1 Collegamenti per diversi metodi di avviamento....................................................87
4.9.2 Collegamenti di dispositivi ausiliari ......................................................................87
4.10 Terminali e senso di rotazione ............................................................................................88
5. Condizioni di funzionamento ..................................................................................................89
5.1 Informazioni generali ......................................................................................................................89
Manuale motori in bassa tensione, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 81
6. Motori a bassa tensione in funzionamento a velocità variabile ..........................................90
6.1 Introduzione.......................................................................................................................90
6.2 Isolamento dell'avvolgimento .............................................................................................90
6.2.1 Selezione dell'isolamento dell'avvolgimento per convertitori ABB ........................90
6.2.2 Selezione dell'isolamento dell'avvolgimento per tutti gli altri convertitori .............90
6.3 Protezione termica ............................................................................................................90
6.4 Correnti nei cuscinetti ........................................................................................................90
6.4.1 Eliminazione delle correnti nei cuscinetti con convertitori ABB .............................91
6.4.2 Eliminazione delle correnti nei cuscinetti con tutti gli altri convertitori ...................91
6.5 Cablaggio, messa a terra ed EMC .....................................................................................91
6.6 Velocità operativa ..............................................................................................................91
6.7 Motori in applicazioni a velocità variabile ............................................................................91
6.7.1 Informazioni generali ...........................................................................................91
6.7.2 Caricabilità dei motori con convertitori serie AC_8_ _ e controllo DTC .................91
6.7.3 Caricabilità dei motori con convertitori serie AC_5_ _ ..........................................91
6.7.4 Caricabilità dei motori con altre origini di tensione con convertitori tipo PWM ......92
6.7.5 Sovraccarichi di breve periodo............................................................................92
6.8 Dati nominali riportati sulle targhette ..................................................................................92
6.9 Messa in servizio per applicazioni a velocità variabile .........................................................92
7. Manutenzione ............................................................................................................................93
7.1 Ispezione generale .............................................................................................................93
7.1.1 Motori in standby ................................................................................................93
7.2 Lubrificazione ....................................................................................................................93
7.2.1 Motori con cuscinetti a ingrassaggio permanente ...............................................93
7.2.2 Motori con cuscinetti ingrassabili ........................................................................94
7.2.3 Intervalli e quantità di lubrificazione .....................................................................94
7.2.4 Lubrificanti ..........................................................................................................96
8. Assistenza postvendita ............................................................................................................97
8.1 Parti di ricambio.................................................................................................................97
8.2 Smontaggio, riassemblaggio e riavvolgimento....................................................................97
8.3 Cuscinetti ..........................................................................................................................97
9. Requisiti ambientali ..................................................................................................................97
10. Risoluzione dei problemi ..........................................................................................................98
82 ABB Motors and Generators | Manuale motori in bassa tensione, 3GZF500730-85 Rev F 02-2015
1. Introduzione 2. Considerazioni riguardanti
la sicurezza
NOTA.
Seguire attentamente le seguenti istruzioni, atte Il motore deve essere installato e utilizzato da personale
ad assicurare un'appropriata e sicura installazione, qualificato che sia a conoscenza dei requisiti di sicurezza
funzionamento e manutenzione del motore. indicati dalle normative nazionali vigenti.
Tutto il personale addetto all'installazione, al
funzionamento e alla manutenzione del motore Le attrezzature antinfortunistiche necessarie alla
o delle apparecchiature associate deve essere a prevenzione di incidenti durante l'installazione e il
conoscenza di tali istruzioni. Il motore deve essere funzionamento del motore sull'impianto, devono essere
installato e utilizzato da personale qualificato che sia conformi alle normative nazionali vigenti.
a conoscenza dei requisiti di sicurezza indicati dalle
normative nazionali vigenti. L'inosservanza di queste
istruzioni rende nulle tutte le garanzie applicabili. AVVERTENZA!
I controlli per l'arresto di emergenza devono essere
dotati di dispositivi di blocco del riavvio. Dopo un
1.1 Dichiarazione di conformità arresto di emergenza, un comando di avvio può
avere effetto solo dopo il ripristino intenzionale dei
La conformità del prodotto finale con la Direttiva 2006/42/ dispositivi di blocco del riavvio.
CE (Macchine) deve essere confermata dalla parte
responsabile della messa in opera quando il motore viene
collegato al macchinario.
Istruzioni da osservare:
1. Non salire sul motore.
1.2 Validità 2. La temperatura della carcassa del motore può risultare
Queste istruzioni sono valide per i seguenti tipi di macchine estremamente calda al contatto della mano durante
elettriche ABB, utilizzate sia come motore che come il normale funzionamento e in particolare dopo lo
generatore. spegnimento.
3. Alcune applicazioni speciali posso richiedere istruzioni
serie MT*, MXMA, speciali (ad esempio alimentazione a mezzo convertitore
serie M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*, di frequenza).
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, 4. Prestare attenzione a tutte le parti in rotazione del
M2V*/M3V* motore.
grandezze carcassa 56 - 450.
5. Non aprire le scatole morsetti mentre l'alimentazione è
attiva.
È disponibile un manuale specifico per i motori Ex,
"Manuale per i motori a bassa tensione per atmosfere
esplosive: installazione, funzionamento e manutenzione
(3GZF500730-47)".
Informazioni aggiuntive potrebbero essere richieste per

alcune macchine con applicazioni e/o con progettazioni
particolari.
Sono disponibili manuali aggiuntivi per i motori seguenti:

– motori per vie a rulli
– motori raffreddati ad acqua
– motori per aspirazione fumi
– motori autofrenanti
– motori per temperature ambiente elevate
– motori per applicazioni marine per montaggio
all'aperto sul ponte di navi o unità offshore
3. Gestione I golfari di sollevamento devono essere serrati prima
dell'utilizzo. Se necessario, la posizione dei golfari di
sollevamento può essere regolata utilizzando rondelle
3.1 Controllo al ricevimento idonee.
Ispezionare immediatamente il motore al ricevimento per Assicurarsi che vengano utilizzate apparecchiature di
verificare che non abbia subito danni durante il trasporto, sollevamento appropriate e che le dimensioni dei ganci di
ad esempio alle estremità dell'albero, alle flange e sulle sollevamento siano adatte ai golfari.
superfici verniciate. Se si dovessero riscontrare danni,
contestarli subito allo spedizioniere. Fare attenzione a non danneggiare le apparecchiature
ausiliarie e i cavi collegati al motore.
Controllare tutte le caratteristiche elencate sulla
targhetta, in particolare tensione e tipo di collegamento Rimuovere eventuali attrezzature utilizzate per fissare il
dell'avvolgimento (a stella o a triangolo). Ad eccezione delle motore al pallet durante il trasporto.
grandezze più piccole, il tipo di cuscinetto è specificato
sulla targhetta con i dati nominali dei motori. ABB può fornire istruzioni per il sollevamento specifiche.
Nel caso di applicazioni con azionamento a velocità

variabile, verificare la caricabilità massima ammessa in AVVERTENZA!
funzione della frequenza indicata nella seconda targhetta Durante il sollevamento, il montaggio o interventi di
del motore. manutenzione, è necessario mettere in atto tutte le
precauzioni necessarie per la sicurezza e prestare
particolare attenzione affinché nessuno si trovi sotto
3.2 Trasporto e immagazzinaggio carichi sospesi.
Il motore dovrà sempre essere immagazzinato in luogo
coperto (temperatura superiore a -20 °C), asciutto, privo
di vibrazioni e di polvere. Durante il trasporto, evitare urti, 3.4 Peso del motore
cadute e umidità. In condizioni diverse, contattare ABB.
Il peso complessivo di motori con la stessa altezza d'asse
Le superfici lavorate non protette (flange ed estremità può variare in funzione della potenza, della disposizione di
dell'albero) devono essere trattate con prodotti montaggio e delle apparecchiature ausiliarie.
anticorrosivi.
La seguente tabella indica i pesi massimi stimati per
L'albero deve essere ruotato a mano periodicamente per macchine standard in funzione del tipo di materiale usato
prevenire perdite di lubrificante. per la carcassa.
Si consiglia di utilizzare le resistenze anticondensa, se Ad eccezione delle grandezze più piccole (56 e 63), il peso
montate, per evitare formazione di condensa nel motore. dei motori ABB è specificato sulla targhetta con i dati
nominali.
Da fermo, il motore non deve essere sottoposto a vibrazioni
esterne, per evitare danni ai cuscinetti. Grandezza Alluminio Ghisa Agg.
carcassa per freno
I motori provvisti di cuscinetti a rulli cilindrici e/o a contatto Peso (kg) Peso (kg)
angolare devono essere bloccati durante il trasporto. 56 4,5 - -
63 6 - -
3.3 Sollevamento 71 8 13 5
80 14 20 8
Tutti i motori ABB pesanti più di 25 kg sono dotati di golfari 90 20 30 10
di sollevamento. 100 32 40 16
112 36 50 20
Per sollevare il motore devono essere utilizzati solo i golfari
132 93 90 30
di sollevamento principali, che non devono essere utilizzati
160 149 130 30
per sollevare il motore quando è agganciato ad altre
180 162 190 45
apparecchiature o strutture.
200 245 275 55
I golfari per le apparecchiature ausiliarie, quali freni e 225 300 360 75
ventole di raffreddamento separate, o scatole morsetti, 250 386 405 75
280 425 800 -
non devono essere utilizzati per sollevare il motore. A
315 - 1700 -
causa delle potenze diverse, degli accessori e delle
355 - 2700 -
apparecchiature ausiliarie montate, motori con la stessa
400 - 3500 -
carcassa potrebbero avere un baricentro diverso.
450 - 4500 -
I golfari danneggiati non devono essere utilizzati. Prima di
sollevare il motore assicurarsi che i golfari di sollevamento
Se il motore è dotato di ventola separata, richiedere il peso
non siano danneggiati.
ad ABB.
4. Installazione e messa in servizio
La resistenza d'isolamento, corretta a 25 °C, non deve in
AVVERTENZA! nessun caso essere minore di 100 MΩ (misurati con 500
Scollegare il motore prima di operare su di esso o o 1000 VCC). Il valore della resistenza d'isolamento viene
sull'apparecchiatura azionata. dimezzato ogni 20 °C di aumento della temperatura. Per
la correzione dell'isolamento secondo la temperatura
desiderata, è possibile utilizzare la figura 1.
4.1 Informazioni generali
Tutti i dati nominali inerenti alla certificazione devono essere AVVERTENZA!
controllati accuratamente per garantire che protezione del Per evitare rischi di shock elettrici, la carcassa
motore e collegamento siano adeguati. del motore deve essere collegata a terra
e gli avvolgimenti devono essere scaricati
4.2 Motori senza cuscinetti a sfere immediatamente dopo ogni misurazione.
Rimuovere eventuali blocchi per il trasporto. Ruotare

Se il valore di riferimento della resistenza di isolamento
a mano l'albero del motore per verificare che ruoti
non viene raggiunto, l'avvolgimento è troppo umido
liberamente.
e deve essere asciugato in forno. La temperatura del forno
deve essere di 90 °C per 12-16 ore e successivamente di
Motori dotati di cuscinetti a rulli: 105 °C per 6-8 ore.
Il funzionamento del motore in assenza di spinte radiali
applicate all'albero potrebbe danneggiare il cuscinetto a Gli eventuali tappi dei fori di scarico condensa devono
rulli a causa dello "scorrimento". essere rimossi e le eventuali valvole di chiusura devono
essere aperte durante il riscaldamento. Dopo tale
Motori dotati di cuscinetto a contatto angolare: operazione assicurarsi che i tappi vengano riposizionati.
Anche se i tappi di scarico sono montati, si consiglia di
Il funzionamento del motore in assenza di spinte assiali smontare gli scudi e i coperchi delle scatole morsetti prima
applicate all'albero nella direzione corretta potrebbe del processo di asciugatura.
danneggiare il cuscinetto a contatto angolare.
Gli avvolgimenti impregnati di acqua di mare devono
solitamente essere rifatti.
AVVERTENZA!
Per i motori con cuscinetti a contatto angolare
la forza assiale non deve cambiare direzione per
4.4 Fondazione
nessun motivo. L'utente finale ha la piena responsabilità per la
preparazione della fondazione.
Il tipo dei cuscinetti è indicato sulla targhetta del motore. Le fondazioni metalliche devono essere verniciate per
evitare la corrosione.
Motori dotati di nippli d'ingrassaggio:
Le fondazioni devono essere in piano e sufficientemente
Al primo avviamento del motore, oppure dopo un lungo
rigide per supportare eventuali sollecitazioni da corto
periodo di fermo, applicare la quantità di grasso specificata.
circuito.
Per ulteriori informazioni, vedere la sezione "7.2.2 Motori
Devono essere progettate e dimensionate in modo da
con cuscinetti ingrassabili".
evitare il trasferimento di vibrazioni al motore e l'insorgere di
Quando il motore è installato in posizione verticale con vibrazioni dovute a risonanza. Vedere la figura seguente.
l'albero rivolto verso il basso, il motore deve essere
provvisto di tettuccio per evitare l'ingresso di oggetti o liquidi Livella
provenienti dall'alto nelle aperture per il passaggio d'aria.
Lo stesso risultato può essere ottenuto con un tettuccio
separato non fissato al motore, ma, in questo caso, sul
motore deve essere applicata un'etichetta di avviso. Nota. La differenza di altezza
tra i piedi del motore non deve
4.3 Controllo della resistenza superare ± 0,1 mm.
d'isolamento
Controllare la resistenza d'isolamento prima della messa
in servizio e quando si sospetti una formazione di umidità
negli avvolgimenti. Posizione del piede
4.5 Bilanciamento e montaggio 4.7 Forze radiali e accoppiamenti
di semigiunti e pulegge a cinghia
Come standard, la bilanciatura del motore viene effettuata Mettere in tensione le cinghie secondo le istruzioni del
utilizzando una mezza chiavetta. fornitore dell'apparecchiatura azionata. Non superare le
tensioni di cinghia massime (ovvero i carichi radiali sui
Semigiunti o pulegge devono essere bilanciati dopo la cuscinetti) indicate nei relativi cataloghi prodotto.
lavorazione delle sedi delle chiavette. La bilanciatura deve
essere eseguita con lo stesso metodo di bilanciatura
utilizzato per il motore. AVVERTENZA!
Un'eccessiva tensione delle cinghie danneggia i
Semigiunti e pulegge devono essere montati sull'albero cuscinetti e può causare una rottura dell'albero.
utilizzando esclusivamente attrezzature e utensili che non
danneggino i cuscinetti e le tenute.
Non montare mai semigiunti o pulegge utilizzando un 4.8 Motori con fori di scarico
martello, né rimuoverli utilizzando una leva infulcrata contro
il corpo del motore. condensa
Controllare che i fori di scarico e i tappi siano rivolti verso il
basso. Nei motori montati in posizione verticale, i tappi di
4.6 Montaggio e allineamento scarico possono essere in posizione orizzontale.
del motore I motori dotati di tappi di scarico in plastica sigillabili sono

forniti con i tappi in posizione aperta. In ambienti polverosi
Assicurarsi che attorno al motore vi sia spazio sufficiente a tutti i fori di scarico devono essere chiusi.
garantire la circolazione dell'aria. La distanza minima tra il
coperchio della ventola e la parete deve essere almeno pari
a metà della misura della presa d'aria sul coperchio della 4.9 Cablaggio e collegamenti
ventola. Per ulteriori informazioni, consultare il catalogo
prodotti o i disegni con quote reperibili sul Web: www.abb. elettrici
com/motors&generators.
La scatola morsetti dei motori standard a velocità singola
Un corretto allineamento è indispensabile per prevenire contiene normalmente 6 terminali dell'avvolgimento e
guasti ai cuscinetti, vibrazioni e possibili rotture dell'albero. almeno un morsetto di terra.
Montare il motore sulla fondazione utilizzando bulloni o Oltre ai terminali dell'avvolgimento principale e ai morsetti di
prigionieri idonei e inserire degli spessori tra la fondazione e terra, la scatola morsetti può contenere i collegamenti per
i piedi. termistori, scaldiglie o altri dispositivi ausiliari.
Allineare il motore utilizzando metodi idonei. Per il collegamento di tutti i cavi principali devono essere
utilizzati capicorda idonei. I cavi per i dispositivi ausiliari
Se possibile, praticare dei fori per le spine di centraggio e possono essere direttamente collegati ai relativi terminali.
fissare le spine nella posizione corretta.
I motori sono destinati solo a installazioni fisse. Salvo
Precisione di montaggio del semigiunto: controllare che il diversa indicazione, le filettature di ingresso dei cavi sono
gioco b sia minore di 0,05 mm e che la differenza tra a1 e espresse in unità metriche. La classe IP dei pressacavi
a2 sia anch'essa minore di 0,05 mm. deve essere almeno pari a quelle delle scatole morsetti.
Ricontrollare l'allineamento dopo il serraggio finale dei Al momento dell'installazione, devono essere utilizzati
bulloni o dei prigionieri. canaline o connettori dei cavi certificati.
Non superare i valori di carico ammessi per i cuscinetti e
riportati sui cataloghi dei prodotti. NOTA.
I cavi devono essere meccanicamente protetti e
Controllare che il motore sia sufficientemente areato. fissati vicino alla scatola morsetti in conformità a
Assicurarsi che oggetti vicini o l'azione diretta del sole non EN 60079-0 e alle normative locali in merito alle
irradino calore aggiuntivo al motore. installazioni.
Per i motori montati su flangia (ad esempio B5, B35, V1),
assicurarsi che la costruzione sia tale da consentire un
flusso di aria sufficiente sulla superficie esterna della flangia. Gli ingressi cavi non utilizzati devono essere chiusi con
appositi tappi aventi la stessa classe di protezione e classe
IP della scatola morsetti.
Il grado di protezione e il diametro sono specificati nella

documentazione relativa ai pressacavi.
4.9.1 Collegamenti per diversi metodi di
AVVERTENZA! avviamento
Per gli ingressi cavi, utilizzare pressacavi e tenute
conformi al tipo di protezione e al tipo e al diametro La scatola morsetti dei motori standard a velocità singola
del cavo. contiene normalmente 6 terminali dell'avvolgimento e
almeno un morsetto di terra. In questo modo è possibile
realizzare l'avviamento DOL o Y/D.
La messa a terra deve essere eseguita in accordo
alle normative locali prima di collegare il motore Per i motori speciali o a due velocità, seguire attentamente
all'alimentazione di rete. le istruzioni di collegamento presenti all'interno della scatola
morsetti o nel manuale del motore.
Il morsetto di terra posto sulla carcassa deve essere
collegato alla messa a terra protettiva con un cavo come La tensione e il tipo di collegamento sono indicati sulla
illustrato nella Tabella 5 della normativa IEC/EN 60034-1: targhetta del motore.
Sezione minima dei conduttori protettivi Avviamento diretto da rete (DOL):

È possibile utilizzare collegamenti a stella (Y) o a triangolo
Sezione dei conduttori Sezione minima del
corrispondente conduttore (D).
di fase dell'installazione,
S, [mm2] protettivo, SP, [mm2]
Ad esempio, 690 VY, 400 VD indica un collegamento a
4 4
stella (Y) per 690 V e a triangolo (D) per 400 V.
6 6
10 10 Avviamento a stella/triangolo (Y/D):
16 16
Quando si utilizza un collegamento a triangolo, la tensione
25 25
di alimentazione deve essere uguale alla tensione nominale
35 25
del motore.
50 25
70 35 Rimuovere tutte le piastrine di collegamento dai terminali.
95 50
120 70 Altri metodi di avviamento e condizioni di avviamento
150 70 difficili:
185 95 Nei casi in cui vengono utilizzati altri metodi di avviamento
240 120 come convertitori o soft starter per impieghi di tipo S1 e
300 150 S2, si considera che il dispositivo sia "isolato dal sistema di
400 185 alimentazione quando la macchina elettrica è in funzione",
Inoltre, la messa a terra o gli impianti di collegamento come previsto dalla norma IEC 60079-0 e la protezione
equipotenziale sul lato esterno dell'apparecchiatura elettrica termica è opzionale.
devono garantire il collegamento efficace di un conduttore
con sezione di almeno 4 mm2. 4.9.2 Collegamenti di dispositivi ausiliari
I cavi di collegamento tra la rete e i morsetti del motore Se un motore è dotato di termistori o altri RTD (Pt100,
devono soddisfare i requisiti indicati dalle normative relè termici e così via) e dispositivi ausiliari, è consigliabile
nazionali per l'installazione o essere conformi alla norma che vengano utilizzati e collegati nei modi appropriati.
IEC/EN 60204-1, in base al valore di corrente nominale Per determinate applicazioni è obbligatorio utilizzare una
indicato sulla targhetta del motore. protezione termica. Per ulteriori informazioni, vedere la
documentazione in dotazione con il motore. Gli schemi di
NOTA. collegamento per gli elementi ausiliari e i componenti di
Quando la temperatura ambiente supera i +50 °C, collegamento si trovano all'interno della scatola morsetti.
devono essere utilizzati cavi con temperatura
La tensione di misurazione massima per i termistori è 2,5
operativa ammissibile di almeno +90 °C. Quando
V. La corrente di misurazione massima per Pt100 è 5 mA.
si dimensionano i cavi devono essere considerati
L'utilizzo di tensione o corrente di misurazione maggiore
anche tutti gli altri fattori di conversione che
può determinare errori nella lettura o danneggiare il
dipendono dalle condizioni di installazione.
rilevatore della temperatura.
Assicurarsi che il grado di protezione del motore sia L'isolamento dei sensori termici soddisfa i requisiti di
adatto alle condizioni ambientali e climatiche. Ad esempio, isolamento base.
assicurarsi che non possa entrare acqua all'interno del
motore o delle scatole morsetti.
Le tenute delle scatole morsetti devono essere inserite

correttamente nelle rispettive sedi al fine di assicurare la
classe IP corretta. Una discontinuità potrebbe causare
l'ingresso di polvere o acqua con il rischio di flash sulle parti
attive.
4.10 Terminali e senso
di rotazione
L'albero ruota in senso orario visto dal lato comando
quando la sequenza di fase L1, L2, L3 è collegata ai
terminali come illustrato nella figura 3.
Per invertire il senso di rotazione, scambiare tra loro i

collegamenti di due cavi di alimentazione qualsiasi.
Se il motore ha una ventola unidirezionale, controllare che

ruoti nello stesso senso indicato dalla freccia posta sul
motore.
5. Condizioni di funzionamento
5.1 Informazioni generali
Salvo diversa indicazione nella targhetta dei dati nominali, i
motori sono progettati per le condizioni ambientali seguenti:
- I motori devono essere installati solo in installazioni fisse.

- Intervallo di temperatura ambiente: da –20 °C a +40 °C.
- Altitudine massima: 1000 m sul livello del mare.
- Le variazioni della tensione e della frequenza di
alimentazione non possono superare i limiti definiti
nelle normative pertinenti. Tolleranza per la tensione di
alimentazione ±5% e per la frequenza ±2% in conformità
con la figura 4 (EN / IEC 60034-1, paragrafo 7.3, Zona
A). Si presume che entrambi i valori estremi non si
verifichino contemporaneamente.
Il motore può essere utilizzato solo nelle applicazioni per

le quali è stato progettato. I valori nominali e le condizioni
operative sono indicati sulle targhette del motore. Inoltre,
devono essere rispettati tutti i requisiti indicati nel presente
manuale e in altre istruzioni e standard correlati.
Se tali limiti vengono superati, è necessario controllare i dati

del motore e le caratteristiche di costruzione. Per ulteriori
informazioni, contattare ABB.
AVVERTENZA!
L'inosservanza delle istruzioni o la mancata
manutenzione dell'apparecchiatura può
compromettere la sicurezza e quindi impedire
l'utilizzo del motore.
6. Motori a bassa tensione in funzionamento
a velocità variabile
6.1 Introduzione 6.2.2 Selezione dell'isolamento
dell'avvolgimento per tutti gli altri
In questa sezione del manuale vengono fornite istruzioni
convertitori
aggiuntive per i motori utilizzati con alimentazione a mezzo
convertitore di frequenza. Il motore è progettato per Lo sforzo di tensione deve rientrare nei limiti accettati
funzionare con un singolo convertitore di frequenza, non Per garantire la sicurezza dell'applicazione, contattare
è prevista la possibilità di motori funzionanti in parallelo il fornitore del sistema. Quando si dimensiona il motore
alimentati da un convertitore di frequenza. Seguire le è necessario tenere in considerazione l'influenza degli
istruzioni fornite dal produttore del convertitore. eventuali filtri.
Informazioni aggiuntive possono essere richieste da ABB
per stabilire l'idoneità di determinati tipi di motori utilizzati in
applicazioni e/o con modifiche progettuali speciali. 6.3 Protezione termica
Per la maggior parte, i motori illustrati nel presente manuale
sono dotati di termistori PTC o di altri tipi di RTD negli
6.2 Isolamento dell'avvolgimento avvolgimenti dello statore. Si consiglia di collegarli al
convertitore di frequenza. Per ulteriori informazioni, vedere il
Gli azionamenti a velocità variabile provocano maggiori
capitolo 4.9.2.
sollecitazioni di tensione sull'avvolgimento del motore
rispetto all'alimentazione sinusoidale. Pertanto è necessario
dimensionare l'isolamento dell'avvolgimento del motore e
il filtro in corrispondenza dell'uscita del convertitore in base 6.4 Correnti nei cuscinetti
alle istruzioni riportate di seguito.
Utilizzare cuscinetti isolati o strutture di cuscinetti, filtri CMF
e cablaggi e metodi di messa a terra idonei in base alle
6.2.1 Selezione dell'isolamento dell'avvolgi- istruzioni fornite di seguito e utilizzando la tabella 6.1.
mento per convertitori ABB
Per azionamenti singoli, come gli ABB serie AC_8_ _
e AC_5_ _ con unità di alimentazione a diodi (tensione
CC non controllata), la selezione dell'isolamento
dell'avvolgimento e dei filtri può essere effettuata in base
alla tabella 6.1.
PN < 100 kW PN ≥ 100 kW o PN ≥ 350 kW o
IEC315 ≤ Grandezza carcassa ≤ IEC355 IEC400 ≤ Grandezza carcassa ≤ IEC450
UN ≤ 500 V Motore standard Motore standard Motore standard
+ cuscinetto N isolato + cuscinetto N isolato
+ Filtro di common mode
500 V >UN ≤ 600 V Motore standard Motore standard Motore standard
+ filtro dU/dt (reattore) + filtro dU/dt (reattore) + cuscinetto N isolato
OPPURE + cuscinetto N isolato + filtro dU/dt (reattore)
Isolamento rinforzato OPPURE + Filtro di common mode
Isolamento rinforzato OPPURE
+ cuscinetto N isolato Isolamento rinforzato
+ cuscinetto N isolato
500 V >UN ≤ 600 V Motore standard Motore standard Motore standard
(lunghezza cavo > 150 m) + cuscinetto N isolato + cuscinetto N isolato
600 V >UN ≤ 690 V Isolamento rinforzato Isolamento rinforzato Isolamento rinforzato

+ filtro dU/dt (reattore) + filtro dU/dt (reattore) + cuscinetto N isolato
+ cuscinetto N isolato + filtro dU/dt (reattore)
600 V >UN ≤ 690 V Isolamento rinforzato Isolamento rinforzato Isolamento rinforzato
(lunghezza cavo > 150 m) + cuscinetto N isolato + cuscinetto N isolato
Tabella 6.1 Selezione dell'isolamento dell'avvolgimento per convertitori ABB
Per ulteriori informazioni sulla resistenza di frenatura e sui convertitori con alimentatore controllato, contattare ABB.
6.4.1 Eliminazione delle correnti nei Ulteriori informazioni sulla messa a terra e il cablaggio di
cuscinetti con convertitori ABB azionamenti a velocità variabile sono disponibili nel manuale
"Messa a terra e cablaggio degli azionamenti a velocità
Per convertitori di frequenza ABB come le serie AC_8_ _ e
variabile" (codice: 3AFY 61201998).
AC_5_ _ con unità di alimentazione a diodi, è necessario
utilizzare i metodi secondo la tabella 6.1 per evitare correnti
dannose nei cuscinetti dei motori.
6.6 Velocità operativa
Per velocità superiori alla velocità nominale indicata sulla
NOTA.
targhetta del motore o nel relativo catalogo prodotti,
Si consigliano cuscinetti isolati con sede interna
assicurarsi che non venga superata la massima velocità
e/o esterna rivestita in ossido di alluminio o con
di rotazione ammissibile del motore o la velocità critica
elementi rotanti in ceramica. I rivestimenti in ossido
dell'intera applicazione.
di alluminio vengono anche trattati con sigillante
per impedire a sporco e umidità di penetrare nel
rivestimento poroso. Per l'esatto tipo di isolamento
dei cuscinetti, vedere la targhetta del motore. Non è 6.7 Motori in applicazioni
consentito cambiare il tipo dei cuscinetti o il metodo
di isolamento senza l'autorizzazione di ABB.
a velocità variabile
6.7.1 Informazioni generali
6.4.2 Eliminazione delle correnti nei
Con i convertitori di frequenza ABB, il dimensionamento
cuscinetti con tutti gli altri convertitori dei motori può essere eseguito con il programma per il
Gli utenti sono responsabili della protezione del motore e dimensionamento DriveSize di ABB. Lo strumento può
dell'apparecchiatura azionata dalle correnti pericolose nei essere scaricato dal sito Web di ABB (www.abb.com/
cuscinetti. È possibile utilizzare le istruzioni descritte nel motors&generators).
capitolo 6.4.1 come linee guida, ma la loro efficacia non
può essere garantita in tutti i casi. Per applicazioni alimentate da altri convertitori, è necessario
dimensionare i motori manualmente. Per ulteriori
informazioni, contattare ABB.
6.5 Cablaggio, messa a terra
Le curve di caricabilità, o curve di capacità di carico,
ed EMC si basano sulla tensione di alimentazione nominale.
Il funzionamento in condizioni di sovratensione o
Per fornire la messa a terra appropriata e garantire la
sottotensione può influire sulle prestazioni dell'applicazione.
conformità a tutti i requisiti EMC applicabili, i motori
superiori a 30 kW devono essere cablati utilizzando cavi
simmetrici schermati e pressacavi EMC, ovvero pressacavi 6.7.2 Caricabilità dei motori con convertitori
che forniscono aderenza a 360°. serie AC_8_ _ e controllo DTC
I cavi simmetrici schermati sono consigliati anche per Le curve di caricabilità illustrate nelle Figure 5a - 5d sono
motori più piccoli. Eseguire la disposizione a terra a 360° valide per convertitori ABB serie AC_8_ _ con tensione
per tutti gli ingressi cavo come descritto nelle istruzioni CC non controllata e controllo DTC. Le figure mostrano
per i pressacavi. Torcere le schermature dei cavi insieme e la coppia di uscita continua massima approssimativa dei
collegare al morsetto/barra bus di terra più vicino all'interno motori in funzione della frequenza dell'alimentazione. La
della scatola morsetti, dell'armadietto del convertitore, ecc. coppia di uscita è fornita come percentuale della coppia
nominale del motore. I valori sono indicativi; i valori esatti
sono disponibili su richiesta.
NOTA.
È necessario utilizzare pressacavi con aderenza a
360° in tutti i punti terminali, ad esempio su motore, NOTA.
convertitore, eventuali interruttori di sicurezza e così Non superare la velocità massima del motore e
via. dell'applicazione.
6.7.3 Caricabilità dei motori con convertitori

Per i motori in grandezza carcassa IEC 280 e superiori,
serie AC_5_ _
è necessaria un'equalizzazione aggiuntiva dei potenziali
tra la carcassa del motore e l'apparecchiatura azionata, a Le curve di caricabilità illustrate nelle Figure 6a - 6d sono
meno che entrambe non siano montate su un basamento valide per convertitori serie AC_5_ _. Le figure mostrano
comune in acciaio. In tal caso, è necessario verificare la la coppia di uscita continua massima approssimativa dei
conduttività ad alta frequenza del collegamento fornito dal motori in funzione della frequenza dell'alimentazione. La
basamento in acciaio, ad esempio misurando la differenza coppia di uscita è fornita come percentuale della coppia
di potenziale tra i componenti. nominale del motore. I valori sono indicativi; i valori esatti
sono disponibili su richiesta.
NOTA.
6.9 Messa in servizio per
Non superare la velocità massima del motore e applicazioni a velocità
dell'applicazione.
variabile
La messa in servizio per applicazioni a velocità variabile
6.7.4 Caricabilità dei motori con altre origini
deve essere eseguita attenendosi alle istruzioni per il
di tensione con convertitori tipo PWM convertitore di frequenza e alle leggi e normative nazionali.
Per altri convertitori con tensione CC non controllata e Devono inoltre essere tenuti in considerazione i requisiti e le
frequenza di commutazione minima di 3 kHz (200…500 limitazioni imposti dall'applicazione.
V), è possibile utilizzare come linee guida le istruzioni per il
dimensionamento illustrate nel capitolo 6.7.3. Tuttavia, si Tutti i parametri necessari per l'impostazione del
deve notare che l'effettiva caricabilità termica può anche convertitore devono essere ricavati dalle targhette del
essere inferiore. Contattare il produttore del convertitore o il motore. I parametri richiesti in genere sono:
fornitore del sistema.
- tensione nominale
- corrente nominale
NOTA. - frequenza nominale
La caricabilità termica effettiva di un motore può - velocità nominale
essere minore di quella indicata nelle curve. - potenza nominale
6.7.5 Sovraccarichi di breve periodo

NOTA.
Normalmente i motori ABB prevedono la possibilità di Nel caso di informazioni mancanti o imprecise, non
sovraccarichi temporanei e l'utilizzo in cicli intermittenti. Il azionare il motore senza aver prima verificato le
metodo più pratico per dimensionare applicazioni di questo impostazioni corrette.
tipo consiste nell'utilizzo dello strumento DriveSize.
6.8 Dati nominali riportati sulle ABB raccomanda l'utilizzo di tutte le caratteristiche
di protezione fornite dal convertitore per migliorare la
targhette sicurezza dell'applicazione. I convertitori garantiscono
in genere caratteristiche quali (nomi e disponibilità delle
L'utilizzo di motori ABB in applicazioni a velocità variabile caratteristiche dipendono dal produttore e dal modello del
non richiede, generalmente, targhette aggiuntive. I convertitore):
parametri necessari alla messa in servizio del convertitore
sono disponibili nella targhetta principale. Tuttavia, in - velocità minima
alcune applicazioni speciali i motori possono essere dotati - velocità massima
di ulteriori targhette per applicazioni a velocità variabile. Tali - tempi di accelerazione e decelerazione
targhette includono le informazioni seguenti: - corrente massima
- coppia massima
- intervallo di velocità - protezione da arresti accidentali
- intervallo di potenza
- intervallo di tensione e corrente
- tipo di coppia (costante o quadratica)
- tipo di convertitore e frequenza di commutazione
minima richiesta.
7. Manutenzione 7.1.1 Motori in standby
Se il motore rimane in standby per un lungo periodo di
tempo su una nave o in altri ambienti con vibrazioni, è
AVVERTENZA!
necessario adottare le seguenti precauzioni:
Durante le fermate, all'interno della scatola morsetti
potrebbe essere presente tensione utilizzata per 1. L'albero deve essere fatto ruotare periodicamente ogni
alimentare resistenze o riscaldare direttamente 2 settimane (riportare gli interventi) eseguendo un avvio
l'avvolgimento. del sistema. Nel caso l'avvio non sia possibile, per
qualsiasi motivo, ruotare l'albero a mano una volta alla
settimana in modo che assuma posizioni diverse. Le
vibrazioni causate da altre apparecchiature della nave
7.1 Ispezione generale causeranno la vaiolatura dei cuscinetti che può essere
ridotta al minimo con il funzionamento normale o la
1. Ispezionare il motore a intervalli regolari, almeno con
rotazione manuale.
cadenza annuale. La frequenza dei controlli dipende,
ad esempio, dal livello di umidità presente nell'ambiente 2. È necessario ingrassare il cuscinetto ogni anno mentre
e dalle specifiche condizioni climatiche e, determinata si ruota l'albero (riportare gli interventi). Se il motore è
inizialmente in modo sperimentale, deve essere poi stato fornito con un cuscinetto a sfere lato azionamento,
rispettata con estrema precisione. rimuovere il blocco per il trasporto prima di ruotare
2. Mantenere il motore pulito e assicurare una buona l'albero. In caso di trasporto, rimontare il blocco.
ventilazione. Se il motore è utilizzato in un ambiente 3. Per prevenire danni ai cuscinetti, è opportuno evitare
polveroso, il sistema di ventilazione deve essere tutte le vibrazioni. È necessario seguire tutte le
regolarmente pulito e controllato. istruzioni fornite nel manuale per la messa in opera
3. Controllare le condizioni delle tenute dell'albero (es. e la manutenzione del motore. Se tali istruzioni non
V-ring o tenuta radiale) e se necessario sostituirle. vengono seguito, la garanzia non coprirà eventuali danni
all'avvolgimento e ai cuscinetti.
4. Controllare le condizioni dei collegamenti e dei bulloni di
fissaggio e fondazione.
5. Controllare le condizioni dei cuscinetti prestando 7.2 Lubrificazione
attenzione ai rumori anomali, alle vibrazioni, alla
temperatura, analizzando il grasso consumato o
effettuando monitoraggi con rilevatori SPM dove AVVERTENZA!
esistenti. Prestare particolare attenzione ai cuscinetti Prestare attenzione a tutte le parti rotanti.
quando la durata prevista è prossima al termine.
Quando si rilevano segni di usura, smontare il motore, AVVERTENZA!

controllarne le parti ed effettuare le necessarie sostituzioni. I lubrificanti possono causare irritazioni alla pelle e
Quando i cuscinetti vengono sostituiti, è necessario infiammazioni agli occhi. Seguire tutte le precauzioni
utilizzare cuscinetti identici a quelli montati originariamente. di sicurezza indicate dal produttore del grasso.
Contemporaneamente alla sostituzione del cuscinetto
dovranno essere sostituite le tenute dell'albero, che
dovranno avere la stessa qualità e le stesse caratteristiche Il tipo dei cuscinetti è specificato nel relativo catalogo
di quelle originali. prodotti e sulla targhetta con i dati nominali dei motori, ad
Nel caso di motori IP 55 e quando il motore viene fornito eccezione delle grandezze più piccole.
con un tappo chiuso, è consigliabile aprire periodicamente Intervalli di lubrificazione corretti sono essenziali per
i tappi di scarico per verificare che la via di uscita della garantire l'affidabilità dei cuscinetti. ABB segue per la
condensa non sia ostruita e per consentire la fuoriuscita lubrificazione il principio L1, secondo il quale il 99% dei
della condensa dal motore. Questa operazione deve essere motori avrà la durata prevista.
eseguita a motore fermo e in condizioni di sicurezza.
7.2.1 Motori con cuscinetti a ingrassaggio

permanente
I cuscinetti sono, di solito, lubrificati in modo permanente e
di tipo 1Z, 2Z, 2RS o equivalente.
A titolo indicativo, nella tabella seguente sono illustrate le

durate che possono essere ottenute in conformità a L1 per
grandezze fino a 250. Per applicazioni con temperature
ambiente più elevate, contattare ABB. Formula per passare
dai valori L1 a valori approssimativamente corrispondenti a
L10: L10 = 2,0 x L1.
Ore di funzionamento per cuscinetti lubrificati a vita a Ingrassaggio con il motore fermo
temperature ambiente di 25 °C e 40°C: Se non è possibile eseguire l'ingrassaggio dei cuscinetti
con il motore in funzione, la lubrificazione può essere
Ore di funzio- Ore di funzio- eseguita a motore fermo.
Grandezza namento namento – In questo caso usare solo la metà della quantità di
carcassa Poli a 25 °C a 40 °C grasso richiesta, quindi mettere in funzione il motore per
56 2 52.000 33.000 alcuni minuti alla velocità massima.
56 4-8 65.000 41.000 – Quando il motore si ferma, introdurre nel cuscinetto il
63 2 49.000 31.000 resto del grasso.
63 4-8 63.000 40.000 – Dopo 1-2 ore di funzionamento, chiudere il tappo di
71 2 67.000 42.000 scarico del grasso o la valvola di chiusura, se montata.
71 4-8 100.000 56.000
B. Lubrificazione automatica
80-90 2 100.000 65.000
80-90 4-8 100.000 96.000 In caso di lubrificazione automatica, rimuovere
100-112 2 89.000 56.000 permanentemente il tappo di scarico del grasso o aprire la
100-112 4-8 100.000 89.000 valvola di chiusura, se montata.
132 2 67.000 42.000
132 4-8 100.000 77.000 Si raccomanda di utilizzare esclusivamente sistemi
160 2 60.000 38.000
elettromeccanici.
160 4-8 100.000 74.000 La quantità di grasso necessario per ogni intervallo di
180 2 55.000 34.000 lubrificazione riportata nella tabella deve essere triplicata
180 4-8 100.000 70.000 quando si utilizza un sistema di lubrificazione centrale.
200 2 41.000 25.000 Quando si utilizza un'unità di ingrassaggio automatico
200 4-8 95.000 60.000 più piccole (una o due cartucce per motore), è possibile
225 2 36.000 23.000 utilizzare la quantità normale di grasso.
225 4-8 88.000 56.000
Per l'ingrassaggio automatico dei motori a due poli, seguire
250 2 31.000 20.000
la nota sui lubrificanti per i motori a due poli nella sezione
250 4-8 80.000 50.000
relativa ai lubrificanti.
Dati validi fino a 60 Hz.
Il grasso utilizzato deve essere idoneo per la lubrificazione
automatica. Controllare il distributore del sistema di
7.2.2 Motori con cuscinetti ingrassabili lubrificazione automatica e le raccomandazioni del
Targhetta con i dati sulla lubrificazione e produttore del grasso.
suggerimenti generali sulla lubrificazione Esempio di calcolo della quantità di grasso per il
Se il motore è dotato di targhetta con i dati di lubrificazione, sistema di lubrificazione automatica
seguire i valori indicati. Sistema di lubrificazione centrale: Motore IEC M3_P 315_
Gli intervalli di lubrificazione in relazione a montaggio, 4-poli in rete a 50 Hz, l'intervallo di lubrificazione secondo la
temperatura ambiente e velocità di rotazione sono indicati tabella è 7600 h/55 g (DE) e 7600 h/40g (NDE):
sulla targhetta con le informazioni per la lubrificazione. (DE) RLI = 55 g/7600h*3*24 = 0,52 g/giorno
Durante il primo avviamento o dopo la lubrificazione di un
cuscinetto, è possibile che si manifesti temporaneamente (NDE) RLI = 40 g/7600*3*24 = 0,38 g/giorno
un aumento di temperatura, per circa 10-20 ore. Esempio di calcolo della quantità di grasso per unità
È possibile che alcuni motori siano muniti di un raccoglitore di lubrificazione automatica (cartuccia) singola
per il grasso usato. Seguire le istruzioni specifiche fornite (DE) RLI = 55 g/7600h*24 = 0,17 g/giorno
per l'attrezzatura.
(NDE) RLI = 40 g/7600*24 = 0,13 g/giorno
A. Lubrificazione manuale
RLI = Intervallo di lubrificazione, DE = Lato comando, NDE = Lato
Ingrassaggio con il motore in funzione opposto comando
– Rimuovere il tappo di scarico del grasso o aprire la
valvola di chiusura se montata. 7.2.3 Intervalli e quantità di lubrificazione
– Controllare che il canale di lubrificazione sia aperto.
– Iniettare nel cuscinetto la quantità di grasso specificata. Gli intervalli di lubrificazione per i motori verticali sono la
– Far funzionare il motore per 1-2 ore per assicurarsi metà dei valori riportati nella tabella seguente.
che tutto il grasso in eccesso venga spinto fuori dai
A titolo indicativo, nella tabella seguente sono illustrate le
cuscinetti. Chiudere il tappo di scarico del grasso o la
durate che possono essere ottenute in conformità a L1.
valvola di chiusura, se montata.
Per applicazioni con temperature ambiente più elevate,
contattare ABB. La formula per passare dai valori L1 a valori
approssimativamente corrispondenti a L10 è L10 = 2,0 x L1,
con lubrificazione manuale.
Gli intervalli di lubrificazione si basano su una temperatura In caso di funzionamento a velocità superiori, ad es. in
di funzionamento dei cuscinetti di 80 °C (temperatura applicazioni con convertitori di frequenza, o a velocità
ambiente +25 °C). inferiori con carichi pesanti, sarà necessario ridurre gli
intervalli di lubrificazione.
NOTA.
Un aumento della temperatura ambiente determina
AVVERTENZA!
un pari aumento della temperatura dei cuscinetti. I
La temperatura massima di esercizio del grasso e
valori degli intervalli devono essere dimezzati ogni
dei cuscinetti, +110 °C, non deve essere superata.
15 °C di aumento della temperatura dei cuscinetti
La velocità massima nominale del motore non deve
e possono essere raddoppiati ogni 15 °C di
essere superata.
diminuzione della temperatura dei cuscinetti.
Quantità
Grandezza 3600 3000 1800 1500 1000 500-900
di grasso kW kW kW kW
carcassa g/min g/min g/min g/min g/min g/min
g/cuscinetto
Cuscinetti a sfere, intervalli di lubrificazione in ore di funzionamento
112 10 tutti 10.000 13.000 tutti 18.000 21.000 tutti 25.000 tutti 28.000
132 15 tutti 9.000 11.000 tutti 17.000 19.000 tutti 23.000 tutti 26.500
160 25 ≤ 18,5 9.000 12.000 ≤ 15 18.000 21.500 ≤ 11 24.000 tutti 24.000
160 25 > 18,5 7.500 10.000 > 15 15.000 18.000 > 11 22.500 tutti 24.000
180 30 ≤ 22 7.000 9.000 ≤ 22 15.500 18.500 ≤ 15 24.000 tutti 24.000
180 30 > 22 6.000 8.500 > 22 14.000 17.000 > 15 21.000 tutti 24.000
200 40 ≤ 37 5.500 8.000 ≤ 30 14.500 17.500 ≤ 22 23.000 tutti 24.000
200 40 > 37 3.000 5.500 > 30 10.000 12.000 > 22 16.000 tutti 20.000
225 50 ≤ 45 4.000 6.500 ≤ 45 13.000 16.500 ≤ 30 22.000 tutti 24.000
225 50 > 45 1.500 2.500 > 45 5.000 6.000 > 30 8.000 tutti 10.000
250 60 ≤ 55 2.500 4.000 ≤ 55 9.000 11.500 ≤ 37 15.000 tutti 18.000
250 60 > 55 1.000 1.500 > 55 3.500 4.500 > 37 6.000 tutti 7.000
2801) 60 tutti 2.000 3.500 - - - - - - -
2801) 60 - - - tutti 8.000 10.500 tutti 14.000 tutti 17.000
280 35 tutti 1.900 3.200 - - - -
280 40 - - tutti 7.800 9.600 tutti 13.900 tutti 15.000
315 35 tutti 1.900 3.200 - - - -
355 35 tutti 1.900 3.200 - - - -
400 40 tutti 1.500 2.700 - - - -
450 40 tutti 1.500 2.700 - - - -
Cuscinetti a rulli, intervalli di lubrificazione in ore di funzionamento

160 25 ≤ 18,5 4.500 6.000 ≤ 15 9.000 10.500 ≤ 11 12.000 tutti 12.000
160 25 > 18,5 3.500 5.000 > 15 7.500 9.000 > 11 11.000 tutti 12.000
180 30 ≤ 22 3.500 4.500 ≤ 22 7.500 9.000 ≤ 15 12.000 tutti 12.000
180 30 > 22 3.000 4.000 > 22 7.000 8.500 > 15 10.500 tutti 12.000
200 40 ≤ 37 2.750 4.000 ≤ 30 7.000 8.500 ≤ 22 11.500 tutti 12.000
200 40 > 37 1.500 2.500 > 30 5.000 6.000 > 22 8.000 tutti 10.000
225 50 ≤ 45 2.000 3.000 ≤ 45 6.500 8.000 ≤ 30 11.000 tutti 12.000
225 50 > 45 750 1.250 > 45 2.500 3.000 > 30 4.000 tutti 5.000
250 60 ≤ 55 1.000 2.000 ≤ 55 4.500 5.500 ≤ 37 7.500 tutti 9.000
250 60 > 55 500 750 > 55 1.500 2.000 > 37 3.000 tutti 3.500
2801) 60 tutti 1.000 1.750 - - - - - - -
2801) 70 - - - tutti 4.000 5.250 tutti 7.000 tutti 8.500
280 35 tutti 900 1.600 - - - -
315 35 tutti 900 1.600 - - - -
355 35 tutti 900 1.600 - - - -
400 40 tutti - 1.300 - - - -
450 40 tutti - 1.300 - - - -
1)
M3AA
7.2.4 Lubrificanti I grassi seguenti possono essere utilizzati per motori in
ghisa ad alta velocità, ma non miscelati con grassi con
composto al litio:
AVVERTENZA!
Non mischiare grassi di tipo diverso. - Klüber Klüber Quiet BQH 72-102 (base di poliurea)
Lubrificanti non compatibili possono danneggiare i - Lubcon Turmogrease PU703 (base di poliurea)
cuscinetti.
Se vengono utilizzati altri lubrificanti, controllare con il
produttore che le caratteristiche corrispondano a quelle
Per il reingrassaggio utilizzare solo lubrificanti specifici per dei lubrificanti riportati sopra. Gli intervalli di lubrificazione
cuscinetti a sfere che abbiano le seguenti caratteristiche: si basano sui grassi ad alte prestazioni elencati sopra.
L'utilizzo di altri tipi di grasso può ridurre l'intervallo.
– grasso di buona qualità con composto al sapone di litio
e con olio PAO o minerale
– viscosità dell'olio di base 100-160 cST a 40 °C
– consistenza NLGI grado 1,5-3 *)
– intervallo di temperatura -30 °C - +120 °C, continuativa
*) Per i motori montati in verticale o in condizioni di elevato

calore, si suggerisce un valore fine scala più duro.
Le specifiche del grasso indicate sono valide per

temperatura ambiente compresa tra -30 °C e +55 °C e
temperatura dei cuscinetti inferiore a 110 °C; per valori
diversi, consultare ABB per avere indicazioni sul grasso più
adatto.
Il grasso con le proprietà corrette è disponibile presso tutti i

maggiori produttori di lubrificanti.
Si consiglia l'impiego di additivi, ma, soprattutto nel caso

di additivi EP, è necessario richiedere al produttore del
lubrificante una garanzia scritta attestante che l'additivo
non danneggia i cuscinetti o non altera le proprietà della
temperatura operativa dei lubrificanti.
AVVERTENZA!
Si sconsiglia l'uso di lubrificanti con additivi EP in
presenza di elevate temperature dei cuscinetti in
carcasse di grandezza 280-450.
È possibile utilizzare i seguenti tipi di grasso ad alto

rendimento:
– Mobil Unirex N2 or N3 (base con composto al litio)
– Mobil Mobilith SHC 100 (base con composto al litio)
– Shell Gadus S5 V 100 2 (base con composto al litio)
– Klüber Klüberplex BEM 41-132 (base al litio speciale)
– FAG Arcanol TEMP110 (base con composto al litio)
(base al litio speciale)
– Total Multiplex S2 A (base con composto al litio)
– Rhenus Rhenus LKZ 2 (base con composto al litio)
NOTA.
Utilizzare sempre grasso per alte velocità se si usano
motori a due poli ad alta velocità in cui il fattore
velocità è superiore a 480.000 (calcolato come
Dm x n, dove Dm = diametro medio del cuscinetto,
in mm; n = velocità di rotazione, in g/min).
8. Assistenza postvendita 9. Requisiti ambientali
Nella maggior parte dei motori ABB il livello di rumorosità
8.1 Parti di ricambio non supera 82 dB (A) (± 3 dB) a 50 Hz.
Se non diversamente specificato, le parti di ricambio I valori per motori specifici sono indicati nel relativo catalogo
devono essere originali o approvate da ABB. prodotto. Per alimentazione sinusoidale a 60 Hz aggiungere
Nell'ordinare le parti di ricambio di un motore, indicare circa 4 dB(A) ai valori a 50 Hz riportati nei cataloghi di
il numero di serie, la designazione completa del tipo e il prodotto.
codice prodotto, come indicato sulla targhetta del motore Per il livello di rumorosità con alimentazione con
stesso. convertitore di frequenza, contattare ABB.
Quando i motori devono essere demoliti o riciclati, attenersi

8.2 Smontaggio, riassemblaggio alle modalità appropriate e ai regolamenti e leggi locali.
e riavvolgimento
Il riavvolgimento deve sempre essere eseguito da una
officina autorizzata.
Contattare ABB prima di procedere al riavvolgimento di

motori per aspirazione fumi e altri motori speciali.
8.3 Cuscinetti
I cuscinetti necessitano di cure speciali.
Devono essere rimossi con l'uso di estrattori e montati a

caldo o con l'uso di utensili speciali.
La sostituzione dei cuscinetti è descritta in dettaglio in

un opuscolo separato che può essere richiesto all'ufficio
commerciale ABB.
Devono essere seguite eventuali indicazioni riportate sul

motore, ad esempio con etichette. Il tipo dei cuscinetti
riportato sulla targhetta non deve essere cambiato.
NOTA.
Se non espressamente autorizzata dal costruttore,
qualsiasi riparazione eseguita dall'utilizzatore finale
fa decadere ogni responsabilità del costruttore sulla
conformità del motore fornito.
10. Risoluzione dei problemi
Le istruzioni seguenti non coprono tutti i particolari o Risoluzione dei problemi del motore
variazioni nelle apparecchiature, né forniscono informazioni
su tutte le possibili condizioni che potrebbero verificarsi La manutenzione e la riparazione dei guasti del motore
durante l'installazione, il funzionamento e la manutenzione. devono essere eseguite da personale qualificato
Per ulteriori informazioni, contattare l'ufficio commerciale utilizzando utensili e attrezzature idonei.
ABB di zona.
PROBLEMA CAUSA AZIONE

Il motore non si Fusibili bruciati Sostituire con fusibili adeguati per tipo e capacità.
avvia Il sovraccarico scatta Controllare e ripristinare il sovraccarico nel motorino di avviamento.
Alimentazione non corretta Controllare che l'alimentazione corrisponda a quanto indicato sulla
targhetta del motore e al fattore di carico.
Collegamenti della linea non corretti Controllare i collegamenti in base allo schema fornito con il motore.
Circuito aperto nell'avvolgimento o Indicato da un ronzio quando l'interruttore viene chiuso. Controllare
nell'interruttore di controllo che non vi siano collegamenti interrotti e assicurarsi che tutti i contatti
di controllo si chiudano.
Guasto meccanico Verificare se il motore e l'azionamento ruotano liberamente.
Controllare cuscinetti e lubrificazione.
Statore in corto circuito
Collegamento dell'avvolgimento statore Indicato dai fusibili bruciati. Eseguire il riavvolgimento del motore.
inefficiente Rimuovere gli scudi e individuare il guasto.
Rotore difettoso Verificare che non vi siano barre o anelli di testa rotti.
Motore sovraccarico Ridurre il carico.
Motore in stallo Potrebbe essere aperta una fase Controllare che non vi siano fasi aperte.
Applicazione non corretta Cambiare tipo o grandezza. Consultare il fornitore
dell'apparecchiatura.
Sovraccarico Ridurre il carico.
Bassa tensione Assicurarsi che sia mantenuta la tensione nominale. Verificare il
collegamento.
Circuito aperto Fusibili bruciati. Controllare il relè di sovraccarico, lo statore e i
pulsanti.
Il motore funziona, Alimentazione interrotta Controllare che non vi siano collegamenti interrotti alla linea, ai fusibili e
quindi si spegne al controllo.
Il motore non Applicato non correttamente Consultare il fornitore dell'apparecchiatura in merito al tipo corretto.
raggiunge la Tensione troppo bassa ai terminali del Utilizzare una tensione più elevata, i terminali trasformatore o ridurre il
velocità nominale motore a causa di caduta di linea carico
Verificare i collegamenti. Verificare la sezione dei cavi.
Carico eccessivo all'avviamento Controllare che il motore si avvii senza carico.
Barre del rotore rotte o rotore allentato Verificare che non vi siano rotture vicino agli anelli. Potrebbe essere
necessario un nuovo rotore in quanto le riparazioni sono in genere
provvisorie.
Circuito primario aperto Individuare il guasto con il tester e riparare.
PROBLEMA CAUSA AZIONE
Il motore accelera Carico eccessivo Ridurre il carico.
troppo lentamente Bassa tensione all'avviamento Controllare che la resistenza non sia eccessiva. Assicurarsi che la
e/o consuma sezione dei cavi sia adeguata.
molta corrente
Rotore a gabbia di scoiattolo difettoso Sostituire con un rotore nuovo.
Tensione applicata troppo bassa Correggere l'alimentazione.
Senso di rotazione Sequenza delle fasi non corretta Invertire i collegamenti sul motore o sul quadro di comando.
errato
Il motore si Sovraccarico Ridurre il carico.
surriscalda durante La carcassa o le aperture per il Aprire i fori di ventilazione e controllare che vi sia un flusso d'aria
il funzionamento passaggio d'aria potrebbero essere continuo dal motore.
intasate e impedire la ventilazione del
motore.
Il motore potrebbe avere una fase Assicurarsi che tutti i conduttori e i cavi siano collegati correttamente.
aperta
Avvolgimento a terra Eseguire il riavvolgimento del motore.
Tensione ai morsetti non bilanciata Controllare che non vi siano conduttori, collegamenti o trasformatori
guasti.
Il motore vibra Motore non allineato Riallineare.
Supporto debole Rinforzare la base.
Giunti non bilanciati Bilanciare i giunti.
Apparecchiatura azionata non Bilanciare l'apparecchiatura azionata.
bilanciata
Cuscinetti difettosi Sostituire i cuscinetti.
Cuscinetti non in linea Riparare il motore
Pesi di bilanciamento spostati Bilanciare il rotore.
Bilanciamento del rotore e del giunto Bilanciare il giunto o il rotore.
diverso (mezza chiavetta - chiavetta
intera)
Motore polifase funzionante in Controllare che non vi siano circuiti aperti.
monofase
Gioco eccessivo Regolare il cuscinetto o aggiungere uno spessore.
Rumore di Ventola che sfrega sullo scudo o sul Correggere il montaggio della ventola.
sfregamento copriventola
Basamento allentato Serrare i bulloni di fissaggio.
Funzionamento Traferro non uniforme Controllare e regolare il montaggio dello scudo o dei cuscinetti.
rumoroso Rotore sbilanciato Bilanciare il rotore.
Cuscinetti caldi Albero piegato Raddrizzare o sostituire l'albero.
Cinghia eccessivamente tesa Ridurre la tensione della cinghia.
Pulegge troppo lontane dalla spalla Avvicinare le pulegge al cuscinetto del motore.
dell'albero
Diametro delle pulegge troppo piccolo Utilizzare pulegge più grandi.
Disallineamento Correggere riallineando l'azionamento.
Grasso insufficiente Mantenere la qualità e la quantità di grasso corrette nel cuscinetto.
Deterioramento del grasso o Rimuovere il grasso vecchio, lavare a fondo i cuscinetti con cherosene
contaminazione del lubrificante e sostituire con grasso nuovo.
Lubrificante in eccesso Ridurre la quantità di grasso, il cuscinetto deve essere pieno solo fino
a metà.
Cuscinetto sovraccarico Controllare allineamento e spinta laterale e finale.
Sfere rotte o piste danneggiate Pulire bene la sede del cuscinetto e sostituirlo.
Motores de baixa tensão
Manual de instalação, operação, manutenção e segurança
Índice
1. Introdução ...............................................................................................................................103
1.1 Declaração de Conformidade ..........................................................................................103
1.2 Validade...........................................................................................................................103
2. Considerações relativas à segurança...................................................................................103
3. Manuseamento .......................................................................................................................104
3.1 Verificação no momento da recepção ..............................................................................104
3.2 Transporte e armazenamento ..........................................................................................104
3.3 Elevação ..........................................................................................................................104
3.4 Peso do motor ................................................................................................................104
4. Instalação e colocação em serviço.......................................................................................106
4.1 Geral ...............................................................................................................................106
4.2 Motores não equipados com rolamentos de esferas ........................................................106
4.3 Verificação da resistência de isolamento ..........................................................................106
4.4 Fundações ......................................................................................................................106
4.5 Equilibrar e instalar os meios-acoplamentos e polias .......................................................107
4.6 Montagem e alinhamento do motor .................................................................................107
4.7 Forças radiais e correias de transmissão .........................................................................107
4.8 Motores com bujões de drenagem para condensação ....................................................107
4.9 Cablagem e ligações eléctricas........................................................................................107
4.9.1 Ligações para diferentes métodos de arranque ................................................108
4.9.2 Ligações de equipamentos auxiliares................................................................109
4.10 Terminais e sentido de rotação ........................................................................................109
5. Funcionamento ......................................................................................................................110
5.1 Geral ...............................................................................................................................110
Manual para motores de baixa tensão 3GZF500730-85 Rev F 02-2015 | Motores e Geradores ABB 101
6. Motores de baixa tensão em aplicações com velocidade variável ...................................111
6.1 Introdução .......................................................................................................................111
6.2 Isolamento dos enrolamentos ..........................................................................................111
6.2.1 Selecção do isolamento dos enrolamentos para conversores ABB ...................111
6.2.2 Selecção do isolamento dos enrolamentos com todos os outros conversores 111
6.3 Protecção térmica ..........................................................................................................111
6.4 Correntes nos rolamentos................................................................................................112
6.4.1 Eliminação de correntes nos rolamentos com conversores ABB .......................112
6.4.2 Eliminação de correntes nos rolamentos com todos os outros conversores .....112
6.5 Cablagem, ligação à terra e CEM ....................................................................................112
6.6 Velocidade de funcionamento ..........................................................................................112
6.7 Motores em aplicações de velocidade variável.................................................................112
6.7.1 Geral ................................................................................................................112
6.7.2 Capacidade de carga do motor com conversores da série AC_8_ _
com controlo DTC ............................................................................................113
6.7.3 Capacidade de carga do motor com conversores da série AC_5_ _ ................113
6.7.4 Capacidade de carga do motor com outros conversores
de alimentação tipo PWM.................................................................................113
6.7.5 Sobrecargas de curta duração .........................................................................113
6.8 Chapas de características ...............................................................................................113
6.9 Colocação em serviço da aplicação de velocidade variável..............................................113
7. Manutenção .............................................................................................................................114
7.1 Inspecção geral ...............................................................................................................114
7.1.1 Motores de reserva ..........................................................................................114
7.2 Lubrificação .....................................................................................................................114
7.2.1 Motores com rolamentos que não necessitam de lubrificação .........................114
7.2.2 Motores com rolamentos que necessitam de lubrificação .................................115
7.2.3 Intervalos de lubrificação e quantidades de lubrificante .....................................116
7.2.4 Lubrificantes .....................................................................................................118
8. Apoio pós-venda .....................................................................................................................119
8.1 Peças sobressalentes ......................................................................................................119
8.2 Desmontar, voltar a montar e rebobinar ...........................................................................119
8.3 Rolamentos .....................................................................................................................119
9. Requisitos ambientais ............................................................................................................119
10. Resolução de problemas .......................................................................................................120
102 Motores e Geradores ABB | Manual para motores de baixa tensão 3GZF500730-85 Rev F 02-2015
1. Introdução 2. Considerações relativas
à segurança
NOTA!
Estas instruções devem ser seguidas para assegurar O motor destina-se a ser instalado e utilizado por pessoal
uma correcta e segura instalação, operação e qualificado, familiarizado com os requisitos de segurança e
manutenção do motor. Devem ser disponibilizadas saúde relevantes e com a legislação nacional.
e seguidas pelo pessoal encarregue da instalação,
operação e manutenção deste motor ou do Os equipamentos de segurança necessários para
equipamento associado. O motor destina-se a a prevenção de acidentes no local de montagem e
ser instalado e utilizado por pessoal qualificado, funcionamento devem ser fornecidos de acordo com
familiarizado com os requisitos de segurança e regulamentos locais.
saúde relevantes e com a legislação nacional.
Ignorar estas instruções poderá invalidar todas as
garantias aplicáveis. AVISO!
Os controlos de paragem de emergência têm de
ser equipados com bloqueios de reinício. Após a
1.1 Declaração de Conformidade paragem de emergência, um novo comando de
início pode ter efeito apenas depois de o bloqueio
A conformidade do produto final com a Directiva 2006/42/ de reinício ter sido intencionalmente reposto.
CE (Maquinaria) tem de ser estabelecida pela parte
responsável pela colocação em serviço, quando o motor é
Pontos a observar:
instalado na máquina.
1. Não subir para cima do motor.
2. A temperatura da carcaça exterior do motor pode ser
1.2 Validade mais quente ao tacto durante o funcionamento normal
Estas instruções são válidas para os seguintes tipos de e, especialmente, depois da paragem.
máquinas eléctricas da ABB, utilizadas como motores ou 3. Algumas aplicações especiais do motor podem
geradores: requerer instruções adicionais (por exemplo, se
for utilizada uma alimentação com conversor de
séries MT*, MXMA, frequência).
séries M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*, 4. Tenha atenção às peças rotativas do motor.
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, 5. Não abrir as caixas de terminais enquanto estiverem
M2V*/M3V* com energia.
com os tamanhos 56 a 450.
Existe um manual em separado para, por exemplo,

motores de baixa tensão para utilização em atmosferas
explosivas: Manual de instalação, operação e manutenção
e segurança (3GZF500730-47)
São necessárias informações adicionais para alguns

tipos de máquinas devido à sua aplicação especial e/ou
considerações relativas à sua concepção.
Estão disponíveis manuais adicionais para os seguintes

motores:
– motores para mesas de rolos
– motores arrefecidos a água
– motores de extracção de fumo
– motores com travão
– motores para ambientes com temperaturas elevadas
– motores para aplicações marítimas, para montagem
num deck aberto de navios ou unidades marítimas
3. Manuseamento Não se devem utilizar patilhas de elevação danificadas.
Verifique se as patilhas de elevação ou os olhais integrados
não estão danificados, antes de proceder à elevação.
3.1 Verificação no momento
Os parafusos dos olhais de elevação deverão ser
da recepção apertados antes de iniciar a elevação. Se necessário, a
Imediatamente após a recepção, verifique o motor para posição do parafuso deve ser ajustada utilizando anilhas
identificar danos exteriores (por exemplo, extremidades adequadas como espaçadores.
dos veios, flanges e superfícies pintadas) e, se forem Certifique-se de que é utilizado o equipamento de elevação
encontrados danos, informe sem demora o transitário. adequado e de que os tamanhos dos ganchos são
Verifique todos os dados da chapa de características, adequados para as patilhas de elevação.
nomeadamente a tensão e as ligações dos enrolamentos Devem ser tomados os cuidados necessários para não
(estrela ou triângulo). O tipo de rolamentos é especificado danificar o equipamento auxiliar e os cabos ligados ao
na chapa de características para todos os motores, motor.
excepto para os motores de tamanhos mais reduzidos.
Remova os dispositivos instalados para transporte e que
No caso de uma aplicação de transmissão de velocidade fixam o motor à palete.
variável, verificar a capacidade de carga máxima permitida
de acordo com a frequência que se encontra gravada na A ABB disponibiliza instruções de elevação específicas.
segunda chapa de características do motor.
AVISO!
3.2 Transporte e armazenamento Durante os trabalhos de elevação, montagem ou
O motor deve ser sempre armazenado no interior (com manutenção, devem ser implementadas todas
temperaturas acima de –20 °C), em ambientes secos, não as considerações necessárias sobre segurança,
sujeitos a vibrações e sem poeiras. Durante o transporte, devendo ser prestada especial atenção ao facto de
devem ser evitados choques, quedas e humidade. Para que ninguém corre o risco de ser atingido pela carga
outras situações, contactar a ABB. elevada.
As superfícies maquinadas não protegidas (extremidades

dos veios e flanges) devem ser tratadas contra a corrosão. 3.4 Peso do motor
Recomenda-se que os veios sejam rodados O peso total do motor varia dentro do mesmo tamanho
periodicamente à mão para impedir a migração da massa (altura do centro), consoante as diferentes potências,
lubrificante. as diferentes disposições de montagem e os diferentes
Recomenda-se a utilização de aquecedores anti- equipamentos auxiliares.
condensação, se instalados, para evitar a condensação de O seguinte quadro mostra os valores aproximados para os
água no motor. pesos máximos dos motores nas suas versões básicas em
O motor não pode estar sujeito a quaisquer vibrações função do material da estrutura.
externas quando parado, para evitar danificar os O peso real de todos os motores ABB, excepto nas
rolamentos. dimensões de estrutura mais reduzidas (56 e 63), é
Durante o transporte, os motores equipados com indicado na chapa de características.
rolamentos de rolos e/ou angulares devem ser equipados
com dispositivos de travamento.
3.3 Elevação
Todos os motores ABB acima dos 25 kg estão equipados
com olhais de elevação.
Apenas as patilhas ou olhais de elevação principais do

motor devem ser utilizados para elevar o motor. Não
devem ser utilizados para elevar o motor quando este
estiver ligado a outros equipamentos.
As patilhas de elevação dos equipamentos auxiliares

(por exemplo, travões, ventiladores de arrefecimento
separados) ou caixas de terminais não devem ser utilizadas
para elevar o motor. Devido às diferentes potências,
disposições de montagem e equipamentos auxiliares, os
motores com a mesma estrutura podem ter um centro de
gravidade diferente.
Tamanho da Alumínio Ferro fundido Ad.
estrutura para o travão
Peso kg Peso kg
56 4.5 - -
63 6 - -
71 8 13 5
80 14 20 8
90 20 30 10
100 32 40 16
112 36 50 20
132 93 90 30
160 149 130 30
180 162 190 45
200 245 275 55
225 300 360 75
250 386 405 75
280 425 800 -
315 - 1700 -
355 - 2700 -
400 - 3500 -
450 - 4500 -
Se o motor estiver equipado com uma ventoinha em

separado, contactar a ABB para obter o respectivo peso.
4. Instalação e colocação em serviço
AVISO! 4.3 Verificação da resistência
Desligue e bloqueie todo o sistema antes de realizar de isolamento
trabalhos no motor ou no equipamento accionado.
Meça a resistência de isolamento antes de colocar o motor
em funcionamento e se houver suspeitas de humidade no
4.1 Geral enrolamento.
Devem ser verificados com cuidado todos os valores A resistência de isolamento, corrigida para 25 °C, nunca
indicados nas chapas de características, para garantir pode ser inferior a 1 MΩ (medidos com 500 ou 1000 V
que a protecção e as ligações do motor são feitas CC). O valor da resistência de isolamento é reduzido para
adequadamente. metade por cada aumento de 20 °C na temperatura. A
Figura 1 pode ser utilizada para a correcção do isolamento
para a temperatura desejada.
4.2 Motores não equipados
com rolamentos de esferas AVISO!
Para evitar o risco de choque eléctrico, a estrutura
Remova o travamento para o transporte, caso tenha sido
do motor tem e ser ligada à terra e os enrolamentos
aplicado. Rode o veio do motor à mão para comprovar
deverão ser descarregados contra a estrutura
que roda livremente, se possível.
imediatamente após cada medição.
Motores equipados com rolamentos de rolos:

Colocar o motor em funcionamento sem a aplicação de Se não for atingido o valor de referência da resistência
uma força radial ao veio pode danificar o rolamento de de isolamento, isso indica que o enrolamento está muito
rolos, devido ao "deslizamento". húmido, devendo por isso ser seco numa estufa. A
temperatura da estufa deve ser de 90 °C durante 12 a 16
horas, seguindo-se de 105 °C durante 6 a 8 horas.
Motores equipados com rolamentos de contacto
angular: Se instalados, os bujões dos orifícios de drenagem devem
Colocar o motor em funcionamento sem a aplicação de de ser removidos e as válvulas de fecho devem estar
uma força axial ao veio na direcção certa pode danificar o abertas durante o aquecimento. Após o aquecimento,
rolamento de contacto angular. certificar-se de que os bujões são novamente equipados.
Mesmo que os bujões de drenagem estejam instalados,
recomenda-se a desmontagem das tampas e das
AVISO! coberturas das caixas de terminais durante o processo de
Nos motores com rolamentos de contacto angular secagem.
a força axial não deve em caso algum mudar de
direcção. Normalmente, os enrolamentos molhados com água
salgada devem ser rebobinados.
O tipo de rolamento está especificado na chapa de

características.
4.4 Fundações
O utilizador final é o único responsável pela preparação das
Motores equipados com copos de lubrificação: fundações.
Ao fazer o arranque do motor pela primeira vez, ou As fundações metálicas devem ser pintadas para evitar a
após uma paragem prolongada, aplicar a quantidade ocorrência de corrosão.
especificada de massa lubrificante.
As fundações devem ser uniformes e suficientemente
Para mais pormenores, consulte a secção “7.2.2 Motores rígidas para resistir a eventuais forças de curto-circuito.
com rolamentos que requerem lubrificação”.
Têm de ser concebidas e dimensionadas de forma a evitar
Quando colocado numa posição vertical com o veio a a transferência de vibrações para o motor e vibrações
apontar para baixo, o motor tem de ter uma cobertura provocadas pela ressonância. Ver figura abaixo.
protectora para evitar que objectos estranhos e fluidos
caiam nas aberturas da ventilação. Isto também pode
ser conseguido através de uma cobertura protectora não
fixada ao motor. Neste caso, o motor tem de ter uma
etiqueta de aviso.
Volte a verificar o alinhamento após o último aperto dos
Régua parafusos ou cavilhas.
Não exceder os valores de carga permitidos para

rolamentos, como indicado nos catálogos do produto.
Nota! A diferença de alturas
em relação a qualquer outro
pé do motor não deve exceder Verificar se o motor tem um fluxo de ar suficiente.
± 0,1mm Certificar-se de que nem os objectos próximos nem a luz
solar directa irradiam calor adicional sobre motor.
Para motores montados com flanges (por exemplo, B5,

B35, V1), certificar-se de que a construção permite um
fluxo de ar suficiente na superfície exterior da flange.
Localização do pé
4.7 Forças radiais e correias

4.5 Equilibrar e instalar os de transmissão
meios-acoplamentos e polias As correias têm de ser apertadas de acordo com as
instruções do fornecedor do equipamento accionado.
Por norma, a equilibragem do motor foi feita utilizando Contudo, nunca devem ser excedidas as forças máximas
meias chavetas da correia (ou seja, as forças radiais exercidas sobre os
rolamentos) que se encontram indicadas nos respectivos
Os meios-acoplamentos ou polias devem ser equilibrados
catálogos de produtos.
depois maquinados os escatéis. A equilibragem deve
ser efectuada de acordo com o método de equilibragem
especificado para o motor. AVISO!
Uma tensão excessiva da correia causa danos nos
Os meios-acoplamentos e as polias devem ser instalados
rolamentos e pode provocar a ruptura do veio.
no veio utilizando ferramentas e equipamentos apropriados
que não danifiquem os rolamentos e os vedantes.
Nunca se deve instalar um meio-acoplamento ou uma

polia utilizando um martelo, nem removê-los utilizando uma
4.8 Motores com bujões de
alavanca apoiada na carcaça do motor. drenagem para condensação
Verificar se os bujões e os orifícios de drenagem estão
4.6 Montagem e alinhamento voltados para baixo. Em motores montados verticalmente,
os bujões de drenagem podem estar na posição
do motor horizontal.
Certificar-se de que há espaço suficiente para a livre Os motores com bujões de drenagem em plástico vedáveis
circulação de ar em torno do motor. É aconselhável ter são entregues com os orifícios abertos. Em ambientes com
uma folga entre a tampa do ventilador e a parede, etc, de muita poeira, todos os orifícios de drenagem devem ser
pelo menos ½ da entrada de ar da tampa do ventilador. fechados.
Poderá encontrar informações adicionais no catálogo do
produto ou nos desenhos das dimensões disponíveis no
nosso site na Internet: www.abb.com/motors&generators. 4.9 Cablagem e ligações
O alinhamento correcto é fundamental para evitar avarias eléctricas
nos rolamentos, vibrações e possíveis falhas nos veios.
As caixas de terminais dos motores normais com uma
Montar o motor na fundação utilizando os parafusos ou única velocidade têm normalmente seis terminais para os
pernos adequados e colocando calços entre a fundação e enrolamentos e, pelo menos, um terminal para ligação à
os pés. terra.
Alinhe o motor utilizando os métodos adequados. Para além dos terminais para os enrolamentos principais e
para ligação à terra, a caixa de terminais pode também ter
Se aplicável, fazer furos de posicionamento e fixar os ligações para os termístores, elementos de aquecimento
pernos de posicionamento no lugar. ou outros dispositivos auxiliares.
Precisão de montagem dos meios acoplamentos: verifique Têm de ser utilizados terminais de condutores adequados
se a folga b é inferior a 0,05 mm e se a diferença entre a1 e para a ligação de todos os cabos principais. Os cabos
a2 é também inferior a 0,05 mm. Ver figura 2. para os equipamentos auxiliares podem ser ligados
directamente aos blocos de terminais sem necessidade de
terminais.
Os motores destinam-se apenas a instalação fixa. Salvo A ligação de cabos entre a rede e os terminais do motor
especificação em contrário, as roscas das entradas de tem de cumprir os requisitos indicados nas normas
cabos são métricas. A classe de protecção IP do bucim nacionais para a instalação ou na norma CEI/EN 60204-1
para o cabo deve ser, pelo menos, a mesma das caixas de de acordo com a corrente nominal indicada na chapa de
terminais. características.
Na instalação, deve ser utilizada um encaixe de conduta ou

NOTA!
um conector de cabo certificado.
Quando a temperatura ambiente excede +50 °C,
devem ser utilizados cabos com uma temperatura
NOTA! de funcionamento admissível de +90 °C, no mínimo.
Os cabos têm de ser mecanicamente protegidos Além disso, todos os outros factores de conversão,
e fixados junto da caixa de terminais para cumprir em função das condições de instalação, devem ser
os requisitos adequados da CEI/EN 60079-0 e as tomados em consideração no dimensionamento dos
normas locais de instalação. cabos.
Certifique-se de que a protecção do motor corresponde

As entradas de cabos não utilizadas devem ser fechadas às condições ambientais e climatéricas. Por exemplo,
com tampas de obturação de acordo a classe de certifique-se de que a água não pode entrar no motor ou
protecção IP da caixa de terminais. nas caixas de terminais.
O grau de protecção e o diâmetro estão especificados nos Os vedantes das caixas de terminais devem de ser
documentos relacionados com o bucim do cabo. colocados correctamente nos entalhes previstos, para
garantir a classe IP correcta. Uma fuga pode levar à
penetração de poeira ou água, provocando um risco de
AVISO!
descarga nos elementos vivos.
Utilize bucins para cabo e vedantes adequados
nas entradas dos cabos de acordo com o tipo de
protecção e o tipo e diâmetro do cabo. 4.9.1 Ligações para diferentes métodos de
arranque
As caixas de terminais dos motores normais com uma
A ligação à terra deve ser efectuada de acordo com as
única velocidade têm normalmente seis terminais para os
normas locais antes de ligar o motor à alimentação.
enrolamentos e, pelo menos, um terminal para ligação à
O terminal de terra na estrutura tem de ser ligado ao terra. Isto permite a utilização de arranque DOL (arranque
terminal PE com um cabo, conforme indicado na Tabela 5 directo) ou Y/D (estrela-triângulo).
da CEI/EN 60034-1:
Para motores de duas velocidades e motores especiais,
Área de secção transversal mínima de condutores de a ligação de alimentação deve ser feita de acordo com
protecção as instruções que se encontram no interior da caixa de
terminais ou no manual do motor.
Área de secção transversal Área de secção transversal
de condutores de fase da mínima do condutor de A tensão de alimentação e o modo de ligação encontram-
instalação, S, [mm2] protecção correspondente, se gravados na chapa de características.
SP, [mm2]
4 4 Arranque directo (DOL):
6 6 Podem ser empregues ligações dos enrolamentos do tipo
10 10 Y ou D.
16 16
25 25 Por exemplo, 690 VY, 400 VD indica uma ligação Y para
35 25 690 V e uma ligação D para 400 V.
50 25
Arranque Estrela-Triângulo (Y/D):
70 35
95 50 A tensão de alimentação deve ser igual à tensão nominal
120 70 indicada para o motor quando se utiliza uma ligação D.
150 70
185 95 Remover todos os elos de ligação da caixa de terminais.
240 120
Outros métodos de arranque e condições de
300 150
arranque severas:
400 185
Caso sejam utilizados outros métodos de arranque, tais
Para além disto, a ligação à terra ou soldadura de recursos como conversor ou arrancador suave, nos tipos de serviço
de ligação no exterior de aparelhos eléctricos tem de S1 e S2, considera-se que o dispositivo está "isolado do
fornecer uma ligação eficaz de um condutor com uma área sistema de potência quando o equipamento eléctrico está
de secção transversal de, pelo menos, 4 mm2. em funcionamento", de acordo com a norma CEI 60079-0,
e a protecção térmica é opcional.
4.9.2 Ligações de equipamentos auxiliares
Se um motor estiver equipado com termístores ou outros
RTDs (Pt100, relés térmicos, etc.) e dispositivos auxiliares,
recomenda-se que sejam utilizados e ligados de forma
adequada. Para certas aplicações, é obrigatória a utilização
de protecção térmica. Estão disponíveis informações mais
pormenorizadas na documentação entregue com o motor.
Os diagramas de ligação de elementos auxiliares e peças
de ligação encontram-se no interior da caixa de terminais.
A tensão de medição máxima para termístores é de 2,5

V. A corrente de medição máxima para Pt100 é 5 mA. A
utilização de uma tensão de medição ou corrente superior
pode originar erros de leituras ou danos num detector de
temperatura.
O isolamento dos sensores térmicos cumpre os requisitos

de isolamento básico.
4.10 Terminais e sentido

de rotação
O veio roda no sentido dos ponteiros do relógio quando
visto do lado do veio de accionamento do motor e a
sequência das fases de linha - L1, L2, L3 - está ligada aos
terminais, de acordo com a figura 3.
Para alterar o sentido de rotação, trocar quaisquer duas

ligações dos cabos de alimentação.
Se o motor tiver um ventilador com um sentido de rotação

definido, certificar-se de que roda na direcção da seta
marcada no motor.
5. Funcionamento
5.1 Geral
Os motores foram concebidos para as seguintes
condições, salvo indicação em contrário na chapa de
características:
- Os motores só devem ser utilizados em instalações

fixas.
- O intervalo normal de temperatura ambiente é entre
–20 °C e +40 °C.
- A altitude máxima é de 1.000 m acima do nível do mar.
- A variação da tensão de alimentação e da frequência
não pode exceder os limites mencionados nas normas
relevantes. A tolerância da tensão de alimentação é
de ±5 % e da frequência é de ±2 %, de acordo com
a figura 4 (EN / CEI 60034-1, parágrafo 7.3, Zona A).
Não devem ocorrer simultaneamente ambos os valores
extremos.
O motor só pode ser utilizado para as aplicações às

quais se destina. Os valores nominais e as condições
de funcionamento estão indicados nas chapas de
características dos motores. Para além disto, têm de
ser seguidos todos os requisitos deste manual e outras
instruções e normas relacionadas.
Se estes limites forem ultrapassados, as características do

motor e os dados de construção devem ser verificados.
Contacte a ABB para mais informações.
AVISO!
Ignorar quaisquer instruções de operação ou de
manutenção do aparelho pode comprometer a
segurança e impedir a utilização do motor.
6. Motores de baixa tensão em aplicações com velocidade
variável
6.1 Introdução 6.2.1 Selecção do isolamento dos
enrolamentos para conversores ABB
Esta parte do manual contém instruções adicionais para
motores utilizados com conversores de frequência. O No caso de conversores de frequência ABB, por exemplo
motor destina-se a ser utilizado apenas com alimentação das séries AC_8_ _ e AC_5_ _ , com uma unidade de
de um único conversor de frequência, e não motores alimentação com díodos (tensão CC não controlada), a
a funcionar em paralelo a partir de um conversor de selecção do isolamento dos enrolamentos e dos filtros
frequência. Devem ser respeitadas as instruções do pode ser feita de acordo com a tabela 6.1.
fabricante do conversor.
A ABB pode necessitar de informações adicionais para 6.2.2 Selecção do isolamento dos
decidir a adequação de alguns tipos de motor utilizados enrolamentos com todos os outros
em aplicações especiais ou com alterações de concepção conversores
especiais.
Os esforços dieléctricos devem ser mantidos abaixo dos
limites aceitáveis. Contacte o fornecedor do sistema para
se certificar da segurança da aplicação. Ao dimensionar
6.2 Isolamento dos enrolamentos o motor, deve ser tida em consideração a influência de
As transmissões com velocidade variável provocam possíveis filtros.
tensões no enrolamento do motor superiores à tensão
sinusoidal de alimentação do motor. Por esse motivo, o
isolamento dos enrolamentos do motor, assim como o 6.3 Protecção térmica
filtro de saída do conversor, devem ser dimensionados de
acordo com as instruções seguintes. A maior parte do motores abrangidos por este manual
estão equipados com termístores PTC, ou outros tipos
de RTDs, nos enrolamentos do estator. Recomenda-se
que sejam ligados ao conversor de frequência. Para mais
informações, consultar o capítulo 4.9.2.
PN < 100 kW PN ≥ 100 kW ou PN ≥ 350 kW ou

IEC315 ≤ Tamanho da estrutura ≤ IEC400 ≤ Tamanho da estrutura ≤
IEC355 IEC450
UN ≤ 500 V Motor standard Motor standard Motor standard
+ Rolamento N isolado + Rolamento N isolado
+ Filtro de modo comum
500 V >UN ≤ 600 V Motor standard Motor standard Motor standard
+ dU/dt –filtro (reactância) + dU/dt –filtro (reactância) + Rolamento N isolado
OU + Rolamento N isolado + dU/dt –filtro (reactância)
Isolamento reforçado OU + Filtro de modo comum
Isolamento reforçado OU
+ Rolamento N isolado Isolamento reforçado
+ Rolamento N isolado
500 V >UN ≤ 600 V Motor standard Motor standard Motor standard
(comprimento do cabo + Rolamento N isolado + Rolamento N isolado
> 150 m) + Filtro de modo comum
600 V >UN ≤ 690 V Isolamento reforçado Isolamento reforçado Isolamento reforçado

+ dU/dt –filtro (reactância) + dU/dt –filtro (reactância) + Rolamento N isolado
+ Rolamento N isolado + dU/dt –filtro (reactância)
600 V >UN ≤ 690 V Isolamento reforçado Isolamento reforçado Isolamento reforçado
(comprimento do cabo + Rolamento N isolado + Rolamento N isolado
> 150 m) + Filtro de modo comum
Tabela 6.1 Selecção do isolamento dos enrolamentos para conversores ABB
Para mais informações sobre travagem com resistências e conversores com unidades de alimentação controladas,
contactar a ABB.
6.4 Correntes nos rolamentos NOTA!
Devem ser utilizados rolamentos isolados ou rolamentos de Devem ser utilizados bucins para cabos adequados
construção especial, filtros de modo comum e métodos de que permitam fazer uma ligação a 360° em todos os
cablagem e ligação à terra adequados, de acordo com as pontos de conexão, tais como o motor, conversor,
instruções seguintes e utilizando a tabela 6.1. eventual interruptor de segurança, etc.
6.4.1 Eliminação de correntes nos Para motores com tamanho CEI 280 e superior, é
rolamentos com conversores ABB necessário fazer uma equalização do potencial adicional
No caso dos conversores de frequência, por exemplo das entre a estrutura do motor e o equipamento accionado,
séries AC_8_ _ e AC_5_ _ da ABB, com uma unidade de a não ser que ambos estejam montados sobre a mesma
alimentação com díodos, têm de ser utilizados os métodos base em aço. Neste caso, a condutividade de alta-
indicados na tabela 6.1 para evitar correntes prejudiciais frequência da ligação fornecida pela base em aço deve
nos rolamentos nos motores. ser verificada através de, por exemplo, uma medição da
diferença de potencial entre os componentes.
Estão disponíveis mais informações sobre a ligação à

NOTA!
terra e a cablagem de transmissões de velocidade variável
Recomenda-se a utilização de rolamentos
no manual “Ligação à terra e cablagem do sistema de
isolados que tenham as superfícies interiores e/ou
transmissão" (Código: 3AFY 61201998).
exteriores revestidas a óxido de alumínio ou que
tenham elementos de rolamento cerâmicos. Os
revestimentos de óxido de alumínio devem também
ser tratados com um material vedante para evitar 6.6 Velocidade de funcionamento
que poeiras e a humidade penetrem no revestimento
Para velocidades superiores à velocidade nominal indicada
poroso. Para saber o tipo exacto do isolamento dos
na chapa de características do motor ou no respectivo
rolamentos, ver a chapa de características do motor.
catálogo, certifique-se de que não é ultrapassada a
É proibido alterar o tipo de rolamentos ou o método
velocidade de rotação máxima admissível para o motor
de isolamento sem autorização da ABB.
nem a velocidade crítica para toda a aplicação.
6.4.2 Eliminação de correntes nos

rolamentos com todos os outros 6.7 Motores em aplicações
conversores
O utilizador é responsável por proteger o motor e o
de velocidade variável
equipamento de transmissão contra correntes prejudiciais
nos rolamentos. Podem ser seguidas como uma 6.7.1 Geral
orientação geral as instruções contidas no capítulo 6.4.1, Nos casos em que são utilizados conversores de
mas a sua eficácia não pode ser garantida em todos os frequência da ABB, os motores podem ser dimensionados
casos. utilizando o programa de dimensionamento DriveSize
da ABB. É possível descarregar esta ferramenta a
partir da página da ABB na Internet (www.abb.com/
6.5 Cablagem, ligação à terra motors&generators).
e CEM Para aplicações alimentadas por outros conversores, os
Para proporcionarem uma ligação à terra adequada e para motores devem ser dimensionados através de um cálculo
garantirem a conformidade com quaisquer requisitos de manual. Para mais informações, contactar a ABB.
Compatibilidade Electromagnética (CEM) aplicáveis, os As curvas da capacidade de carga baseiam-se na tensão
motores acima dos 30 kW devem ser ligados utilizando de alimentação nominal. O funcionamento com tensões
cabos simétricos blindados e bucins CEM, ou seja, bucins superiores ou inferiores à tensão nominal pode influenciar o
para cabo que permitam uma ligação a 360°. desempenho da aplicação.
Os cabos simétricos e blindados também são altamente
recomendados para motores mais pequenos. Fazer
a ligação à terra em 360° nas entradas dos cabos da
forma descrita nas instruções para os bucins. Enrole as
blindagens dos cabos em feixes e ligue-os ao terminal/
barramento de terra mais próximo dentro da caixa de
terminais, caixa do conversor, etc.
6.7.2 Capacidade de carga do motor com 6.8 Chapas de características
conversores da série AC_8_ _ com
A utilização dos motores da ABB em aplicações com
controlo DTC
velocidade variável não exige normalmente chapas de
As curvas de capacidade de carga apresentadas nas características adicionais. Os parâmetros necessários para
Figuras 5a - 5d são válidas para os conversores da série a colocação em serviço do conversor estão indicados
AC_8_ _ da ABB com tensões CC não controladas e na chapa de características principal. No entanto, para
com controlo DTC. As figuras mostram o binário de saída algumas aplicações especiais, os motores podem ter
máximo contínuo aproximado dos motores em função da chapas de características adicionais para aplicações com
frequência da alimentação. O binário de saída é indicado velocidade variável. Essas chapas incluem as seguintes
como uma percentagem do binário nominal do motor. Os informações:
valores são apenas indicativos, podendo ser indicados
valores exactos a pedido. - limites de velocidade
- limites de potência
NOTA! - limites de tensão e corrente
A velocidade máxima do motor e da aplicação não - tipo de binário (constante ou quadrático)
deve ser ultrapassada! - e tipo de conversor e frequência mínima de comutação
necessária.
6.7.3 Capacidade de carga do motor com

conversores da série AC_5_ _
As curvas de capacidade de carga apresentadas nas
6.9 Colocação em serviço
Figuras 6a - 6d são válidas para a série de conversores da aplicação de velocidade
AC_5_ _. As figuras mostram o binário de saída máximo
contínuo aproximado dos motores em função da
variável
frequência da alimentação. O binário de saída é indicado
A colocação em serviço da aplicação de velocidade
como uma percentagem do binário nominal do motor. Os
variável deve ser feita de acordo com as instruções para
valores são apenas indicativos, podendo ser indicados
o conversor de frequência e as leis e regulamentos locais.
valores exactos a pedido.
Também devem ser tidos em consideração os requisitos e
limitações definidos pela aplicação.
NOTA!
A velocidade máxima do motor e da aplicação não Todos os parâmetros necessários para configurar
deve ser ultrapassada! o conversor têm de ser retirados das chapas de
características do motor. Os parâmetros frequentemente
mais necessários são:
6.7.4 Capacidade de carga do motor com
outros conversores de alimentação - tensão nominal
tipo PWM - corrente nominal
Para outros conversores, que têm uma tensão CC não - frequência nominal
controlada e uma frequência de comutação mínima de - velocidade nominal
3 kHz (200…500 V), as instruções de dimensionamento - potência nominal
indicadas no capítulo 6.7.3 podem ser utilizadas como
uma orientação geral. No entanto, deve ter-se em conta
que a capacidade de carga térmica real pode também NOTA!
ser inferior. Contacte o fabricante do conversor ou o No caso de informações em falta ou pouco precisas,
fornecedor do sistema. não colocar o motor a funcionar antes de comprovar
que as configurações estão correctas!
NOTA!
A capacidade de carga térmica real de um A ABB recomenda a utilização de todas as características
motor pode ser inferior à indicada pelas curvas protectoras adequadas fornecidas pelo conversor para
orientadoras. melhorar a segurança da aplicação. Os conversores têm
normalmente funções como (os nomes e disponibilidade
6.7.5 Sobrecargas de curta duração das funções dependem do fabricante e do modelo do
conversor):
Os motores da ABB podem normalmente suportar
sobrecargas temporárias e podem também ser utilizados
- velocidade mínima
com regimes de serviço intermitentes. O método mais
- velocidade máxima
adequado para dimensionar essas aplicações é utilizando
- tempos de aceleração e desaceleração
a ferramenta DriveSize.
- corrente máxima
- binário máximo
- protecção de bloqueio de motor
7. Manutenção funcionamento por qualquer razão, o veio deverá pelo
menos ser rodado à mão de modo a que fique numa
posição de repouso diferente, uma vez por semana. As
AVISO! vibrações provocadas pelos outros equipamentos do
Durante a paragem, a tensão pode ser ligada navio causam picadas (pitting) nos rolamentos, situação
dentro da caixa de terminais para elementos esta que deve ser evitada através da colocação em
de aquecimento ou aquecimento directo dos funcionamento/rotação manual regular.
enrolamentos. 2. Os rolamentos devem ser lubrificados ao mesmo tempo
que o veio é rodado, uma vez por ano (deve ser feito um
registo). Se o motor estiver equipado com rolamentos de
rolos no lado do veio motriz, o dispositivo de bloqueio
7.1 Inspecção geral para transporte tem de ser removido antes de se rodar o
1. Inspeccione o motor a intervalos regulares, pelo veio. O dispositivo de bloqueio para transporte deve ser
menos uma vez por ano. A frequência das inspecções novamente instalado se o motor for transportado.
depende, por exemplo, do nível de humidade do 3. Devem ser evitadas todas as vibrações para evitar
ar ambiente e das condições climatéricas locais. A danos e falhas dos rolamentos Devem ser seguidas
frequência das inspecções pode ser estabelecida todas as instruções contidas no manual de instruções
inicialmente de forma experimental e depois deve ser do motor, referentes à sua manutenção e colocação
estritamente respeitada. em serviço. A garantia não cobrirá danos causados aos
2. Manter o motor limpo e certificar-se de que o ar de enrolamentos e aos rolamentos se estas instruções não
ventilação circula livremente. Se o motor for utilizado em tiverem sido seguidas.
ambientes com muitas poeiras, o sistema de ventilação
deve ser verificado e limpo regularmente.
3. Verifique o estado dos vedantes do veio (por exemplo, 7.2 Lubrificação
anel em V ou vedante radial) e substitua-os, se
necessário.
AVISO!
4. Verifique o estado das ligações, a montagem e os
Cuidado com todas as peças rotativas!
parafusos de fixação.
5. Controle o estado dos rolamentos tentando detectar
quaisquer ruídos não habituais, medindo as vibrações,
medindo a temperatura dos rolamentos, inspeccionando AVISO!
a massa lubrificante gasta ou fazendo um controlo SPM Muitas massas podem provocar irritações da pele e
dos rolamentos. Preste especial atenção aos rolamentos inflamação dos olhos. Seguir todas as precauções
quando a sua vida útil nominal estiver a chegar ao fim. de segurança especificadas pelo fabricante da
massa.
Quando surgirem sinais de desgaste, desmonte o motor,
verifique as peças e substitua-as, se necessário. Ao
substituir os rolamentos, os rolamentos de substituição Os tipos dos rolamentos encontram-se especificados
devem ser do mesmo tipo dos originalmente instalados. nos catálogos dos produtos em questão e na chapa de
Quando se mudarem os rolamentos, os vedantes do veio características de todos os motores, excepto para os
têm de ser substituídos por vedantes da mesma qualidade motores de menores dimensões.
e características dos originais.
A fiabilidade é uma questão fundamental para os intervalos
No caso de motores com uma classe de protecção de lubrificação dos rolamentos. A ABB utiliza, para o seu
IP 55, e quando o motor tiver sido entregue com os bujões programa de lubrificação, sobretudo o princípio L1 (ou seja,
fechados, é aconselhável abrir os bujões de drenagem que 99% dos motores atingem o seu tempo de vida útil
periodicamente para garantir que a saída da condensação previsto).
não está bloqueada e permitir que a condensação saia
do motor. Esta operação tem de ser efectuada quando o
motor estiver parado e for seguro trabalhar nele. 7.2.1 Motores com rolamentos que não
necessitam de lubrificação
7.1.1 Motores de reserva Os rolamentos que não necessitam de lubrificação são dos
tipos 1Z, 2Z, 2RS ou equivalentes.
Se um motor estiver numa situação de reserva durante um
longo período de tempo num navio ou noutro ambiente Por norma, a lubrificação adequada para tamanhos
sujeito a vibrações, devem ser tomadas as seguintes até 250 pode ser atingida com os seguintes intervalos
medidas: de lubrificação, de acordo com L1. Para condições de
funcionamento com temperaturas ambiente superiores,
1. O veio deve ser rodado regularmente todas as 2 contactar a ABB. A fórmula para mudar os valores L1
semanas (deve ser feito um registo) pondo o sistema em aproximadamente para valores L10 é: L10 = 2.0 x L1.
funcionamento. Caso não seja possível pôr o motor em
As horas de funcionamento para rolamentos que não A. Lubrificação manual
necessitam de lubrificação a temperaturas ambiente de
25 °C e 40 °C são: Renovar a lubrificação com o motor em
funcionamento
Horas de Horas de – Remover o tampão de saída da massa ou abrir a válvula
Tamanho
da funcionamento funcionamento de fecho, se instalada.
estrutura Pólos a 25° C a 40° C – Certificar-se de que o canal de lubrificação está aberto.
56 2 52 000 33 000 – Injecte a quantidade especificada de massa lubrificante
56 4-8 65 000 41 000 no rolamento.
63 2 49 000 31 000
– Deixar o motor a funcionar durante 1 a 2 horas para
assegurar que todo o excesso de massa é forçado a sair
63 4-8 63 000 40 000
do rolamento. Fechar o tampão de saída da massa ou a
71 2 67 000 42 000
válvula de fecho, se instalada.
71 4-8 100 000 56 000
80-90 2 100 000 65 000 Renovar a lubrificação com o motor parado
80-90 4-8 100 000 96 000 Se não for possível renovar a lubrificação dos rolamentos
100-112 2 89 000 56 000 com os motores em funcionamento, a lubrificação pode
100-112 4-8 100 000 89 000 ser feita com o motor parado.
132 2 67 000 42 000 – Neste caso, utilize apenas metade da quantidade de
132 4-8 100 000 77 000 massa lubrificante e, em seguida, coloque o motor em
160 2 60 000 38 000 funcionamento durante alguns minutos, à velocidade
160 4-8 100 000 74 000
máxima.
– Quando o motor parar, aplique o resto da quantidade
180 2 55 000 34 000
especificada de massa no rolamento.
180 4-8 100 000 70 000
– Após 1 a 2 horas de funcionamento, feche o tampão de
200 2 41 000 25 000
saída da massa ou a válvula de fecho, se instalada.
200 4-8 95 000 60 000
225 2 36 000 23 000 B. Lubrificação automática
225 4-8 88 000 56 000
Quando é utilizada a lubrificação automática, o tampão de
250 2 31 000 20 000
saída da massa deve ser removido permanentemente, ou a
250 4-8 80 000 50 000
válvula de fecho, se instalada, deve ser deixada aberta.
Os dados são válidos até 60 Hz.
A ABB recomenda apenas a utilização de sistemas
electromecânicos.
7.2.2 Motores com rolamentos que
necessitam de lubrificação Se for utilizado um sistema de lubrificação central, deve ser
utilizado o triplo da quantidade de massa por intervalo de
Chapa de informações sobre lubrificação e lubrificação indicada no quadro. No caso de uma unidade
conselhos gerais sobre lubrificação mais pequena de renovação da lubrificação (um ou dois
Se o motor estiver equipado com uma chapa de cartuchos por motor), pode ser utilizada a quantidade
informações sobre lubrificação, respeite os valores normal de massa.
indicados.
Quando for utilizada uma lubrificação automática em
Na chapa de informações sobre lubrificação, estão motores com 2 pólos, deve ser seguida a nota sobre as
recomendações relativas aos lubrificantes para os motores
definidos os intervalos de lubrificação no que diz respeito com 2 pólos, no capítulo Lubrificantes.
à montagem, à temperatura ambiente e à velocidade de
rotação. A massa utilizada deve ser adequada para a lubrificação
automática. Devem ser consultadas as recomendações
Após o primeiro arranque ou após uma lubrificação dos do fornecedor e do fabricante do sistema, relativas à
rolamentos, pode surgir um aumento temporário da lubrificação automática.
temperatura, durante aproximadamente 10 a 20 horas de
funcionamento. Exemplo de cálculo da quantidade de massa para
sistema de lubrificação automática
Alguns motores poderão estar equipados com um colector
para massas lubrificantes usadas. Siga as instruções Sistema de lubrificação central: Motor CEI M3_P 315_ de
especiais dadas para o equipamento. 4 pólos em rede de 50 Hz, com o intervalo de renovação
da lubrificação especificado na Tabela 7600 h/55 g (DE) e
7600 h/40 g (NDE):
(DE) RLI = 55 g/7600 h*3*24 = 0,52 g/dia
(NDE) RLI = 40 g/7600*3*24 = 038 g/dia
Exemplo de cálculo da quantidade de massa para
unidade de lubrificação automática (cartucho)
(DE) RLI = 55 g/7600 h*24 = 0,17 g/dia
(NDE) RLI = 40 g/7600*24 = 0,13 g/dia

RLI = Intervalo de renovação de lubrificação, DE = Lado do
ataque, NDE = Lado oposto ao ataque
7.2.3 Intervalos de lubrificação e

quantidades de lubrificante
Os intervalos de lubrificação para motores verticais são
metade dos valores indicados na tabela abaixo.
Por norma, a lubrificação adequada pode ser atingida com

os seguintes intervalos de lubrificação, de acordo com
L1. Para condições de funcionamento com temperaturas
ambiente superiores, contactar a ABB. A fórmula
informativa para mudar os valores L1 para valores L10 é L10
= 2.0 x L1, com lubrificação manual.
Os intervalos de lubrificação baseiam-se na temperatura

de funcionamento dos rolamentos de 80 °C (temperatura
ambiente de +25 °C).
NOTA!
Um aumento na temperatura ambiente aumenta
respectivamente a temperatura dos rolamentos.
Os valores dos intervalos deverão ser reduzidos em
metade para um aumento de 15 °C na temperatura
dos rolamentos e deverão ser duplicados para
um decréscimo de 15 °C na temperatura dos
rolamentos.
Para um funcionamento a velocidade superior, ou seja, em

aplicações de conversores de frequência, ou a velocidade
inferior com carga pesada, serão necessários intervalos de
lubrificação mais reduzidos.
AVISO!
A temperatura máxima de funcionamento do
lubrificante e dos rolamentos, +110 ºC, não deve ser
excedida.
A velocidade máxima de concepção do motor não
deve ser excedida.
Quantidade
Tamanho 3600 3000 1800 1500 1000 500-900
de massa kW kW kW kW
do motor r/min r/min r/min r/min r/min r/min
g/rolamento
Rolamentos de esferas, intervalos de lubrificação em horas de serviço
112 10 todas 10 000 13 000 todas 18 000 21 000 todas 2 5 000 todas 28 000
132 15 todas 9 000 11 000 todas 17 000 19 000 todas 23 000 todas 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 todas 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 todas 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 todas 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 todas 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 todas 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 todas 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 todas 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 todas 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 todas 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 todas 7 000
2801) 60 todas 2 000 3 500 - - - - - - -
2801) 60 - - - todas 8 000 10 500 todas 14 000 todas 17 000
280 35 todas 1 900 3 200 - - - -
280 40 - - todas 7 800 9 600 todas 13 900 todas 15 000
315 35 todas 1 900 3 200 - - - -
355 35 todas 1 900 3 200 - - - -
400 40 todas 1 500 2 700 - - - -
450 40 todas 1 500 2 700 - - - -
Rolamentos de rolos, intervalos de lubrificação em horas de serviço

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 todas 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 todas 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 todas 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 todas 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 todas 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 todas 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 todas 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 todas 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 todas 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 todas 3 500
2801) 60 todas 1 000 1 750 - - - - - - -
2801) 70 - - - todas 4 000 5 250 todas 7 000 todas 8 500
280 35 todas 900 1 600 - - - -
315 35 todas 900 1 600 - - - -
355 35 todas 900 1 600 - - - -
400 40 todas - 1 300 - - - -
450 40 todas - 1 300 - - - -
1)
M3AA
7.2.4 Lubrificantes
NOTA!
Utilize sempre massa lubrificante para altas
AVISO! velocidades em motores com 2 pólos de alta
Não misturar diferentes tipos de massas velocidade em que o factor de velocidade é superior
lubrificantes. a 480 000 calculado como Dm x n onde
Lubrificantes incompatíveis poderão provocar danos Dm = diâmetro médio do rolamento, mm;
nos rolamentos. n = velocidade rotacional, r/min).
Ao renovar a lubrificação, utilizar unicamente massa As seguintes massas lubrificantes podem ser utilizadas
especial para rolamentos de esferas com as seguintes em motores de ferro fundido de alta velocidade, mas não
características: podem ser misturadas com massas de complexo de lítio:
– massa de boa qualidade com sabão de complexo de - Klüber Klüber Quiet BQH 72-102 (base de poliureia)
lítio e com óleo PAO ou mineral - Lubcon Turmogrease PU703 (base de poliureia)
– viscosidade do óleo de base 100-160 cST a 40 °C
– consistência NLGI de grau 1,5 - 3 *) Se forem utilizados outros lubrificantes, confirme com
– intervalo de temperatura entre -30 °C e +120 °C, o fabricante que as qualidades correspondem às dos
continuamente lubrificantes acima mencionados. Os intervalos de
lubrificação baseiam-se nas massas lubrificantes de
*) Para motores montados verticalmente ou em condições elevados desempenhos acima indicadas. A utilização de
de altas temperaturas, recomenda-se um valor superior outras massas lubrificantes poderá reduzir esses intervalos.
mais elevado.
A especificação para massas lubrificantes acima referida

é válida se a temperatura ambiente for superior a -30 °C
ou inferior a +55 °C e se a temperatura do rolamento
for inferior a 110 °C; caso contrário, consultar a ABB
relativamente à massa lubrificante adequada.
As massas com as características correctas podem ser

adquiridas junto de todos os principais fabricantes de
lubrificantes.
Recomendam-se que sejam usados aditivos, mas deve ser

obtida uma garantia por escrito por parte do fabricante,
especialmente no que respeita a aditivos EP, de que não
danificam os rolamentos nem alteram as propriedades dos
lubrificantes às temperaturas de funcionamento previstas.
AVISO!
Os lubrificantes que contêm aditivos EP não são
recomendados para temperaturas de rolamentos
elevadas em tamanhos de 280 a 450.
Podem ser utilizadas as seguintes massas lubrificantes de

elevado desempenho:
– Mobil Unirex N2 ou N3 (base de complexo de lítio)
– Mobil Mobilith SHC 100 (base de complexo de lítio)
– Shell Gadus S5 V 100 2 (base de complexo de lítio)
– Klüber Klüberplex BEM 41-132 (base de lítio especial)
– FAG Arcanol TEMP110 (base de complexo de lítio)
(base de lítio especial)
– Total Multiplex S2 A (base de complexo de lítio)
– Rhenus Rhenus LKZ 2 (base de complexo de litio)
8. Apoio pós-venda 9. Requisitos ambientais
A maior parte dos motores ABB tem um nível de pressão
8.1 Peças sobressalentes sonora que não excede os 82 dB(A) (± 3 dB) a 50 Hz.
As peças sobresselentes têm de ser peças originais ou Os valores para motores específicos encontram-se
aprovadas pela ABB, salvo especificação em contrário. indicados nos respectivos catálogos dos produtos. Para
Para encomendar peças sobresselentes, é necessário uma alimentação sinusoidal a 60 Hz, os valores são
indicar o número de série do motor, a designação aproximadamente 4 dB(A) mais elevados em comparação
completa do tipo e o código do produto, de acordo com com valores indicados para 50 Hz, nos catálogos dos
as indicações na chapa de características. produtos.
Para obter os níveis de pressão sonora para os sistemas

8.2 Desmontar, voltar a montar com alimentação com conversor de frequência, contacte a
ABB.
e rebobinar
Quando os motores ficam inutilizados ou vão para
A rebobinagem apenas deve ser feita em oficinas de reciclagem, devem ser respeitados os métodos
reparação qualificadas. apropriados e a regulamentação e legislação local.
Os motores utilizados para a exaustão de fumos e outros
motores especiais não deverão ser rebobinados sem
contactar primeiro a ABB.
8.3 Rolamentos
Os rolamentos exigem cuidados especiais.
Devem ser removidos com ferramentas de extracção e

devem ser instalados depois de aquecidos ou utilizando
ferramentas especiais.
A substituição dos rolamentos encontra-se descrita em

pormenor num folheto de instruções suplementar que
pode ser pedido à ABB.
Quaisquer indicações colocadas no motor, como por

exemplo etiquetas, têm de ser seguidas. Os tipos de
rolamentos indicados na chapa de características não
podem ser alterados.
NOTA!
Qualquer reparação efectuada pelo utilizador
final, a menos que seja expressamente aprovada
pelo fabricante, isenta o fabricante da sua
responsabilidade em relação à conformidade.
10. Resolução de problemas
Estas instruções não abrangem todos os pormenores ou
variações nos equipamentos nem incluem informações
sobre todas as possíveis situações relacionadas com
a instalação, funcionamento ou manutenção. Em caso
de necessidade de informações adicionais, contactar o
Departamento de Vendas da ABB mais próximo.
Quadro para resolução de problemas nos

motores
A manutenção do motor e qualquer resolução de
problemas deverão ser levadas a cabo por pessoas
qualificadas que disponham das ferramentas e
equipamento adequados.
PROBLEMA CAUSA O QUE FAZER

O motor não Fusíveis queimados Substituir os fusíveis por outros do mesmo tipo e classificação.
arranca Disparos por sobrecarga Verificar e rearmar o limitador de sobrecarga do arrancador.
Alimentação de energia inadequada Verificar se alimentação eléctrica está de acordo com a chapa de
características do motor e com o factor de carga.
Ligações da linha inadequadas Verificar se as ligações estão em conformidade com o diagrama
fornecido com o motor.
Circuito aberto no enrolamento ou no Indicado por um zumbido quando o interruptor é fechado. Verificar se
interruptor de controlo existem ligações soltas e se todos os contactos de controlo fecham
correctamente.
Avaria mecânica Verificar se o motor e a transmissão giram livremente.
Verificar os rolamentos e a lubrificação.
Estator em curto-circuito
Ligação da bobina do estator fraca Indicado por fusíveis queimados. O motor tem de ser rebobinado.
Retirar as tampas dos topos do motor e localizar a avaria.
Rotor avariado Procure barra ou anéis partidos.
O motor poderá estar em sobrecarga Reduzir a carga.
O motor pára em Uma fase poderá estar aberta Verificar as linhas para identificar a fase aberta.
carga Aplicação errada Mudar de tipo ou tamanho do motor. Consulte o fornecedor do
equipamento.
Sobrecarga Reduzir a carga.
Baixa tensão Certificar-se de que é mantida a tensão indicada na chapa de
características Verificar a ligação.
Circuito aberto Fusíveis queimados. Verificar o relé de sobrecarga, o estator e os
botões de pressão.
O motor arranca Falha de alimentação Verifique a existência de ligações soltas na linha, fusíveis e controlo.
e, depois, vai-se
abaixo
O motor não Motor mal seleccionado Consulte o fornecedor para ver qual o tipo correcto a utilizar.
acelera até à Tensão demasiado baixa nos terminais Utilize uma tensão mais elevada, ligue o motor mais perto dos
velocidade nominal do motor devido a queda de tensão na terminais do transformador ou reduza a carga.
linha Verifique as ligações. Verifique se os condutores têm o tamanho
adequado.
Carga inicial demasiado elevada Verificar o arranque do motor “sem carga”.
Barras do rotor partidas ou rotor solto Procure fissuras junto dos anéis. Poderá ser necessário um novo
rotor, uma vez que as reparações são, normalmente, apenas
temporárias.
Circuito principal aberto Localize a falha com um dispositivo de teste e repare-a.
PROBLEMA CAUSA O QUE FAZER
O motor demora Carga excessiva Reduzir a carga.
demasiado tempo Baixa tensão durante o arranque Verificar se existe uma resistência elevada. Certificar-se de que é
a acelerar e/ou utilizado um cabo de tamanho adequado.
tem um consumo
muito elevado Rotor em curto-circuito (gaiola de Substituir por um rotor novo.
esquilo) com defeito
Tensão aplicada demasiado baixa Corrigir a alimentação eléctrica.
Sentido de rotação Sequência de fases errada Inverta as ligações no motor ou no quadro eléctrico.
errado
O motor entra em Sobrecarga Reduzir a carga.
sobreaquecimento As aberturas da estrutura ou da Abrir os furos de ventilação e verificar se existe um fluxo de ar
durante o ventilação podem estar entupidas ou contínuo na saída de ar do motor.
funcionamento sujas e impedir a ventilação adequada
do motor
O motor poderá ter uma fase aberta Verificar para se certificar de que todos os cabos estão bem ligados.
Bobina com passagem à massa O motor tem de ser rebobinado.
Tensão desequilibrada nos terminais. Verificar se existem avarias nos cabos, nas ligações ou nos
transformadores.
O motor vibra Motor desalinhado Alinhar novamente.
Suporte fraco Reforçar a base.
Acoplamento desequilibrado Equilibrar o acoplamento.
Equipamento accionado desequilibrado Voltar a equilibrar o equipamento accionado.
Rolamentos avariados Substituir os rolamentos.
Rolamentos desalinhados Reparar o motor
Massas de equilibragem deslocadas Voltar a equilibrar o rotor.
Contradição entre o equilíbrio do rotor Voltar a equilibrar o acoplamento ou o rotor
e o acoplamento (meia chaveta –
chaveta completa)
Motor com várias fases a funcionar Verificar a existência de um circuito aberto.
com uma única fase
Folga axial excessiva Ajustar o rolamento ou adicionar um calço.
Ruídos de Ventilador a roçar na tampa do motor Corrigir a montagem do ventilador.
interferências ou do ventilador
mecânicas Motor solto da base Apertar os parafusos de fixação.
Funcionamento Folga não uniforme Verificar e corrigir a instalação das tampas de topo ou dos
ruidoso rolamentos.
Rotor desequilibrado Voltar a equilibrar o rotor.
Rolamentos Veio dobrado ou flectido Endireitar ou substituir o veio.
quentes Tracção excessiva da correia Reduzir a tensão da correia.
Polias demasiado afastadas do apoio Deslocar a polia para uma posição mais próxima do rolamento do
do veio motor.
Diâmetro da polia demasiado pequeno Utilizar polias maiores.
Desalinhamento Corrigir voltando a alinhar a transmissão.
Falta de lubrificação Manter a qualidade e quantidade adequada de lubrificante no
rolamento.
Deterioração da massa ou Remover a massa antiga, lavar bem os rolamentos em querosene e
contaminação do lubrificante lubrificar com massa nova.
Lubrificante em excesso Reduzir a quantidade de massa, o rolamento não deve estar cheio
com mais de metade da sua capacidade.
Rolamento em sobrecarga Verificar o alinhamento e o esforço radial e axial.
Esferas partidas ou caminhos de Substituir o rolamento, limpando bem primeiro a caixa do rolamento.
rolamento danificados ou gripados
Lågspänningsmotorer
Installations-, drifts-, underhålls- och säkerhetsmanual
Innehåll
1. Inledning ..................................................................................................................................125
1.1 EU-deklaration .................................................................................................................125
1.2 Giltighet ...........................................................................................................................125
2. Säkerhetsöverväganden ........................................................................................................125
3. Hantering .................................................................................................................................126
3.1 Ankomstkontroll...............................................................................................................126
3.2 Transport och lagring .......................................................................................................126
3.3 Lyft ..................................................................................................................................126
3.4 Motorns vikt ....................................................................................................................126
4. Installation och driftsättning ..................................................................................................127
4.1 Allmänt ............................................................................................................................127
4.2 Motorer med annat än kullager ........................................................................................127
4.3 Kontroll av isolationsresistansen.......................................................................................127
4.4 Fundament ......................................................................................................................127
4.5 Balansering och montering av kopplingshalvor och remskivor ..........................................128
4.6 Montering och uppriktning av motorn ..............................................................................128
4.7 Radialkrafter och remdrift .................................................................................................128
4.8 Motorer med dräneringspluggar för kondensvatten ..........................................................128
4.9 Kablage och elanslutningar ..............................................................................................128
4.9.1 Anslutningar för olika startmetoder ...................................................................129
4.9.2 Anslutning av hjälputrustning ............................................................................129
4.10 Uttag och rotationsriktning ...............................................................................................129
5. Drift ..........................................................................................................................................130
5.1 Allmänt ............................................................................................................................130
Handbok för lågspänningsmotor, 3GZF500730-85 Rev F 02-2015 | ABB Motorer och generatorer 123
6. Lågspänningsmotorer med omriktarmatning .....................................................................131
6.1 Inledning ..........................................................................................................................131
6.2 Lindningsisolering ............................................................................................................131
6.2.1 Val av lindningsisolering för ABB-omriktare .......................................................131
6.2.2 Val av lindningsisolering med övriga omriktare ..................................................131
6.3 Överhettningsskydd ........................................................................................................131
6.4 Lagerström ......................................................................................................................131
6.4.1 Eliminering av lagerströmmar med ABB-omriktare ............................................131
6.4.2 Eliminering av lagerströmmar med övriga omriktare ..........................................132
6.5 Kabelanslutningar, jordning och EMC...............................................................................132
6.6 Driftsvarvtal ......................................................................................................................132
6.7 Motorer i tillämpningar med omriktarmatning ...................................................................132
6.7.1 Allmänt .............................................................................................................132
6.7.2 Motorns belastbarhet med AC_8_ _-seriens omriktare med DTC-styrning ........132
6.7.3 Motorns belastbarhet med AC_5_ _ -seriens omriktare.....................................132
6.7.4 Motorns belastbarhet med andra spänningsomriktare av PWM-typ ..................132
6.7.5 Kortvarig överbelastning ...................................................................................133
6.8 Märkskyltar ......................................................................................................................133
6.9 Driftsättning av tillämpning med omriktarmatning .............................................................133
7. Underhåll..................................................................................................................................134
7.1 Allmän inspektion ............................................................................................................134
7.1.1 Standby-läge ...................................................................................................134
7.2 Smörjning ........................................................................................................................134
7.2.1 Motorer med permanentsmorda lager ..............................................................134
7.2.2 Motorer med smörjnipplar.................................................................................135
7.2.3 Smörjintervall och fettmängder .........................................................................135
7.2.4 Smörjmedel ......................................................................................................137
8. Eftermarknad...........................................................................................................................138
8.1 Reservdelar .....................................................................................................................138
8.2 Demontering, montering och omlindning .........................................................................138
8.3 Lager ...............................................................................................................................138
9. Miljökrav ..................................................................................................................................138
10. Felsökning ...............................................................................................................................139
124 ABB Motorer och generatorer | Handbok för lågspänningsmotor, 3GZF500730-85 Rev F 02-2015
1. Inledning 2. Säkerhetsöverväganden
Motorn ska installeras och användas av kvalificerad
OBS!
personal som fullt behärskar gällande hälso- och
Dessa regler måste följas för att garantera säker och
säkerhetsmässiga krav samt gällande nationell lagstiftning.
korrekt installation, funktion och underhåll. Dessa
regler måste delges varje person som installerar, Den säkerhetsutrustning som krävs för att förhindra olyckor
använder eller underhåller motorn eller tillhörande vid montering och användning ska användas i enlighet med
utrustning. Motorn ska installeras och användas av lokala föreskrifter.
kvalificerad personal som fullt behärskar gällande
hälso- och säkerhetsmässiga krav samt gällande
nationell lagstiftning. Att ignorera dessa regler kan VARNING!
upphäva samtliga tillämpliga garantier. Nödstoppsfunktioner måste vara utrustade med
omstartspärrar. Efter ett nödstopp kan ett nytt
startkommando inte utföras förrän omstartspärren
1.1 EU-deklaration avsiktligt har återställts.
När motorn monteras i en maskin måste slutproduktens

överensstämmelse med maskindirektivet 2006/42/EG
fastställas av den part som tar produkten i drift. Punkter som ska beaktas:
1. Klättra inte på motorn.
1.2 Giltighet 2. Temperaturen på motorns hölje kan kännas mycket hög
vid beröring även under normal drift och i synnerhet
Dessa anvisningar gäller för följande elektriska efter avstängning.
ABB-motorer, både i motor- och generatordrift: 3. För vissa speciella motortillämpningar kan ytterligare
instruktioner krävas (t.ex. vid frekvensomriktarmatning).
serierna MT*, MXMA,
4. Var uppmärksam på roterande motordelar.
serierna M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/
M3C*, M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, 5. Öppna inte uttagslådor som är spänningssatta.
M2R*/M3R*, M2V*/M3V*
i storlekarna 56–450.
Det finns en separat handbok för t.ex. Ex-motorer

kallad ”Low voltage motors for explosive atmospheres:
Installation, operation and maintenance and safety manual”
(3GZF500730-47).
Ytterligare information behövs för vissa motortyper på

grund av speciellt tillämpningsområde och/eller speciell
utformning.
Ytterligare handböcker finns för följande motorer:

– rullbanemotorer
– vattenkylda motorer
– rökgasventilerande motorer
– bromsmotorer
– motorer för höga omgivningstemperaturer
– motorer för marina tillämpningar för montering
på öppet däck
på fartyg eller offshoreenheter
3. Hantering Lyftöglorna måste vara väl åtdragna före lyft. Vid behov kan
lyftöglornas lägen justeras med hjälp av brickor.
3.1 Ankomstkontroll Kontrollera att korrekt lyftutrustning används och att

krokarnas storlek är anpassad till lyftöglorna.
Kontrollera omedelbart vid ankomsten att motorn inte
skadats under transporten (t.ex. axeltappar, flänsar och Var noga med att inte skada hjälputrustning och kablar som
målade ytor). Om den skadats ska speditören underrättas är anslutna till motorn.
om detta så snart som möjligt.
Avlägsna eventuella transportjiggar som fäster motorn till
Kontrollera samtliga märkskyltdata, särskilt spänning pallen.
och kopplingar (Y eller D). Lagertyp är specificerad
på märkskylten hos alla motorer utom för de minsta Specifika lyftanvisningar är tillgängliga från ABB.
storlekarna.
Vid användning av motorer med omriktarmatning, VARNING!

kontrollera maximal belastbarhet enligt frekvensen som Under lyftning, montering eller underhållsarbete
framgår av motorns tilläggsmärkskylt. måste alla nödvändiga säkerhetsåtgärder vara
vidtagna. Var särskilt noga med att ingen riskerar att
få fallande last över sig.
3.2 Transport och lagring
Motorer ska alltid förvaras inomhus (över –20 °C) under
torra, vibrations- och dammfria förhållanden. Undvik stötar, 3.4 Motorns vikt
fall och fuktighet under transport. Vid andra förhållanden,
kontakta ABB. Motorns totala vikt kan variera inom samma storlek
(axelhöjd) beroende på motoreffekt, monteringssätt och
Oskyddade bearbetade ytor (axeltappar och flänsar) skall hjälputrustning.
behandlas med rostskyddsmedel.
Följande tabell visar uppskattade maximala vikter för
Axeln bör vridas med jämna mellanrum för att förhindra att motorer i standardutförande, som en funktion av materialet
fettfilmen i lagren trängs igenom. i statorhuset.
Stilleståndsuppvärmning, om sådan finns installerad, Den faktiska vikten är specificerad på märkskylten på alla
rekommenderas för att undvika kondensvatten i motorn. ABB-motorer utom för de minsta storlekarna (56 och 63).
Motorn får inte utsättas för externa vibrationer vid Storlek Aluminium Gjutjärn Lägg till
stillastående, då detta kan skada lagren. för broms
Vikt kg Vikt kg
Motorer utrustade med rullager och/eller vinkelkontaktlager 56 4,5 - -
ska vara försedda med transportlåsning av rotorn under 63 6 - -
transport. 71 8 13 5
80 14 20 8
3.3 Lyft 90 20 30 10
100 32 40 16
Alla ABB-motorer över 25 kg är utrustade med lyftöglor. 112 36 50 20
132 93 90 30
Bara motorns huvudlyftöglor ska användas för lyft av
160 149 130 30
motorn. De får inte användas för att lyfta motorn när denna
180 162 190 45
är fäst vid annan utrustning.
200 245 275 55
Lyftöglor för hjälputrustning (t.ex. bromsar, separata 225 300 360 75
kylfläktar) eller uttagslådor får inte användas för lyft av 250 386 405 75
280 425 800 -
motorn. Motorns tyngdpunkt kan, trots samma storlek,
315 - 1 700 -
variera beroende på motoreffekter, monteringssätt och
355 - 2 700 -
hjälputrustning.
400 - 3 500 -
Skadade lyftöglor får inte användas. Kontrollera att 450 - 4 500 -
lyftöglorna på motorstativet är oskadade före lyft.
Om motorn är utrustad med separat kylning, fråga ABB
efter vikt.
4. Installation och driftsättning
VARNING! VARNING!
Frånskilj och lås motorn före arbete på den eller den Motorhöljet måste vara jordat och lindningarna
drivna utrustningen. måste laddas ur mot höljet omedelbart efter varje
mätning så att risken för elektriska stötar undviks.
4.1 Allmänt
Om referensresistansen inte kan uppnås är lindningen
Alla data på motorns märkskylt måste kontrolleras noggrant för fuktig och måste torkas i ugn. Ugnstemperaturen ska
för att säkerställa att motorskydd och anslutningar utförs vara 90 °C under 12–16 timmar, följt av 105 °C under 6–8
korrekt. timmar.
Om det finns pluggar i dräneringshålen måste dessa tas

4.2 Motorer med annat ur och stängningsventiler, om sådana finns, måste vara
än kullager öppna under uppvärmningen. Kom ihåg att sätta tillbaka
pluggarna efter värmningen. Även om dräneringspluggar
Avlägsna eventuell transportlåsning. Vrid om möjligt finns rekommenderas att lagersköldarnas och uttagslådans
motorns axel för hand för att kontrollera fri rotation. lock avmonteras före värmningen.
Lindningar som dränkts in med havsvatten måste normalt

Motorer utrustade med rullager: omlindas.
Om motorn körs utan radiell belastning på axeln kan
rullagret skadas på grund av ”glidning”. 4.4 Fundament
Motorer utrustade med vinkelkontaktlager: Slutanvändaren ansvarar för utförandet av fundamentet.
Om motorn körs utan axiell kraft applicerad i rätt riktning i Fundament av metall ska vara målade för att förhindra
förhållande till axeln kan vinkelkontaktlagret skadas. korrosion.
Fundamenten ska vara plana och tillräckligt stabila för att

VARNING! motstå kortslutningskrafterna.
För motorer med vinkelkontaktlager får den axiella
kraften under inga omständigheter ändra riktning. De ska vara utformade och dimensionerade så att
vibrationer inte överförs till motorn och så att vibrationer
inte uppstår på grund av egenresonans. Se figur nedan.
Lagertypen anges på märkskylten.
Linjal
Motorer utrustade med smörjnipplar:
Pressa in angiven minsta mängd fett när motorn startas
första gången eller efter lång tids förvaring.
Obs! Höjddifferensen får inte
Mer information finns i avsnitt ”7.2.2 Motorer med överstiga ± 0,1 mm mellan
smörjnipplar”. något av fotlägena
När en motor monteras i vertikalt läge med axeln nedåt

måste motorn ha ett skyddstak mot fallande föremål och
vätskor som annars kan hamna i ventilationsöppningarna.
Detta kan även uppnås med ett separat skyddstak som
inte är monterat på motorn. I detta fall måste det finnas en Fotlägen
varningsmärkning på motorn.
4.3 Kontroll av isolations-

resistansen
Mät isolationsresistansen före driftsättning och då
lindningarna kan misstänkas ha blivit fuktiga.
Isolationsresistansen, korrigerad till 25 °C, får under inga

omständigheter understiga 1 MΩ (mätt med 500 eller
1 000 VDC). Isolationsresistansens värde ska halveras för
var 20 °C höjning av temperaturen. Figur 1 kan användas
för isolationskorrigering till önskad temperatur.
4.5 Balansering och montering 4.7 Radialkrafter och remdrift
av kopplingshalvor och Spänn remmarna enligt anvisningarna från leverantören
remskivor av den drivna utrustningen. Överskrid dock inte maximal
remkraft (tillåten radiell kraft på lagret) angiven i tillämplig
Balansering av motorn har som standard utförts med halv produktkatalog.
kil.
Kopplingshalvor och remskivor måste balanseras efter att VARNING!

kilspåret har dragits. Balanseringen måste utföras med den För hög remspänning skadar lagren och kan orsaka
balanseringsmetod som är angiven för motorn. axelskador.
Kopplingshalvor och remskivor ska monteras på axeln med

hjälp av lämplig utrustning och verktyg som inte skadar
lagren och tätningarna. 4.8 Motorer med dränerings-
Montera aldrig en kopplingshalva eller remskiva genom att pluggar för kondensvatten
slå på den och demontera den aldrig genom att ta spjärn
Kontrollera att dräneringshål och pluggar är riktade nedåt.
mot motorn och bryta.
För vertikalt monterade motorer kan dräneringspluggarna
vara i horisontellt läge.
4.6 Montering och uppriktning Motorer med ställbara plastpluggar i dräneringshålen
av motorn levereras med dessa öppna. I extremt dammiga miljöer ska
alla dräneringshål vara stängda.
Se till att det finns tillräckligt med utrymme omkring motorn
så att luften kan strömma fritt. Vi rekommenderar att det
finns ett avstånd mellan fläktkåpan och väggen osv. på 4.9 Kablage och elanslutningar
minst ½ av fläktkåpans luftintag. Ytterligare information
finns i produktkatalogen eller i dimensionsritningarna på Uttagslådan till en enhastighetsmotor av standardtyp
våra webbsidor: www.abb.com/motors&generators. innehåller normalt sex lindningsuttag och minst ett jordat
uttag.
Korrekt uppriktning krävs så att lagerhaverier, vibrationer
och axeltappsbrott undviks. Förutom uttag för huvudlindning och jord kan uttagslådan
också innehålla uttag för termistorer, värmeelement eller
Montera motorn på fundamentet med lämpliga bultar eller andra hjälpenheter.
klotsar och placera mellanläggsplåtar mellan fundamentet
och foten. Lämpliga kabelskor måste användas för anslutning av
samtliga huvudkablar. Kablar för hjälputrustning kan
Rikta upp motorn med lämplig metod. anslutas som de är till respektive plint.
Borra styrhål och fäst styrpinnarna på plats om det behövs. Motorerna är enbart avsedda för fast installation. Gängor
för kabelgenomföringar är metriska om inget annat anges.
Krav på kopplingshalvans monteringsnoggrannhet: Kabelförskruvningens IP-klass måste vara minst samma
kontrollera att frigången b är mindre än 0,05 mm och att som uttagslådornas.
skillnaden mellan a1 och a2 också är mindre än 0,05 mm.
Se figur 2. Ett certifierat ledningsnav eller kabelkontakt måste
användas vid installationstillfället.
Kontrollera uppriktningen på nytt efter en sista åtdragning
av bultar eller klotsar.
OBS!
Överskrid inte lagrens tillåtna belastningar som finns Kablarna ska ha mekaniskt skydd och ska
angivna i produktkatalogerna. vara fixerade nära uttagslådan för att uppfylla
tillämpliga krav i IEC/EN 60079-0 och lokala
Kontrollera att motorn får tillräckligt med kylluft. Säkerställ
installationsföreskrifter.
att ingen angränsande utrustning eller direkt solljus strålar
ytterligare värme mot motorn.
Se till att konstruktionen tillåter tillräckligt luftflöde på Kabelgenomföringar som inte används ska förslutas med
utsidan av flänsen för motorer med flänsmontering (t.ex. skyddsproppar i enlighet med uttagslådans IP-klass.
B5, B35, V1).
Kapslingsklass och diameter anges i de dokument som
medföljer kabelförskruvningen.
4.9.1 Anslutningar för olika startmetoder
VARNING!
Använd rätt kabelförskruvningar och tätningar i Uttagslådan till en enhastighetsmotor av standardtyp
kabelgenomföringarna beroende på kabelns typ och innehåller normalt sex lindningsuttag och minst ett jordat
diameter. uttag. Detta möjliggör användning av direktstart (DOL) eller
Y/D-start.
För tvåhastighetsmotorer och specialmotorer måste

Motorn ska anslutas till jord enligt gällande bestämmelser anslutningen till nätet göras enligt anvisningarna i
innan den ansluts till nätet. uttagslådan eller motorhandboken.
Det jordade uttaget på stommen måste anslutas till PE Spänning och anslutning framgår av märkskylten.
(skyddsjord) med kabel som visas i tabell 5 för IEC/EN
60034-1: Direktstart (DOL):
Y- eller D-lindningsanslutningar kan användas.
Minsta tvärsnittsarea för skyddsledare
690 VY, 400 VD indikerar t.ex. Y-anslutning för 690 V och
Tvärsnittsarea för Minsta tvärsnittsarea för
motsvarande skyddsledare,
D-anslutning för 400 V.
installationens fasledare,
S, [mm2] SP, [mm2]
Y/D-start:
4 4
6 6 Nätspänningen måste vara lika med motorns
10 10 märkspänning när D-anslutning används.
16 16
Alla kopplingsbleck ska tas bort från plinten.
25 25
35 25 Andra startmetoder och svårare startförhållanden:
50 25
Ifall andra startmetoder, t.ex. omriktare eller mjukstartare,
70 35
ska användas i S1- och S2-driftfall anses enheten
95 50
vara ”isolerad från kraftsystemet när den elektriska
120 70
maskinen körs” enligt standarden IEC 60079-0 och
150 70
överhettningsskydd är valfritt.
185 95
240 120
300 150 4.9.2 Anslutning av hjälputrustning
400 185
Om en motor är utrustad med termistorer eller andra
Dessutom måste jordnings- och förbindningsanslutningar motståndstemperaturgivare (Pt100, termiska reläer,
utanför den elektriska apparaturen ge effektiv anslutning för osv.) och hjälpenheter måste de användas och
en ledare med en tvärsnittsarea på minst 4 mm2. anslutas på lämpligt sätt. För vissa applikationer måste
överhettningsskydd användas. Mer utförlig information
Kabelanslutningen mellan nätverket och finns i dokumentationen som levereras med motorn.
motoranslutningarna måste uppfylla kraven som anges Anslutningsscheman för hjälpfunktioner och uttag finns i
i nationella normer för installation eller i standarden IEC/ uttagslådan.
EN 60204-1 enligt nominell strömstyrka indikerad på
märkskylten. Maximal mätspänning för termistorerna är 2,5 V. Maximal
mätström för Pt100 är 5 mA. Om högre mätspänning
OBS! eller mätström används kan avläsningsfel eller skador på
När omgivningstemperaturen överstiger +50 °C temperaturdetektorn uppstå.
måste kablar med en tillåten arbetstemperatur Isoleringen av termiska givare uppfyller grundläggande
på minst +90 °C användas. Dessutom måste isoleringskrav.
alla övriga omvandlingsfaktorer beroende på
installationsförhållandena beaktas när kablarna
dimensioneras.
4.10 Uttag och rotationsriktning
Se till att motorns kapsling motsvarar aktuell miljö och Axeln roterar medurs sett mot axeländen på drivsidan, och
rådande väderförhållanden. Se till exempel till att vatten inte linjefasföljd - L1, L2, L3 – ansluts till terminalerna såsom
kan tränga in i motorn eller uttagslådorna. visas i figur 1.
Tätningarna för uttagslådorna måste placeras på rätt sätt i Låt två av matningskablarna byta plats om rotations-
de förberedda skårorna för att säkerställa rätt IP-klass. Ett riktningen ska ändras.
läckage kan leda till att damm eller vatten tränger in, vilket
innebär risk för överslag i spänningsförande delar. Om motorn har en rotationsberoende fläkt ska rotations-
riktningen överensstämma med pilen på motorn.
5. Drift
5.1 Allmänt
Motorerna är avsedda att användas under följande
förhållanden såvida inget annat anges på märkskylten.
- Motorerna är enbart avsedda för fast installation.

- Gränserna för normal omgivningstemperatur är från
–20 °C till +40 °C.
- Maximal höjd över havet är 1 000 m.
- Variationen av nätspänning och frekvens får inte
överstiga de gränser som anges i relevanta standarder.
Toleransen för nätspänning är ±5 % och för frekvens
± 2% i enlighet med figur 4 (EN/IEC 60034-1, paragraf
7.3, zon A). Båda extremvärdena är inte tänkta att
inträffa samtidigt.
Motorn får endast användas i tillämpningar som den är

avsedd för. Märkvärden och driftsförhållanden visas på
motorns märkskyltar. Dessutom måste alla krav som anges
i denna handbok och övriga tillhörande instruktioner och
normer följas.
Om dessa gränser överskrids måste motor- och

konstruktionsdata kontrolleras. Vänligen kontakta ABB.
VARNING!
Om instruktioner för eller underhåll av apparaten
ignoreras kan säkerheten äventyras och motorn kan
då inte användas.
6. Lågspänningsmotorer med omriktarmatning
6.1 Inledning 6.2.2 Val av lindningsisolering med övriga
omriktare
I den här delen av handboken finns ytterligare instruktioner
för motorer som används med frekvensomriktarmatningar. De elektriska fältstyrkorna måste understiga godkända
Motorn är avsedd att drivas från en enskild frekvens- gränser. Kontakta systemets konstruktör för att säkerställa
omriktarmatning och inte motorer som körs parallellt från tillämpningens säkerhet. Hänsyn måste tas till inverkan av
en frekvensomriktare. Följ anvisningarna från tillverkaren av eventuella filter vid dimensionering av motorn.
omriktaren.
Ytterligare information kan behövas från ABB för att

avgöra hur lämpligt det är att använda vissa motortyper
6.3 Överhettningsskydd
i specialtillämpningar eller med specialutformade De flesta motorer som omfattas av den här handboken är
modifieringar. utrustade med PTC-termistorer eller annan typ av RTD i
statorlindningarna. Vi rekommenderar att dessa ansluts till
frekvensomriktaren. Läs mer i kapitel 4.9.2.
6.2 Lindningsisolering
Omriktarmatning skapar högre fältstyrka i motorlindningen
än sinusmatning och därför måste såväl motorns lindnings-
6.4 Lagerström
isolering som filtret vid omriktarens utgång dimensioneras Isolerade lager eller lagerkonstruktioner, CM-filter (common
enligt nedanstående anvisningar. mode) och lämpliga kabel- och jordningsmetoder måste
användas enligt nedanstående anvisningar och tabell 6.1.
6.2.1 Val av lindningsisolering för
ABB-omriktare 6.4.1 Eliminering av lagerströmmar med
För singeldrift av t.ex. ABB AC_8_ _- och AC_5_ _-serierna
ABB-omriktare
med diodmatningsenhet (oreglerad likspänning) kan valet För ABB-frekvensomriktare i t.ex. AC_8_ _- och AC_5_ _
av lindningsisolering och filter göras enligt tabell 6.1. -serien med diodmatningsenhet måste metoderna i
tabell 6.1 användas för att undvika skadlig lagerström i
motorerna.
PN < 100 kW PN ≥ 100 kW eller PN ≥ 350 kW eller

IEC315 ≤ Storlek ≤ IEC355 IEC400 ≤ Storlek ≤ IEC450
UN ≤ 500 V Standardmotor Standardmotor Standardmotor
+ Isolerande N-lager + Isolerande N-lager
+ CM-filter
500 V >UN ≤ 600 V Standardmotor Standardmotor Standardmotor
+ dU/dt-filter (reaktor) + dU/dt-filter (reaktor) + Isolerande N-lager
ELLER + Isolerande N-lager + dU/dt-filter (reaktor)
Förstärkt isolering ELLER + CM-filter
Förstärkt isolering ELLER
+ Isolerande N-lager Förstärkt isolering
+ Isolerande N-lager
+ CM-filter
500 V >UN ≤ 600 V Standardmotor Standardmotor Standardmotor
(kabellängd > 150 m) + Isolerande N-lager + Isolerande N-lager
+ CM-filter
600 V >UN ≤ 690 V Förstärkt isolering Förstärkt isolering Förstärkt isolering

+ dU/dt-filter (reaktor) + dU/dt-filter (reaktor) + Isolerande N-lager
+ Isolerande N-lager + dU/dt-filter (reaktor)
+ CM-filter
600 V >UN ≤ 690 V Förstärkt isolering Förstärkt isolering Förstärkt isolering
(kabellängd > 150 m) + Isolerande N-lager + Isolerande N-lager
+ CM-filter
Tabell 6.1 Val av lindningsisolering för ABB-omriktare
Kontakta ABB för mer information om motståndsbromsning och omriktare med kontrollerade matningsenheter.
OBS! 6.7 Motorer i tillämpningar
Isolerade lager med aluminiumoxidbelagda inre med omriktarmatning
och/eller yttre lopp eller keramiska rullningselement
rekommenderas. Aluminiumoxidbeläggningarna
ska även behandlas med ett tätningsmedel så 6.7.1 Allmänt
att inte smuts och fukt tränger ned i den porösa Med ABB:s frekvensomriktare kan motorerna
beläggningen. Exakt typ av lagerisolering anges på dimensioneras med hjälp av ABB:s dimensionerings-
märkskylten. Det är inte tillåtet att ändra lagertyp eller program DriveSize. Verktyget kan hämtas på ABB:s
isoleringsmetod utan tillstånd från ABB. webbplats (www.abb.com/motors&generators).
För tillämpningar med matning från andra omriktare måste

6.4.2 Eliminering av lagerströmmar med motorerna dimensioneras manuellt. Kontakta ABB för mer
övriga omriktare information.
Det är användarens ansvar att skydda motorn och driven
Belastbarhetskurvorna (eller lastkapacitetskurvorna) är
utrustning från skadliga lagerströmmar. Anvisningarna i
baserade på nominell nätspänning. Drift med under- eller
kapitel 6.4.1 kan användas som riktlinjer men det är inte
överspänning kan påverka tillämpningens prestanda.
säkert att de fungerar i enskilda fall.
6.7.2 Motorns belastbarhet med

6.5 Kabelanslutningar, jordning AC_8_ _-seriens omriktare med
och EMC DTC-styrning
De belastbarhetskurvor som presenteras i Figurerna 5a -
För tillräckligt jordningsskydd och överensstämmelse 5d gäller för ABB AC_8_ _-seriens omriktare med oreglerad
med gällande EMC-krav ska motorer över 30 kW likspänning och DTC-styrning. I figurerna visas ungefärligt
anslutas med skärmade symmetriska kablar och EMC- maximalt kontinuerligt utmoment hos motorerna som en
kabelförskruvningar, dvs. kabelförskruvningar som ger 360° funktion av matningsfrekvensen. Utmomentet anges som
förbindning. ett procentuellt värde av motorns märkmoment. Värdena är
Symmetriska och skärmade kablar rekommenderas starkt indikativa och exakta värden kan fås på begäran.
även för mindre motorer. Utför 360°-jordningen vid alla
kabelingångar enligt beskrivningen i anvisningarna för OBS!
kabelförskruvningarna. Tvinna kabelskärmarna till buntar Motorns och tillämpningens maximala varvtal får inte
och anslut till närmaste jordningsterminal/samlingsskena i överskridas!
uttagslåda, frekvensomriktarskåp eller liknande.
OBS! 6.7.3 Motorns belastbarhet med

Lämpliga kabelförskruvningar som ger 360° AC_5_ _ -seriens omriktare
förbindning måste användas vid alla terminerings- De belastbarhetskurvor som presenteras i Figurerna 6a -
punkter, t.ex. vid motor, omriktare, ev. säkerhets- 6d gäller för omriktare i AC_5_ _ -serien. I figurerna visas
brytare, m.m. ungefärligt maximalt kontinuerligt utmoment hos motorerna
som en funktion av matningsfrekvensen. Utmomentet
Motorer med storleken IEC 280 eller större måste ha anges som ett procentuellt värde av motorns märkmoment.
ytterligare potentialutjämning mellan motorhöljet och Värdena är indikativa och exakta värden kan fås på
den drivna utrustningen om inte båda är monterade begäran.
på ett gemensamt stålfundament. I det senare fallet
bör anslutningens högfrekvensledningsförmåga som OBS!
stålfundamentet ger kontrolleras, t.ex. genom mätning av Motorns och tillämpningens maximala varvtal får inte
potentialskillnaden mellan komponenterna. överskridas!
Mer information om jordning och ledningsanslutning
för motorer med omriktarmatning finns i handboken
”Grounding and cabling of the drive system” (kod: 3AFY 6.7.4 Motorns belastbarhet med andra
61201998). spänningsomriktare av PWM-typ
För andra omriktare som har oreglerad likspänning och
en minsta kopplingsfrekvens på 3 kHz (200…500 V) kan
6.6 Driftsvarvtal dimensioneringsanvisningarna i kapitel 6.7.3 användas
som riktlinjer, men tänk på att den verkliga termiska
Vid högre varvtal än det som anges på motorns märkskylt
belastbarheten kan vara lägre. Kontakta omriktarens
eller i respektive produktkatalog får varken motorns högsta
tillverkare eller systemleverantören.
tillåtna varvtal eller hela tillämpningens kritiska varvtal
överskridas.
OBS!
6.9 Driftsättning av tillämpning
Motorns faktiska termiska belastbarhet kan vara med omriktarmatning
lägre än vad som visas i riktlinjekurvorna.
Driftsättning av en tillämpning med omriktarmatning måste
utföras enligt anvisningarna för frekvensomriktaren samt
6.7.5 Kortvarig överbelastning lokala lagar och föreskrifter. Hänsyn måste även tas till de
krav och gränser som ställs av tillämpningen.
ABB-motorer kan normalt överbelastas och även användas
för intermittent drift. Det smidigaste sättet att dimensionera Alla parametrar som krävs för inställning av omriktaren
sådana tillämpningar är att använda DriveSize-verktyget. måste hämtas från motorns märkskyltar. De parametrar
som oftast behövs är:
6.8 Märkskyltar - märkspänning
Användning av ABB-motorer i tillämpningar med - märkström
omriktarmatning kräver normalt inte extra märkskyltar. De - märkfrekvens
parametrar som krävs för driftsättning av omriktaren finns - märkvarvtal
på huvudmärkskylten. I vissa specialtillämpningar kan - märkeffekt
motorerna dock utrustas med ytterligare märkskyltar för
tillämpningar med omriktarmatning och dessa innehåller
följande information: OBS!
Om information saknas eller är felaktig ska motorn
- varvtalsområde inte användas förrän korrekta inställningar gjorts!
- effektområde
- spännings- och strömområde
- typ av moment (konstant eller kvadratiskt) ABB rekommenderar att omriktarens alla lämpliga
- och typ av omriktare och minsta tillåtna skyddsfunktioner används för att förbättra tillämpningens
kopplingsfrekvens. säkerhet. Exempel på vanliga funktioner hos omriktare
(funktionernas namn och tillgänglighet beror på omriktarens
tillverkare och modell):
- lägsta varvtal
- högsta varvtal
- accelerations- och retardationstider
- högsta strömstyrka
- högsta moment
- skydd mot fastlåsning
7. Underhåll 2. Lagret måste smörjas medan axeln roteras varje år (ska
rapporteras). Om motorn försetts med ett rullager vid
den drivna änden måste transportlåset tas bort innan
VARNING! axeln roteras. Transportlåset måste sättas tillbaka vid
Även om motorn står stilla kan spänning för transport.
värmeelement eller direktvärmning av lindningen 3. Alla slags vibrationer måste undvikas för att undvika
finnas ansluten i uttagslådan. lagerfel. Dessutom måste alla anvisningar i motorns
instruktionshandbok för driftsättning och underhåll följas.
Garantin täcker inte lindnings- och lagerskador om
dessa anvisningar inte följts.
7.1 Allmän inspektion
1. Inspektera motorn regelbundet, minst en gång om
året. Vilket kontrollintervall som behövs beror bl.a. 7.2 Smörjning
på fukthalten i den omgivande luften och lokala
väderförhållanden. Intervallet skall bestämmas
experimentellt, varefter det ska följas strikt. VARNING!
2. Håll motorn ren och se till att ventilationsluften kan Se upp för roterande delar!
strömma fritt. Om motorn används i dammig miljö
skall ventilationssystemet regelbundet kontrolleras och
rengöras. VARNING!
3. Kontrollera axeltätningarnas kondition (t.ex. V-ring eller Fett kan förorsaka hudirritation och
radialtätning) och ersätt dem om det är nödvändigt. ögoninflammation. Följ alla säkerhetsföreskrifter som
angivits av fettleverantören.
4. Kontrollera nätanslutningarnas tillstånd och alla skruvar
för uppställning och montage.
5. Kontrollera lagrens tillstånd genom att lyssna efter Lagertyper finns angivna i respektive produktkatalog samt
främmande ljud, utföra vibrationsmätning, mäta lagrens på märkskylten för alla motorer utom de minsta storlekarna.
temperatur, inspektera det använda fettet eller utnyttja
SPM lagerövervakning. Speciell uppmärksamhet bör Tillförlitligheten kommer i första hand vid val av
iakttas angående lagren, när den beräknade angivna lagersmörjningsintervall. ABB tillämpar L1-principen (dvs. att
lagerlivslängden närmar sig sitt slut. 99 % av motorerna ska klara livslängden) för smörjning.
Om förslitningsskador upptäcks ska motorn demonteras
och alla delar kontrolleras och vid behov ersättas. När 7.2.1 Motorer med permanentsmorda lager
lagren byts måste ersättningslagren vara av samma typ Lagren är permanentsmorda och vanligtvis av typ 1Z, 2Z,
som originallagren. Vid byte av axeltätningar måste dessa 2RS eller motsvarande.
ersättas med tätningar av samma kvalitet och med samma
egenskaper som originalen. Som riktvärde gäller att tillräcklig smörjning för storlekar upp
till 250 kan uppnås under följande tid, enligt L1. Kontakta
Om en IP 55-motor som har levererats med stängd ABB för drift i högre omgivningstemperaturer. Formel för att
dräneringsplugg bör pluggen öppnas regelbundet så att grovt ändra L1-värdena till L10-värden: L10 = 2,0 x L1.
kondensvatten kan rinna ut ur motorn och inte bli kvar.
Motorn ska vara avstängd och ha gjorts arbetssäker innan
detta utförs.
7.1.1 Standby-läge
Om en motor står i standby-läge en längre tid på ett fartyg
eller i någon annan vibrerande miljö måste följande åtgärder
vidtas:
1. Axeln måste roteras minst varannan vecka (ska

rapporteras) genom att systemet startas. Om start
av någon anledning inte är möjlig måste axeln roteras
för hand så att dess position ändras minst en gång i
veckan. Vibrationer från utrustning i omgivningen orsakar
ytutmattning på lagren, vilket måste minimeras genom
regelbunden rotation.
Driftstimmar för permanentsmorda lager vid Smörjning när motorn står stilla
omgivningstemperaturerna 25 och 40 °C är: Om det inte är möjligt att smörja lagren medan motorn
arbetar kan de istället smörjas under stillestånd.
Driftstimmar Driftstimmar – Använd i så fall endast halva fettmängden och låt därefter
Storlek Poler vid 25 °C vid 40 °C motorn gå några minuter med högsta hastighet.
56 2 52 000 33 000 – Tryck in resten av angiven mängd fett i lagret när motorn
56 4–8 65 000 41 000 har stannat.
63 2 49 000 31 000 – Stäng fettutloppspluggen eller stängningsventilen, om
63 4–8 63 000 40 000 sådan finns, efter 1–2 timmars körning.
71 2 67 000 42 000 B. Automatisk smörjning
71 4–8 100 000 56 000
80–90 2 100 000 65 000 Vid automatisk smörjning ska fettutloppspluggen avlägsnas
80–90 4–8 100 000 96 000 permanent och en ev. stängningsventil ska vara öppen.
100–112 2 89 000 56 000
ABB rekommenderar endast användning av
100–112 4–8 100 000 89 000
elektromekaniska system.
132 2 67 000 42 000
132 4–8 100 000 77 000 De fettmängder per smörjintervall som anges i tabellen ska
160 2 60 000 38 000 multipliceras med tre om centralsmörjsystem används. När
160 4–8 100 000 74 000 en mindre automatisk smörjenhet (en eller två patroner per
180 2 55 000 34 000 motor) används kan den normala fettmängden användas.
180 4–8 100 000 70 000
Om tvåpoliga motorer smörjs automatiskt ska
200 2 41 000 25 000
fettrekommendationerna för tvåpoliga motorer i kapitlet
200 4–8 95 000 60 000 Smörjmedel följas.
225 2 36 000 23 000
225 4–8 88 000 56 000 Smörjmedlet ska vara lämpligt för automatisk smörjning.
250 2 31 000 20 000 Följ rekommendationerna från leverantören av det
250 4–8 80 000 50 000 automatiska smörjsystemet och fettillverkaren.
Data gäller upp till 60 Hz. Räkneexempel för mängd smörjmedel för ett
automatiskt smörjsystem
7.2.2 Motorer med smörjnipplar Centralsmörjsystem: Motor IEC M3_P 315_ 4-polig i
50 Hz-nät, smörjintervall enligt tabellen är 7 600 h/55 g (DE)
Smörjinformationsskylt och allmänna smörjningsråd och 7 600 h/40 g (NDE):
Om motorn är försedd med en informationsskylt för
(DE) RLI = 55 g/7 600 h*3*24 = 0,52 g/dag
smörjning ska denna följas.
På smörjinformationsskylten anges smörjintervall med (NDE) RLI = 40 g/7 600 h*3*24 = 0,38 g/dag
hänsyn tagen till monteringssätt, omgivningstemperatur
Räkneexempel för fettmängd för en enkel automatisk
och varvtal.
smörjenhet (patron)
Vid första start eller efter en lagersmörjning kan en tillfällig (DE) RLI = 55 g/7 600 h*24 = 0,17 g/dag
temperaturhöjning uppstå under cirka 10 till 20 timmar.
(NDE) RLI = 40 g/7 600 h*24 = 0,13 g/dag
En del motorer kan vara försedda med en uppsamlare för
gammalt fett. Följ i så fall de särskilda instruktionerna för RLI = smörjintervall, DE = drivande ände, NDE = icke-drivande
denna utrustning. ände
A. Manuell smörjning
7.2.3 Smörjintervall och fettmängder
Smörjning medan motorn är igång
– Ta bort fettutloppspluggen eller öppna stängningsventilen Smörjintervallen för vertikalt monterade motorer är hälften
om sådan finns. av angivna värden i tabellen nedan.
– Se till att smörjkanalen är öppen. Som riktvärde gäller att tillräcklig smörjning kan uppnås
– Pressa in angiven mängd fett i lagret. under följande tid, enligt L1. Kontakta ABB för drift i högre
– Låt motorn arbeta 1–2 timmar så att allt överskottsfett omgivningstemperaturer. Formeln för att grovt ändra
garanterat har trängt ut ur lagret. Stäng fettutlopps- L1-värdena till L10-värden lyder L10 = 2,0 x L1, med manuell
pluggen eller stängningsventilen om sådan finns. smörjning.
Smörjintervallerna är baserade på en arbetstemperatur i

lagret av 80 °C (omgivningstemperatur cirka +25 °C).
Högvarvsdrifter, t.ex. frekvensomriktardrifter, eller lägre
OBS! varvtal vid stor last kräver kortare smörjintervall.
En höjning av omgivningstemperaturen medför
en motsvarande höjning av temperaturen i lagret.
VARNING!
Intervallvärdena i tabellen bör halveras för 15 °C
Den maximala arbetstemperaturen för fett och lager,
ökning av lagertemperaturen och bör fördubblas för
+110 °C, får inte överskridas.
15 °C minskning av lagertemperaturen.
Det maximala varvtal motorn är konstruerad för får ej
överskridas.
Mängd
Stomme 3 600 3 000 1 800 1 500 1 000 500–900
smörjfett kW kW kW kW
storlek r/min r/min r/min r/min r/min r/min
g/lager
Kullager, smörjintervall i driftstimmar
112 10 alla 10 000 13 000 alla 18 000 21 000 alla 25 000 alla 28 000
132 15 alla 9 000 11 000 alla 17 000 19 000 alla 23 000 alla 26 500
160 25 ≤ 18,5 9 000 12 000 ≤ 15 18 000 21 500 ≤ 11 24 000 alla 24 000
160 25 > 18,5 7 500 10 000 ≤ 15 15 000 18 000 > 11 22 500 alla 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 alla 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 ≤ 15 21 000 alla 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 alla 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 alla 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 alla 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 alla 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 alla 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 alla 7 000
2801) 60 alla 2 000 3 500 - - - - - - -
2801) 60 - - - alla 8 000 10 500 alla 14 000 alla 17 000
280 35 alla 1 900 3 200 - - - -
280 40 - - alla 7 800 9 600 alla 13 900 alla 15 000
315 35 alla 1 900 3 200 - - - -
315 55 - - alla 5 900 7 600 alla 11 800 alla 12 900
355 35 alla 1 900 3 200 - - - -
355 70 - - alla 4 000 5 600 alla 9 600 alla 10 700
400 40 alla 1 500 2 700 - - - -
400 85 - - alla 3 200 4 700 alla 8 600 alla 9 700
450 40 alla 1 500 2 700 - - - -
450 95 - - alla 2 500 3 900 alla 7 700 alla 8 700
Rullager, smörjintervall i driftstimmar

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 alla 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 alla 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 alla 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 alla 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 alla 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 alla 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 alla 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 alla 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 alla 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 alla 3 500
2801) 60 alla 1 000 1 750 - - - - - - -
2801) 70 - - - alla 4 000 5 250 alla 7 000 alla 8 500
280 35 alla 900 1 600 - - - -
280 40 - - alla 4 000 5 300 alla 7 000 alla 8 500
315 35 alla 900 1 600 - - - -
315 55 - - alla 2 900 3 800 alla 5 900 alla 6 500
355 35 alla 900 1 600 - - - -
355 70 - - alla 2 000 2 800 alla 4 800 alla 5 400
400 40 alla - 1 300 - - - -
400 85 - - alla 1 600 2 400 alla 4 300 alla 4 800
450 40 alla - 1 300 - - - -
450 95 - - alla 1 300 2 000 alla 3 800 alla 4 400
1)
M3AA
7.2.4 Smörjmedel Följande typer av fett kan användas för högvarviga
gjutjärnsmotorer, men inte tillsammans med
litiumkomplexfett:
VARNING!
Blanda inte olika typer av fett. - Klüber Klüber Quiet BQH 72-102 (polyureabas)
Inkompatibla smörjmedel kan orsaka lagerskador. - Lubcon Turmogrease PU703 (polyureabas)
Om andra smörjmedel används, kontrollera med tillverkaren

Då motorerna eftersmörjs ska endast fett med att kvaliteten motsvarar den hos ovan nämnda smörjmedel.
nedanstående egenskaper användas: Smörjintervallen gäller för de typer av högprestandafett
som anges ovan. Om annat fett används kan intervallen
– högkvalitetsfett baserat på litiumkomplextvål och med
förkortas.
mineral- eller PAO-olja
– basoljeviskositet 100–160 cST vid 40 °C
– konsistens enligt NLGI 1,5–3 *)
– temperaturområde -30 °C till +140 °C, kontinuerligt.
*) För vertikalt monterade motorer eller vid varm omgivning

rekommenderas det högre värdet.
Specifikationerna ovan gäller när omgivningstemperaturen

är över -30 °C eller under +55 °C och lagertemperaturen är
under 110 °C. I övriga fall, kontakta ABB för att få råd om
lämpligt fett.
Alla större smörjmedelstillverkare erbjuder fetter med ovan

angivna egenskaper.
Tillsatser rekommenderas, men en skriftlig garanti bör fås

från fettillverkaren, särskilt om det gäller EP-tillsatser, att
tillsatserna inte skadar lagren eller förändrar smörjmedlens
egenskaper inom arbetstemperaturintervallet.
VARNING!
Smörjmedel som innehåller EP-tillsatser
rekommenderas inte vid höga lagertemperaturer för
storlekarna 280–450.
Följande typer av högprestandafett kan användas:

– Mobil Unirex N2 eller N3 (litiumkomplexbas)
– Mobil Mobilith SHC 100 (litiumkomplexbas)
– Shell Gadus S5 V 100 2 (litiumkomplexbas)
– Klüber Klüberplex BEM 41-132 (speciell litiumbas)
– FAG Arcanol TEMP110 (litiumkomplexbas)
(speciell litiumbas)
– Total Multiplex S2 A (litiumkomplexbas)
– Rhenus Rhenus LKZ 2 (lithiumkomplexbas)
OBS!
Använd alltid höghastighetsfett för högvarviga
2-poliga motorer om varvtalsfaktorn överstiger
480 000 (beräknad som Dm x n där Dm = lagrets
medeldiameter (mm) och n = varvtal, r/min).
8. Eftermarknad 9. Miljökrav
De flesta av ABB:s motorer har en ljudtrycksnivå som
8.1 Reservdelar underskrider 82 dB(A) vid 50 Hz, med tolerans ±3 dB(A).
Reservdelar måste vara originaldelar eller godkända av
Värden för specifika motorer kan hittas i motsvarande
ABB om inget annat anges.
produktkataloger. Vid 60 Hz sinusmatning ska 50 Hz-
Vid beställning av reservdelar ska motorns tillverknings- värdena i produktkatalogerna ökas med cirka 4 dB(A).
nummer, fullständiga typbeteckning och produktkod enligt
Kontakta ABB för ljudtrycksnivåer vid frekvensomriktar-
märkskylten anges.
matning.
Kassering och återvinning av motorer ska ske på lämpligt

8.2 Demontering, montering sätt och i enlighet med gällande föreskrifter och lagar.
och omlindning
Omlindning bör alltid utföras av kvalificerade reparations-
verkstäder.
Motorer för rökgasventilation och andra specialmotorer får

inte omlindas utan att ABB först kontaktas.
8.3 Lager
Lager kräver speciell omsorg.
Lager ska demonteras med avdragare och monteras med

hjälp av uppvärmning eller specialverktyg.
Lagerbyte beskrivs i detalj i en särskild instruktionsbroschyr

som kan rekvireras från ABB.
Alla eventuella anvisningar som sitter på motorn, i form av

etiketter eller dylikt, måste följas. Lagertyperna som anges
på märkskylten får inte ändras.
OBS!
Om slutanvändaren utför reparationer, som inte
uttryckligen har godkänts av tillverkaren, befrias
tillverkaren från allt ansvar för överensstämmelse.
10. Felsökning
Nedanstående instruktioner täcker inte alla detaljer
eller varianter för utrustningen och beskriver inte heller
alla situationer som kan tänkas uppstå i samband med
installation, drift och underhåll. För närmare information,
kontakta närmaste ABB-försäljningskontor.
Felsökningsschema för motorer

Motorservice och felsökning ska skötas av kvalificerad
personal med ändamålsenlig utrustning.
PROBLEM ORSAK ÅTGÄRD

Motorn startar inte Säkringarna har löst ut Byt till säkringar av korrekt typ och utlösningsvärde.
Överbelastningsutlösning Kontrollera och återställ överbelastningsskyddet i startapparaten.
Felaktig matning Kontrollera att matningen överensstämmer med uppgifterna på
motorns märkskylt och med driftförhållandena.
Felaktig matningsanslutning Kontrollera anslutningarna mot det schema som medföljer motorn.
Lindningsbrott eller öppen brytare Känns igen på ett surrande ljud när brytaren är stängd. Kontrollera
att alla anslutningar är väl åtdragna och att alla hjälpkontakter sluts
korrekt.
Mekaniskt fel Kontrollera att motorn och den drivna utrustningen roterar fritt.
Kontrollera lager och smörjning.
Kortsluten stator
Dålig anslutning av statorspole Känns igen på att säkringarna har löst ut. Motorn måste lindas om.
Demontera lagersköldarna och hitta felet.
Rotorfel Leta efter avbrutna stavar och gavelringar.
Motorn kan vara överbelastad Minska belastningen.
Motor fastlåst En fas kan vara öppen Kontrollera spänningen på alla faser.
Fel tillämpning Ändra typ eller storlek. Kontakta leverantören.
Överbelastning Minska belastningen.
För låg spänning Kontrollera att matningsspänningen uppfyller kraven enligt
märkskylten. Kontrollera anslutningen.
Öppen krets Säkringar utlösta. Kontrollera överbelastningsrelä, stator och
tryckknappar.
Motorn startar, Matningsfel Kontrollera om matningsanslutningarna behöver dras åt. Kontrollera
men retarderar och säkringar och manöverorgan.
stannar
Motorn uppnår Felaktig användning Kontakta leverantören för anvisning om rätt typ.
inte märkvarvtalet För låg spänning vid Använd högre spänning eller transformatoranslutningar för att minska
motoranslutningarna på grund av belastningen.
spänningsfall i matningsnätet Kontrollera anslutningarna. Kontrollera att ledarna har rätt dimension.
För hög startbelastning Kontrollera att motorn startar utan last.
Avbrutna rotorstavar eller lös rotor Kontrollera om det finns sprickor nära ringarna. Vanligtvis är endast en
temporär reparation möjlig. Rotorn måste oftast bytas.
Öppen primärkrets Hitta felet med mätinstrument och reparera.
PROBLEM ORSAK ÅTGÄRD
Motorn behöver Överbelastning Minska belastningen.
för lång tid för att Låg spänning vid start Kontrollera om resistansen är för hög. Kontrollera att rätt
accelerera och/ kabeldimension används.
eller drar mycket
ström Fel på kortsluten rotor Byt till ny rotor.
För låg matningsspänning Korrigera matningsspänningen.
Fel Fel fasföljd Låt två fasledare byta plats vid motorn eller i gruppcentralen.
rotationsriktning
Motorn blir Överbelastning Minska belastningen.
överhettad vid Ventilationsöppningarna kan vara Öppna ventilationsöppningarna och se till att kylluften kan strömma
körning igensatta så att motorn inte får tillräcklig fritt.
kylning
En fas kan vara öppen Kontrollera att samtliga ledare och kablar är korrekt anslutna.
Jordsluten spole Motorn måste lindas om.
Obalanserad uttagsspänning Kontrollera om det finns felaktiga ledare, anslutningar och
transformatorer.
Motorn vibrerar Motorn felaktigt uppriktad Rikta upp motorn.
Svagt fundament Förstärk fundamentet.
Obalanserad koppling Balansera kopplingen.
Driven utrustning obalanserad Balansera den drivna utrustningen.
Lagerfel Byt lager.
Lager ej uppriktade Reparera motorn
Balanseringsvikterna har förskjutits Balansera om rotorn.
Bristande kompatibilitet mellan rotor- Balansera om kopplingen eller rotorn.
och kopplingsbalansering (halv kil – hel
kil)
Flerfasmotor drivs med enfasmatning Kontrollera om någon krets är öppen.
För stort ändspel Justera lager eller sätt in shims.
Skrapljud Fläkten i kontakt med lagersköld eller Korrigera fläktens montering.
fläktkåpa
Motorn lös på fundamentplattan Dra åt fästskruvarna.
Onormalt driftbuller Ojämnt luftgap Kontrollera och korrigera montering av lagersköldar och lager.
Rotor obalanserad Balansera om rotorn.
Överhettade lager Böjd eller sned axel Rikta upp eller byt axeln.
För hög remspänning Minska remspänningen.
Remskivan för långt från axelansatsen För remskivan närmare motorlagret.
För liten remskivediameter Använd större remskivor.
Felaktig uppriktning Korrigera genom att rikta upp drivsystemet.
Bristande smörjning Se till att rätt mängd lagerfett av rätt kvalitet används.
Fettet eller smörjmedlet förbrukat eller Avlägsna gammalt fett, tvätta lagret grundligt med fotogen och pressa
förorenat in nytt fett.
För mycket smörjmedel Minska fettmängden. Lagret ska inte vara fyllt mer än till hälften.
Överhettat lager Kontrollera uppriktningen samt den radiella och axiella belastningen.
Skadade kulor eller löpbanor Byt lager och rengör samtidigt lagerhuset noggrant.
Pienjännitemoottorit
Asennus-, käyttö-, kunnossapito- ja turvallisuusohje
Sisällys
1. Johdanto ..................................................................................................................................143
1.1 Vaatimustenmukaisuusvakuutus ......................................................................................143
1.2 Voimassaolo ....................................................................................................................143
2. Turvallisuusnäkökohtia ...........................................................................................................143
3. Käsittely ...................................................................................................................................144
3.1 Vastaanottotarkastus .......................................................................................................144
3.2 Kuljetus ja säilytys ............................................................................................................144
3.3 Nostaminen .....................................................................................................................144
3.4 Moottorin paino ...............................................................................................................144
4. Asennus ja käyttöönotto ........................................................................................................145
4.1 Yleistä..............................................................................................................................145
4.2 Muilla kuin kuulalaakereilla varustetut moottorit ................................................................145
4.3 Eristysvastuksen tarkistaminen ........................................................................................145
4.4 Alusta ..............................................................................................................................145
4.5 Kytkinpuolikkaiden ja hihnapyörien tasapainottaminen ja asentaminen .............................146
4.6 Moottorin kiinnitys ja linjaus..............................................................................................146
4.7 Radiaaliset voimat ja hihnakäytöt .....................................................................................146
4.8 Vesireiät ...........................................................................................................................146
4.9 Kaapelit ja sähköliitännät..................................................................................................146
4.9.1 Kytkennät eri käynnistystavoille .........................................................................147
4.9.2 Lisälaiteliitännät ................................................................................................147
4.10 Liitännät ja pyörimissuunta ...............................................................................................147
5. Toiminta ..................................................................................................................................148
5.1 Yleistä..............................................................................................................................148
Pienjännitemoottorien käyttöohje, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 141
6. Pienjännitemoottorit taajuusmuuttajakäytössä ..................................................................149
6.1 Johdanto .........................................................................................................................149
6.2 Käämityksen eristys .........................................................................................................149
6.2.1 Käämityksen eristyksen valinta käytettäessä ABB-taajuusmuuttajia..................149
6.2.2 Eristyksen valinta kaikille muille taajuusmuuttajille .............................................149
6.3 Lämpösuojaus ................................................................................................................149
6.4 Laakerivirrat .....................................................................................................................149
6.4.1 Laakerivirtojen ehkäiseminen säätökäytöissä, joissa on
ABB:n taajuusmuuttaja .....................................................................................150
6.4.2 Laakerivirtojen ehkäiseminen kaikissa muissa säätökäytöissä ...........................150
6.5 Kaapelointi, maadoitus ja sähkömagneettinen yhteensopivuus ........................................150
6.6 Pyörimisnopeus ...............................................................................................................150
6.7 Moottorit taajuusmuuttajakäytössä ..................................................................................150
6.7.1 Yleistä ..............................................................................................................150
6.7.2 Moottorin kuormitettavuus AC_8_ _ -sarjan taajuusmuuttajilla,
joissa on DTC-säätö .........................................................................................150
6.7.3 Moottorin kuormitettavuus AC_5_ _ -sarjan taajuusmuuttajilla ...........................150
6.7.4 Moottorin kuormitettavuus muilla PWM-tyyppisillä
jännitelähdetaajuusmuuttajilla ............................................................................151
6.7.5 Lyhytaikaiset ylikuormitukset .............................................................................151
6.8 Arvokilvet .........................................................................................................................151
6.9 Taajuusmuuttajakäytön käyttöönotto ................................................................................151
7. Kunnossapito ..........................................................................................................................152
7.1 Yleinen tarkistus ..............................................................................................................152
7.1.1 Valmiustilassa olevat moottorit .........................................................................152
7.2 Voitelu .............................................................................................................................152
7.2.1 Kestovoidelluilla laakereilla varustetut moottorit .................................................152
7.2.2 Jälkivoideltavilla laakereilla varustetut moottorit .................................................153
7.2.3 Voiteluvälit ja -määrät ........................................................................................153
7.2.4 Voiteluaineet .....................................................................................................155
8. After Sales -tuki ......................................................................................................................156
8.1 Varaosat ..........................................................................................................................156
8.2 Purkaminen, kokoaminen ja uudelleenkäämintä ...............................................................156
8.3 Laakerit ...........................................................................................................................156
9. Ympäristövaatimukset ...........................................................................................................156
10. Vianmääritys ............................................................................................................................157
142 ABB Motors and Generators | Pienjännitemoottorien käyttöohje, 3GZF500730-85 Rev F 02-2015
1. Johdanto 2. Turvallisuusnäkökohtia
Moottori on tarkoitettu pätevien, voimassa olevat
HUOM.! turvallisuusvaatimukset tuntevien henkilöiden
Näitä ohjeita on noudatettava, jotta varmistetaan asennettavaksi ja käytettäväksi.
moottorin turvallinen ja oikea asennus, käyttö ja
huolto. Henkilöiden, jotka asentavat, käyttävät Turvalaitteita, jotka ovat tarpeen onnettomuuksien
tai huoltavat moottoreitamme tai niihin liittyviä estämiseksi asennuksen ja käytön yhteydessä, on
laitteita, on saatava nämä ohjeet käyttöönsä. käytettävä asianomaisen maan määräysten mukaan.
Moottori on tarkoitettu pätevien, voimassa olevat
turvallisuusvaatimukset tuntevien henkilöiden
asennettavaksi ja käytettäväksi. Näiden ohjeiden VAROITUS!
noudattamatta jättäminen voi mitätöidä kaikki Hätäpysäyttimet on varustettava uudelleen-
soveltuvat takuut. käynnistyksen lukituksilla. Hätäpysäytyksen jälkeen
uusi käynnistyskäsky voi astua voimaan vasta sen
jälkeen, kun uudelleenkäynnistyksen lukitus on
tarkoituksella nollattu.
1.1 Vaatimustenmukaisuus-
vakuutus
Kun moottori asennetaan koneeseen, toimeksiantajan on Huomioitavia seikkoja:
määritettävä, vastaako lopputuote konedirektiivin 2006/42/ 1. Älä astu moottorin päälle.
EY vaatimuksia.
2. Moottorin ulkopinta voi olla kuuma normaalikäytössä ja
erityisesti pysäytyksen jälkeen.
1.2 Voimassaolo 3. Jotkin erikoiskäytöt saattavat vaatia erikoisohjeita (esim.
taajuusmuuttajakäytöt).
Nämä ohjeet ovat voimassa seuraaville ABB:n
sähkökoneille sekä moottori- että generaattorikäytöissä: 4. Ota huomioon moottorin pyörivät osat.
5. Älä avaa liitäntäkoteloita, kun ne ovat jännitteisinä.
sarjat MT*, MXMA,
sarjat M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*,
M2V*/M3V*
runkokoot 56–450.
Esimerkiksi Ex-moottoreille on erillinen opas:

Räjähdysvaarallisten tilojen pienjännitemoottorit: Asennus-,
käyttö-, ylläpito- ja turvallisuusopas (3GZF500730-47).
Lisäohjeita tarvitaan moottorityypeissä, jotka on tarkoitettu

erikoiskäyttöön tai jotka ovat erikoisrakenteisia.
Lisäopas on saatavilla seuraaville moottoreille:

– rullaratamoottorit
– vesijäähdytteiset moottorit
– savukaasujen poistoon tarkoitetut moottorit
– jarrumoottorit
– kuivaamomoottorit
– merenkulkusovelluksissa käytettävät moottorit, jotka
asennetaan avoimelle kannelle laivoissa tai
meriyksiköissä.
3. Käsittely Kierteellä kiinnitetyt nostosilmukat täytyy kiristää ennen
nostamista. Tarvittaessa nostosilmukka on säädettävä
oikeaan asentoon sopivia aluslaattoja käyttäen.
3.1 Vastaanottotarkastus
Varmista, että nostovälineet ovat oikeankokoisia ja
Tarkista heti vastaanoton jälkeen, ettei moottori ole nostokoukut sopivat nostosilmukoihin.
vahingoittunut ulkoisesti (tarkista akselien päät, laipat ja
maalatut pinnat). Ota tarvittaessa välittömästi yhteyttä Nostettaessa on varottava vahingoittamasta moottoriin
kuljetusliikkeeseen. kiinnitettyjä lisälaitteita ja kaapeleita.
Tarkista kaikki arvokilven tiedot, etenkin jännite ja kytkennät Irrota mahdolliset kuljetuskiinnittimet, jotka kiinnittävät
(tähti tai kolmio). Laakerityyppi on mainittu kaikkien muiden moottorin lavaan.
paitsi runkokooltaan pienimpien moottoreiden arvokilvessä.
Tarkat nostotiedot saa ABB:ltä.
Taajuusmuuttajakäytössä tarkista sallittu enimmäis-
kuormitettavuus moottorin toiseen tyyppikilpeen leimatun
taajuuden mukaan. VAROITUS!
Nosto-, asennus- tai huoltotöiden aikana kaikkien
tarvittavien turvallisuustoimien on oltava käytössä ja
3.2 Kuljetus ja säilytys erityishuomiota on kiinnitettävä siihen, että kukaan ei
Moottorit tulee varastoida sisätiloissa (lämpötila yli −20 °C), ole nostetun kuorman alla.
kuivissa, tärinättömissä ja pölyttömissä olosuhteissa.
Kuljetuksen aikana moottorit on suojattava iskuilta,
putoamisilta ja kosteudelta. Muissa olosuhteissa ota yhteys 3.4 Moottorin paino
ABB:n edustajaan.
Moottorin kokonaispaino voi vaihdella samassakin
Suojaamattomat koneistetut pinnat (akselien päät ja laipat) runkokoossa (keskikorkeus) eri nimellistehon,
on käsiteltävä korroosionestoaineella. asennusasennon ja lisävarusteiden takia.
Akselia suositellaan pyöritettävän säännöllisin väliajoin käsin Seuraavassa taulukossa on esitetty moottoreiden arvioidut
rasvan muuttumisen estämiseksi. enimmäispainot vakiomallin moottoreille runkomateriaalin
mukaisesti.
Mahdollisten seisontalämmitysvastusten käyttö on
suositeltavaa, jotta kondensaatioveden kerääntyminen Kaikkien ABB:n moottoreiden todellinen paino on mainittu
moottoriin voitaisiin estää. arvokilvessä runkokooltaan pienimpiä moottoreita (56 ja 63)
lukuun ottamatta.
Pysähdyksissä olevaan moottoriin ei saa kohdistua ulkoista
tärinää, jotta laakerit eivät vahingoittuisi. Runkokoko Alumiini Valurauta Lisäys
jarrusta
Moottorit, joissa on rullalaakerit tai viistokuulalaakerit, tulee Paino (kg) Paino (kg)
varustaa lukituksella kuljetuksen ajaksi. 56 4,5 – –
63 6 – –
3.3 Nostaminen 71 8 13 5
80 14 20 8
Kaikissa yli 25 kg:n painoisissa ABB:n moottoreissa on 90 20 30 10
nostosilmukat. 100 32 40 16
112 36 50 20
Moottorin nostamiseen saa käyttää vain sen omia
132 93 90 30
päänostosilmukoita. Niitä ei saa käyttää moottorin
160 149 130 30
nostamiseen silloin, kun se on kytketty muuhun laitteistoon.
180 162 190 45
Lisälaitteiden (esimerkiksi jarrujen tai erillisten puhaltimien) 200 245 275 55
tai liitäntäkoteloiden nostosilmukoita ei saa käyttää 225 300 360 75
moottorin nostamiseen. Eri tehojen, asennusasentojen ja 250 386 405 75
280 425 800 –
lisävarusteiden takia saman runkokoon moottoreilla saattaa
315 – 1 700 –
olla eri painopiste.
355 – 2 700 –
Vahingoittuneita nostosilmukoita ei saa käyttää. Tarkista 400 – 3 500 –
ennen nostoa, että silmukkapultit tai kiinteät nostosilmukat 450 – 4 500 –
ovat vahingoittumattomat.
Jos moottori on varustettu erillisellä puhaltimella, kysy paino
ABB:ltä.
4. Asennus ja käyttöönotto 4.3 Eristysvastuksen
tarkistaminen
VAROITUS! Mittaa eristysvastus ennen käyttöönottoa ja silloin, kun
Katkaise virta moottorista ennen moottorin tai epäilet käämityksen olevan kostea.
käytettävän laitteiston käsittelemistä.
Eristysvastus ei saa 25 °C:n lämpötilaan korjattuna missään
tapauksessa olla alle 1 MΩ (mitattuna jännitteellä 500 tai
4.1 Yleistä 1 000 V DC). Eristysvastuksen arvo tulee puolittaa jokaista
20 °C:n lämpötilan nousua kohti. Eristyksen voi korjata
Tarkista kaikki arvokilven arvot, jotta moottorin oikeasta haluttuun lämpötilaan kuvan 1 mukaisesti.
suojauksesta ja kytkennästä voidaan varmistua.
VAROITUS!
4.2 Muilla kuin kuulalaakereilla Sähköiskujen välttämiseksi moottorin runko on
maadoitettava ja käämitysten sähkövaraus on
varustetut moottorit purettava runkoon välittömästi jokaisen mittauksen
Poista kuljetuslukitukset, jos niitä on. Tarkista jälkeen.
mahdollisuuksien mukaan vapaa pyöriminen kääntämällä
moottorin akselia käsin. Ellei eristysvastusmittauksessa saavuteta ohjearvoa,
käämitys on liian kostea ja se on kuivattava uunissa. Uunin
Rullalaakereilla varustetut moottorit: lämpötilan on oltava 90 °C 12–16 tunnin ajan ja sen jälkeen
Moottorin käyttö ilman säteittäistä kuormitusta akselille 105 °C 6–8 tunnin ajan.
saattaa vahingoittaa rullalaakereita.
Mahdolliset vesireikien tulpat on irrotettava ja sulkuventtiilit
avattava lämmityksen ajaksi. Lämmityksen jälkeen tulpat
Viistokuulalaakerilla varustetut moottorit: on muistettava sulkea. Vaikka moottori on varustettu
Moottorin käyttö ilman oikeansuuntaista ja -suuruista vesireiällä ja tulpalla, on suositeltavaa purkaa laakerikilvet ja
aksiaalivoimaa saattaa vahingoittaa moottorin liitäntäkotelon kansi kuivausta varten.
viistokuulalaakeria.
Meriveden kastelemat käämitykset on useimmiten
käämittävä uudelleen.
VAROITUS!
Moottoreissa, joissa on viistokuulalaakerit,
aksiaalivoima ei saa millään tavoin muuttaa suuntaa. 4.4 Alusta
Loppukäyttäjällä on täysi vastuu alustan valmistamisesta.
Laakerityyppi on mainittu arvokilvessä.
Metalliset alustat on maalattava, jotta ne eivät ruostu.
Jälkivoideltavilla laakereilla varustetut moottorit: Alustan on oltava tasainen ja riittävän tukeva, jotta se
Moottoria käynnistettäessä ensimmäistä kertaa sekä kestää mahdolliset oikosulkuvoimat.
moottorin pitkän varastoinnin jälkeen tulee laakereille tehdä
ensirasvaus, jossa voiteluainetta lisätään voitelukilven Alusta on suunniteltava ja mitoitettava siten, että vältetään
ohjeen mukainen määrä. tärinän johtuminen moottoriin ja resonanssin aiheuttama
tärinä. Katso seuraava kuva.
Katso lisätietoja kohdasta 7.2.2, Jälkivoideltavilla laakereilla
varustetut moottorit. Viivain
Kun moottori asennetaan pystyasentoon akseli alas
osoittaen, on siinä oltava suojakansi, joka estää vieraiden
esineiden ja nesteiden tulemista tuuletusaukkojen läpi.
HUOM.! Moottorin jalkojen
Tämä voidaan toteuttaa myös erillisellä kannella, jota ei ole korkeusero ei saa olla
kiinnitetty moottoriin. Tässä tapauksessa moottorissa on yli ± 0,1 mm.
oltava varoitusmerkintä.
Jalan paikka
4.5 Kytkinpuolikkaiden ja hihna- 4.7 Radiaaliset voimat ja
pyörien tasapainottaminen hihnakäytöt
ja asentaminen Hihnat tulee kiristää käytettävän laitteiston toimittajan
ohjeiden mukaan. Älä kuitenkaan ylitä tuote-
Moottori tasapainotetaan normaalisti puolella kiilalla. esitteissä ilmoitettuja maksimihihnavoimia (laakerin
Kytkinpuolikkaat ja hihnapyörät on tasapainotettava radiaalikuormituksia).
kiilaurien jyrsimisen jälkeen. Tasapainotusmenetelmä tulee
valita akselin tasapainotusmenetelmään sopivaksi. VAROITUS!
Kytkinpuolikkaat ja hihnapyörät tulee asentaa akselille Liiallinen hihnojen kiristys vaurioittaa laakereita ja voi
käyttäen tarkoitukseen sopivia tarvikkeita ja työkaluja, jotka aiheuttaa akselin vahingoittumisen.
eivät vaurioita laakereita tai tiivisteitä.
Älä koskaan asenna kytkinpuolikasta tai hihnapyörää

lyömällä tai poista sitä vipuamalla runkoa vasten. 4.8 Vesireiät
Varmista, että vesireiät ja tulpat ovat alaspäin.
4.6 Moottorin kiinnitys ja linjaus Pystyasentoon kiinnitettävissä moottoreissa vesireiät
saattavat olla vaaka-asennossa.
Varmista, että moottorin ympärillä on riittävästi tilaa
esteetöntä ilmavirtausta varten. On suositeltavaa, että Moottorit, joiden vesirei'issä on suljettavat muovitulpat,
puhaltimen suojuksen ja seinän tai vastaavan välimatka toimitetaan tulpat avoinna. Erittäin pölyisissä oloissa kaikki
on vähintään puolet puhaltimen suojuksen ilman vesireiät tulee sulkea.
sisäänottoaukosta. Lisätietoja on tuoteluettelossa sekä
Web-sivuilta saatavissa mittapiirroksissa: www.abb.com/
motors&generators.
4.9 Kaapelit ja sähköliitännät
Normaalissa yksinopeuksisessa moottorissa on yleensä
Oikea linjaus on erittäin tärkeää laakerivaurioiden, tärinän ja
kuusi liitintä staattorikäämeille (pääliittimet) ja ainakin yksi
akselivaurioiden estämiseksi.
maadoitusliitin.
Kiinnitä moottori alustaan sopivilla pulteilla tai kierretangoilla
Moottorin pääliittimien ja maadoitusliittimien lisäksi
ja lisää alustan ja jalkojen väliin sovitelevyjä.
liitäntäkotelossa voi olla liittimet termistoreille,
Linjaa moottori käyttäen sopivia menetelmiä. lämmitysvastuksille tai muille lisälaitteille.
Poraa tarvittaessa reiät ohjaustapeille ja kiinnitä ohjaustapit Syöttökaapelit on liitettävä sopivien kaapelikenkien avulla.
paikoilleen. Lisälaitteiden kaapelit voidaan liittää kytkentärimaan
sellaisinaan.
Kytkimen asennustarkkuus: Tarkista, että poikkeama b
on alle 0,05 mm ja että ero a1–a2 on myös alle 0,05 mm. Moottorit on tarkoitettu vain kiinteään asennukseen. Jos
Katso kuva 2. erikseen ei ole muuta mainittu, kaapeliläpivienneissä on
metriset kierteet. Holkkitiivisteillä tulee olla vähintään sama
Tarkista linjaus uudelleen, kun pultit tai kierretangot on IP-luokka kuin liitäntäkoteloilla.
kiristetty lopullisesti.
Asennuksen aikana on käytettävä sertifioitua putken
Älä ylitä tuoteluetteloissa mainittuja laakereiden suurimpia keskiötä tai kaapeliliitintä.
sallittuja kuormitusarvoja.
Tarkista, että moottorin ympärillä on tarpeeksi jäähdytyksen HUOM.!

vaatimaa tilaa. Varmista, että lähellä olevista kohteista Kaapelit on suojattava mekaanisesti ja kiristettävä
säteilevä lämpö tai suora auringonpaiste eivät kuumenna lähelle liitäntäkoteloa standardin IEC/EN 60079-0
moottoria liikaa. ja paikallisten asennusstandardien asianmukaisten
vaatimusten täyttämiseksi.
Laippamoottorien (esimerkiksi B5, B35 tai V1) tapauksessa
varmista, että rakenne mahdollistaa riittävän ilmavirran
laipan ulkopinnalla.
Käyttämättömät kaapeliläpiviennit on suljettava tulpilla
liitäntäkotelon IP-luokan mukaisesti.
Suojausluokka ja halkaisija on määritelty holkkitiivisteiden

dokumenteissa.
4.9.1 Kytkennät eri käynnistystavoille
VAROITUS!
Käytä kaapeliläpivienneissä asianmukaisia Normaalissa yksinopeuksisessa moottorissa on yleensä
holkkitiivisteitä kaapelin tyypin ja läpimitan kuusi liitintä staattorikäämeille (pääliittimet) ja ainakin yksi
mukaisesti. maadoitusliitin. Tämä mahdollistaa suoran käynnistyksen tai
tähtikolmiokäynnistyksen.
Kaksinopeus- ja erikoismoottoreilla kytkentä on suoritettava

Maadoitus on hoidettava paikallisten määräysten mukaan liitäntäkotelon sisällä tai moottorin ohjeessa olevan tiedon
ennen moottorin kytkemistä verkkojännitteeseen. mukaisesti.
Rungon maadoitusliitin on kytkettävä suojamaadoitukseen Jännite ja kytkentä on leimattu arvokilpeen.
(PE) kaapelilla standardin IEC/EN 60034-1 taulukon 5
mukaisesti: Suora käynnistys (DOL):
Voidaan käyttää Y- tai D-kytkentää.
Suojajohdinten vähimmäispoikkipinta-ala
Esimerkiksi 690 VY, 400 VD tarkoittaa Y-kytkentää 690 V ja
Asennuksen vaihejohdinten Vastaavan suojajohtimen
vähimmäispoikkipinta-ala, SP
D-kytkentää 400 V.
poikkipinta-ala, S (mm2)
(mm2)
Tähtikolmiokäynnistys (Y/D):
4 4
6 6 D-kytkennässä verkkojännitteen on oltava sama kuin
10 10 moottorin nimellisjännite.
16 16
Poista kaikki kytkentäliuskat liitäntäalustasta.
25 25
35 25 Muut käynnistystavat ja hankalat
50 25 käynnistysolosuhteet:
70 35
Kun käyttötavoissa S1 ja S2 käytetään muita käynnistys-
95 50
tapoja, esim. taajuusmuuttajaa tai pehmokäynnistintä,
120 70
katsotaan, että laite on eristettynä sähköjärjestelmästä
150 70
sähköisen koneen ollessa käynnissä standardin IEC
185 95
60079-0 mukaisesti ja lämpösuojaus on valinnainen.
240 120
300 150
400 185 4.9.2 Lisälaiteliitännät
Lisäksi sähkölaitteen ulkopuolella olevien maadoitus- tai Jos moottori on varustettu termistoreilla tai muilla
liitosliittimien on tuotettava tehokas liitäntä johtimeen, jonka vastuslämpötilamittauksilla (esimerkiksi Pt100:lla tai
poikkipinta-ala on vähintään 4 mm2. lämpöreleillä) ja lisälaitteilla, on suositeltavaa, että näitä
laitteita käytetään ja ne liitetään asianmukaisesti. Tietyissä
Verkon ja moottorin liitäntöjen välisen kaapeliliitännän käyttötarkoituksissa on käytettävä lämpösuojausta.
on täytettävä asennuksen kansallisten standardien tai Lisätietoja on moottorin mukana toimitetuissa asiakirjoissa.
standardin IEC/EN 60204-1 vaatimukset tyyppikilvessä Lisävarusteiden kytkentäkaaviot ovat liitäntäkotelon sisällä.
ilmoitetun nimellisvirran mukaisesti.
Termistorien enimmäismittausjännite on 2,5 V.
HUOM.! Pt100:n enimmäismittausvirta on 5 mA. Suuremman
Kun ympäristön lämpötila on yli +50 °C, on mittausjännitteen tai -virran käyttäminen voi aiheuttaa
käytettävä kaapeleita, joiden sallittu käyttölämpö- virheitä lukemiin tai vaurioittaa lämpötila-anturia.
tila on vähintään +90 °C. Myös muut asennus- Lämpöanturien eristys täyttää peruseristysvaatimukset.
olosuhteista riippuvat muuntokertoimet on
huomioitava kaapeleita mitoitettaessa.
Varmista, että moottorin suojaus vastaa ympäristö- ja

4.10 Liitännät ja pyörimissuunta
sääolosuhteita. Varmista esimerkiksi, että vesi ei pääse Pyörimissuunta on myötäpäivään akselin päästä
moottoriin tai liitäntäkoteloihin. katsottuna, kun vaihejärjestys L1, L2, L3 on kytketty
liittimiin kuvan 3 mukaan.
Liitäntäkoteloiden tiivisteiden täytyy olla kunnolla urissaan,
jotta kotelon moottorin kotelointiluokka vastaa suunniteltua Pyörimissuunta muutetaan vaihtamalla kahden
ja moottorin arvokilvessä mainittua IP-luokkaa. Virheellisesti vaihejohtimen päät keskenään.
asennettu tiiviste saattaa aiheuttaa veden tai pölyn
tunkeutumisen liitäntäkoteloon, mistä voi aiheutua kipinä- Jos moottorissa on vain yhteen suuntaan pyörivä tuuletin,
tai räjähdysvaara. tarkista, että pyörimissuunta on moottoriin merkityn nuolen
mukainen.
5. Toiminta
5.1 Yleistä
Moottorit on suunniteltu käytettäviksi seuraavissa
olosuhteissa, ellei arvokilvessä ole toisin ilmoitettu.
– Moottorit on tarkoitettu vain kiinteään asennukseen.

– Normaali ympäristön lämpötila on −20 °C...+40 °C.
– Asennuskorkeus on enintään 1 000 metriä meren
pinnasta
– Syöttöjännitteen ja taajuuden vaihtelu ei saa ylittää
asiaankuuluvissa standardeissa mainittuja rajoja.
Syöttöjännitteen toleranssi on ±5 % ja taajuuden
toleranssi ±2 % kuvan 4 (EN / IEC 60034-1, kohta 7.3,
vyöhyke A) mukaan. Kumpikin ääriarvo ei saa esiintyä
yhtä aikaa.
Moottoria saa käyttää vain niissä kohteissa, joihin se on

tarkoitettu. Nimellisarvot ja käyttöolosuhteet on ilmoitettu
moottorien arvokilvissä. Lisäksi tulee noudattaa kaikkia
tässä oppaassa ilmoitettuja vaatimuksia sekä muita asiaan
liittyviä ohjeita ja standardeja.
Jos nämä rajat ylittyvät, on kaikki moottorin arvot ja

asennusarvot tarkistettava. Lisätietoja saa ABB:ltä.
VAROITUS!
Laitteiden käyttö- ja kunnossapito-ohjeiden
laiminlyöminen voi vaarantaa turvallisuuden ja estää
moottorin käyttämisen.
6. Pienjännitemoottorit taajuusmuuttajakäytössä
6.1 Johdanto 6.2.2 Eristyksen valinta kaikille muille
taajuusmuuttajille
Ohjeen tässä osassa on lisäohjeita taajuusmuuttajakäytössä
käytettävistä moottoreista. Moottori on tarkoitettu Jänniterasitukset eivät saa ylittää sallittuja raja-arvoja.
käytettäväksi yhdestä taajuusmuuttajakäytöstä, eikä Sovelluksen turvallisuus tulee varmistaa laitteiston
useita moottoreita saa käyttää rinnakkain yhdestä toimittajalta. Mahdollisten suodattimien vaikutus on otettava
taajuusmuuttajasta. Taajuusmuuttajan valmistajan antamia huomioon moottorin mitoituksessa.
ohjeita on noudatettava.
ABB saattaa tarvita lisätietoja käytöstä voidakseen

päättää moottorin soveltuvuudesta erikoiskäyttöihin ja/tai
6.3 Lämpösuojaus
erikoismoottorin tarpeesta. Useimmat tässä ohjeessa käsiteltävät moottorit on
varustettu staattorikäämityksen PTC-termistoreilla tai
muuntyyppisillä vastuslämpötilamittauksilla. Niiden
6.2 Käämityksen eristys kytkeminen taajuusmuuttajaan on suositeltavaa. Lue lisää
luvusta 4.9.2.
Taajuusmuuttajat aiheuttavat korkeampia jänniterasituksia
kuin sinimuotoinen syöttö moottorin käämitykseen.
Tämän vuoksi moottorin käämieristys ja taajuusmuuttajan
lähtösuodatin tulee mitoittaa seuraavien ohjeiden
6.4 Laakerivirrat
mukaisesti. Eristettyjä laakereita tai laakerirakenteita, yhteismuotoisia
suodattimia sekä asianmukaisia kaapelointi- ja
6.2.1 Käämityksen eristyksen valinta maadoitusmenetelmiä tulee käyttää seuraavien ohjeiden ja
käytettäessä ABB-taajuusmuuttajia taulukon 6.1 mukaisesti laakerivirtaongelmien välttämiseksi.
Kun käytetään ABB:n dioditasasuuntaajalla (ei-säädettävä

tasajännite) varustettuja erilliskäyttöjä (esim. AC_8_ _- ja
AC_5_ _ -sarjat), käämityksen eristys ja suodattimet
voidaan valita taulukon 6.1 mukaan.
PN < 100 kW PN ≥ 100 kW tai PN ≥ 350 kW tai

IEC315 ≤ Runkokoko ≤ IEC355 IEC400 ≤ Runkokoko ≤ IEC450
UN ≤ 500 V Vakiomoottori Vakiomoottori Vakiomoottori
+ Eristetty N-laakeri + Eristetty N-laakeri
+ Yhteismuotoinen suodatin
500 V >UN ≤ 600 V Vakiomoottori Vakiomoottori Vakiomoottori
+ dU/dt -suodatin (reaktori) + dU/dt -suodatin (reaktori) + Eristetty N-laakeri
TAI + Eristetty N-laakeri + dU/dt -suodatin (reaktori)
Vahvistettu eristys TAI + Yhteismuotoinen suodatin
Vahvistettu eristys TAI
+ Eristetty N-laakeri Vahvistettu eristys
+ Eristetty N-laakeri
500 V >UN ≤ 600 V Vakiomoottori Vakiomoottori Vakiomoottori
(kaapelin pituus > 150 m) + Eristetty N-laakeri + Eristetty N-laakeri
600 V >UN ≤ 690 V Vahvistettu eristys Vahvistettu eristys Vahvistettu eristys

+ dU/dt -suodatin (reaktori) + dU/dt -suodatin (reaktori) + Eristetty N-laakeri
+ Eristetty N-laakeri + dU/dt -suodatin (reaktori)
600 V >UN ≤ 690 V Vahvistettu eristys Vahvistettu eristys Vahvistettu eristys
(kaapelin pituus > 150 m) + Eristetty N-laakeri + Eristetty N-laakeri
Taulukko 6.1 Käämityksen eristyksen valinta käytettäessä ABB-taajuusmuuttajia
Ota yhteyttä ABB:hen, jos tarvitset lisätietoja vastusjarrutuksesta tai ohjatulla syöttöyksiköllä varustetuista
taajuusmuuttajista.
6.4.1 Laakerivirtojen ehkäiseminen Lisätietoja taajuusmuuttajakäyttöjen maadoittamisesta ja
säätökäytöissä, joissa on ABB:n kaapeloinnista on ohjeessa "Grounding and cabling of the
drive system" (Koodi: 3AFY 61201998).
taajuusmuuttaja
Kun käytetään ABB:n dioditasasuuntaajalla varustettua
taajuusmuuttajaa (esim. AC_8_ _- ja AC_5_ _ -sarjat),
taulukon 6.1 mukaisia menetelmiä on käytettävä haitallisten
6.6 Pyörimisnopeus
laakerivirtojen välttämiseksi. Moottorin arvokilvessä tai tuoteoppaassa ilmoitettua
nimellisnopeutta suuremmilla nopeuksilla on varmistettava,
että nopeus ei kasva suuremmaksi kuin moottorin suurin
HUOM.! sallittu pyörimisnopeus tai koko sovelluksen kriittinen
On suositeltavaa käyttää eristettyjä laakereita, joiden nopeus.
sisä- ja/tai ulkokehät on pinnoitettu alumiinioksidilla,
tai laakereita, joissa on keraamiset vierintäelimet.
Lisäksi alumiinioksidipinnoitteet tulee käsitellä
kyllästeellä, joka estää lian ja kosteuden pääsyn 6.7 Moottorit taajuusmuuttaja-
huokoiseen pinnoitteeseen. Tarkat tiedot laakereiden käytössä
eristyksestä on ilmoitettu moottorin arvokilvessä.
Laakerityypin tai eristysmenetelmän muuttaminen
ilman ABB:n lupaa on kiellettyä.
6.7.1 Yleistä
Jos käytössä on ABB:n taajuusmuuttaja, moottorit voidaan
mitoittaa ABB:n DriveSize-mitoitusohjelman avulla. Tämän
6.4.2 Laakerivirtojen ehkäiseminen kaikissa ohjelman voi ladata ABB:n Web-sivustosta (www.abb.com/
muissa säätökäytöissä motors&generators).
Käyttäjä on vastuussa moottorin ja käytettävän laitteiston
suojaamisesta haitallisilta laakerivirroilta. Luvussa 6.4.1 Jos käytössä on muita taajuusmuuttajia, moottorien
annettuja ohjeita voidaan soveltaa, mutta niiden toimivuutta mitoitus täytyy tehdä manuaalisesti. Lisätietoja saat
ei voida taata kaikissa tapauksissa. ABB:ltä.
Kuormitettavuuskäyrät (tai kuormituskäyrät) perustuvat

6.5 Kaapelointi, maadoitus ja nimellisjännitteeseen. Käyttö yli- tai alijännitteellä voi
vaikuttaa sovelluksen suorituskykyyn.
sähkömagneettinen
yhteensopivuus 6.7.2 Moottorin kuormitettavuus AC_8_ _
-sarjan taajuusmuuttajilla, joissa on
Jotta laitteet maadoittuvat asianmukaisesti ja voimassa
DTC-säätö
olevat sähkömagneettista yhteensopivuutta (EMC) koskevat
vaatimukset tulevat täytetyiksi, yli 30 kW:n moottorit on Kuvissa 5a–5d esitetyt kuormitettavuuskäyrät koskevat
kaapeloitava käyttäen suojattuja symmetrisiä kaapeleita ja ABB:n AC_8_ _ -sarjan taajuusmuuttajia, joissa on
EMC-holkkitiivisteitä, joissa on 360°:n liitos. ei-säädettävä tasajännite ja DTC-säätö. Kuvissa on
ilmoitettu suurin sallittu moottorin tuottama jatkuva
Symmetrisiä ja suojattuja kaapeleita on suositeltavaa momentti syöttötaajuuden funktiona. Momentti ilmoitetaan
käyttää myös pienemmissä moottoreissa. 360°:n prosenttiosuutena moottorin nimellismomentista. Arvot ovat
maadoitusliitokset tulee tehdä kaikkiin kaapeliaukkoihin viitteellisiä; tarkat arvot ovat saatavilla pyynnöstä.
noudattaen holkkitiivisteiden tyyppikohtaisia asennusohjeita.
Kierrä kaapelin suojavaipan johtimet nipuiksi ja kytke ne
lähimpään maadoitusliittimeen tai -kiskoon liitäntäkotelon HUOM.!
sisällä, taajuusmuuttajan kotelossa jne. Moottorin ja sovelluksen suurinta sallittua nopeutta ei
saa ylittää!
HUOM.! 6.7.3 Moottorin kuormitettavuus AC_5_ _

Kaikissa läpivienneissä (esimerkiksi moottorissa,
taajuusmuuttajassa ja mahdollisessa -sarjan taajuusmuuttajilla
turvakytkimessä) on käytettävä asianmukaisia Kuvissa 6a–6d esitetyt kuormitettavuuskäyrät koskevat
läpivientiholkkeja, joissa on 360°:n liitos. AC_5_ _ -sarjan taajuusmuuttajia. Kuvissa on ilmoitettu
suurin sallittu moottorin tuottama jatkuva momentti
syöttötaajuuden funktiona. Momentti ilmoitetaan
Moottoreissa, joiden runkokoko on vähintään IEC 280, prosenttiosuutena moottorin nimellismomentista. Arvot ovat
tarvitaan ylimääräistä potentiaalintasausta moottorin viitteellisiä; tarkat arvot ovat saatavilla pyynnöstä.
rungon ja käytetyn laitteiston välillä, elleivät molemmat ole
samalla teräsalustalla. Tässä tapauksessa teräsalustan
sähkönjohtavuus suurilla taajuuksilla on tarkistettava HUOM.!
esimerkiksi mittaamalla komponenttien välinen Moottorin ja sovelluksen suurinta sallittua nopeutta ei
potentiaaliero. saa ylittää!
6.7.4 Moottorin kuormitettavuus 6.9 Taajuusmuuttajakäytön
muilla PWM-tyyppisillä
jännitelähdetaajuusmuuttajilla
käyttöönotto
Muilla taajuusmuuttajilla, joilla on ei-säädettävä tasajännite Taajuusmuuttajakäytön käyttöönotossa on noudatettava
ja vähimmäiskytkentätaajuus 3 kHz (200–500 V), luvussa taajuusmuuttajan ohjeita ja paikallista lainsäädäntöä.
6.7.3 mainittuja mitoitusohjeita voidaan käyttää viitteellisinä Lisäksi on otettava huomioon käyttökohteen asettamat
ohjeina. On kuitenkin huomioitava, että todellinen terminen vaatimukset ja rajoitukset.
kuormitettavuus voi myös olla pienempi. Ota yhteyttä
taajuusmuuttajan valmistajaan tai järjestelmän toimittajaan. Kaikki taajuusmuuttajan säätämiseen tarvittavat parametrit
on luettava tai otettava moottorin arvokilvistä. Tavallisimmin
tarvittavat parametrit ovat seuraavat:
HUOM.!
Moottorin todellinen terminen kuormitettavuus voi
– nimellisjännite
olla pienempi kuin ohjeellisissa käyrissä ilmoitettu
– nimellisvirta
arvo.
– nimellistaajuus
– nimellisnopeus
6.7.5 Lyhytaikaiset ylikuormitukset – nimellisteho.
ABB:n moottoreita voidaan tavallisesti ylikuormittaa
väliaikaisesti sekä käyttää jaksottaisesti. Tällaisten
sovellusten mitoittaminen on helpointa DriveSize-työkalulla. HUOM.!
Jos tietoja puuttuu tai ne ovat epätäsmällisiä,
moottoria ei saa käyttää, ennen kuin oikeat
6.8 Arvokilvet asetukset on varmistettu laitteiden valmistajilta.
ABB:n moottorien käyttö taajuusmuuttajakäytössä ei
tavallisesti vaadi ylimääräisiä arvokilpiä. Taajuusmuuttajan ABB suosittelee kaikkien tilanteeseen soveltuvien
käyttöönotossa tarvittavat parametrit löytyvät taajuusmuuttajan suojausominaisuuksien käyttämistä
pääarvokilvestä. Joissakin erikoistapauksissa turvallisuuden parantamiseksi. Taajuusmuuttajissa on
moottorit saatetaan varustaa taajuusmuuttajakäytön yleensä seuraavanlaisia ominaisuuksia (ominaisuuksien
lisäarvokilvillä. Niissä on seuraavat tiedot: nimet ja käytettävyys vaihtelevat taajuusmuuttajan
valmistajan ja mallin mukaan):
– nopeusalue
– tehoalue – vähimmäisnopeus
– jännite- ja virta-alue – enimmäisnopeus
– momenttityyppi (vakio tai neliöllinen) – kiihdytys- ja jarrutusajat
– taajuusmuuttajatyyppi ja vaadittava – enimmäisvirta
vähimmäiskytkentätaajuus. – enimmäismomentti
– jumisuojaus.
7. Kunnossapito 7.1.1 Valmiustilassa olevat moottorit
Jos laivalla tai muussa tärisevässä ympäristössä oleva
moottori on valmiustilassa pidemmän aikaa, on suoritettava
VAROITUS!
seuraavat toimenpiteet:
Moottorin seisoessa jännite voi olla kytkettynä
liitäntäkotelon sisällä lämmitysvastuksille tai suoraan 1. Akselia täytyy pyörittää säännöllisesti kahden viikon
käämityksen lämmitykselle. välein (raportoidaan) käynnistämällä järjestelmä. Jos
käynnistys ei ole jostakin syystä mahdollinen, akselia
tulee vähintäänkin kääntää käsin kerran viikossa,
jotta se tulee eri asentoon. Muista aluksella olevista
7.1 Yleinen tarkistus laitteista johtuva tärinä aiheuttaa laakerin kolosyöpymää,
joka tulee minimoida säännöllisen käytön / käsin
1. Tarkista moottori säännöllisin väliajoin, vähintään kerran
pyörittämisen avulla.
vuodessa. Tarkastusten väli määräytyy esimerkiksi
ympäröivän ilman kosteustason ja paikallisten sääolojen 2. Laakeri täytyy rasvata akselin pyörittämisen yhteydessä
mukaan. Tarkastusten väli voidaan aluksi määrittää vuosittain (raportoidaan). Jos moottorin käyttöpäässä on
kokeellisesti, ja sitä on jatkossa noudatettava. rullalaakeri, kuljetuslukitus täytyy irrottaa ennen akselin
2. Pidä moottori puhtaana ja huolehdi jäähdytysilman pyörittämistä. Kuljetuslukitus täytyy asentaa takaisin
vapaasta kulusta. Jos moottoria käytetään pölyisessä paikalleen ennen kuljetusta.
ympäristössä, tuuletusjärjestelmä on tarkistettava ja 3. Kaikkea tärinää tulee välttää, jotta laakerin vioittuminen
puhdistettava säännöllisesti. voidaan estää. Kaikkia moottorin käyttöoppaassa olevia
3. Seuraa akselitiivisteiden (esim. V-renkaan tai käyttöönotto- ja huolto-ohjeita on noudatettava. Takuu ei
säteistiivisteen) kuntoa ja uusi ne tarvittaessa. kata käämityksen ja laakerin vahinkoja, jos näitä ohjeita ei
ole noudatettu.
4. Seuraa kytkentöjen ja kiinnitysruuvien kuntoa.
5. Tarkkaile laakerien kuntoa laakeriääntä kuuntelemalla,
laakerien tärinää tai lämpötilaa mittaamalla, poistuvaa 7.2 Voitelu
voiteluainetta tarkkailemalla tai SPM-valvontalaitteilla.
Tarkkaile laakereita erityisen huolellisesti silloin, kun
niiden laskettu käyttöikä alkaa lähestyä loppuaan.
VAROITUS!
Kun muuttumista alkaa tapahtua, avaa moottori, tarkista Varo pyöriviä osia!
osat ja uusi ne tarvittaessa. Moottoreihin vaihdettavien
laakereiden on oltava samaa tyyppiä kuin alkuperäisten.
Akselitiiviste on vaihdettava laakerivaihdon yhteydessä,
VAROITUS!
ja tiivisteen on oltava ominaisuuksiltaan samanlainen kuin
Monet voiteluaineet saattavat ärsyttää ihoa tai
alkuperäinen tiiviste.
aiheuttaa silmätulehduksia. Noudata voiteluaineen
Jos IP 55 -moottori on toimitettu tulppa suljettuna, on valmistajan antamia turvaohjeita.
suositeltavaa avata vesireikien tulpat säännöllisesti,
jotta moottoriin kondensoituneen veden poistumistie ei
tukkeutuisi ja jotta vesi pääsisi ulos. Tämä tehdään, kun Laakerityypit on mainittu tuote-esitteissä ja kaikkien
moottori on pysähdyksissä ja sellaisessa tilassa, jossa sen moottoreiden arvokilvissä runkokooltaan pienimpiä
käsittely on turvallista. moottoreita lukuun ottamatta.
Käyttövarmuus on tärkeä tekijä laakerien voiteluvälejä

määritettäessä. ABB käyttää voitelussa pääasiassa L1-
periaatetta, joka tarkoittaa, että 99 % moottoreista toimii
häiriöttömästi ilmoitetun käyttötuntimäärän ajan.
7.2.1 Kestovoidelluilla laakereilla varustetut

moottorit
Laakerit ovat yleensä 1Z-, 2Z- tai 2RS-tyyppisiä tai
vastaavia kestovoideltuja laakereita.
Ohjeena on seuraava taulukko, jossa esitetään voitelun

riittävyys runkokokoon 250 asti L1-periaatteen mukaan.
Lisätietoja käyttötunneista korkeammissa lämpötiloissa
saa tarvittaessa ABB:ltä. Ohjeellinen kaava L1-arvojen
likimääräiseen muuntamiseen L10-arvoiksi: L10 = 2,0 x L1.
Kestovoideltujen laakereiden käyttötunnit lämpötiloissa Uudelleenvoitelu moottorin ollessa pysähtyneenä
25 °C ja 40 °C ovat seuraavat: Moottori voidellaan yleensä moottorin pyöriessä,
mutta voitelu voidaan suorittaa myös moottorin ollessa
Runko- Käyttötunteja Käyttötunteja pysähtyneenä.
koko Napaluku 25 °C 40 °C – Tällöin lisätään ensin vain puolet suositellusta voitelu-
56 2 52 000 33 000 ainemäärästä ja annetaan koneen käydä täydellä
56 4–8 65 000 41 000 nopeudella muutama minuutti.
63 2 49 000 31 000 – Kun moottori on pysähtynyt, lisätään loput
63 4–8 63 000 40 000 voiteluaineesta.
71 2 67 000 42 000 – Anna moottorin pyöriä 1–2 tuntia ja sulje sen jälkeen
71 4–8 100 000 56 000 tiivistystulpilla varustetut poistoaukot tai sulkuventtiili.
80–90 2 100 000 65 000
B. Automaattivoitelu
80–90 4–8 100 000 96 000
100–112 2 89 000 56 000 Poistoaukon tulppa on poistettava pysyvästi tai mahdollinen
100–112 4–8 100 000 89 000 sulkuventtiili on avattava, jos käytetään automaattista
132 2 67 000 42 000 voitelua.
132 4–8 100 000 77 000
ABB suosittelee vain sähkömekaanisten järjestelmien
160 2 60 000 38 000
käyttöä.
160 4–8 100 000 74 000
180 2 55 000 34 000 Taulukoissa mainitut voiteluainemäärät voiteluväliä kohti
180 4–8 100 000 70 000 täytyy nelinkertaistaa, jos käytetään keskusvoitelu-
200 2 41 000 25 000 järjestelmää. Pienemmän automaattivoiteluyksikön (yksi tai
200 4–8 95 000 60 000 kaksi kasettia moottoria kohti) tapauksessa voidaan käyttää
225 2 36 000 23 000 normaalia voiteluainemäärää.
225 4–8 88 000 56 000
Käytettäessä automaattivoitelua kaksinapaisille moottoreille
250 2 31 000 20 000
on noudatettava niitä koskevaa voiteluainesuositusta, joka
250 4–8 80 000 50 000 on annettu luvussa Voiteluaineet.
Tiedot ovat voimassa 60 Hz:iin asti.
Käytetyn voiteluaineen tulee soveltua automaattivoiteluun.
Automaattivoitelujärjestelmän jakaja ja voiteluaineen
7.2.2 Jälkivoideltavilla laakereilla varustetut valmistajan suositukset tulee tarkistaa.
moottorit
Laskentaesimerkki automaattivoitelujärjestelmän
Voiteluohjekilpi ja yleisiä voiteluohjeita voiteluainemäärälle
Jos moottorissa on voiteluohjekilpi, noudata siinä olevia Keskusvoitelujärjestelmä: Moottori IEC M3_P 315_
arvoja. 4-napainen 50 Hz:n verkossa, taulukon mukainen
uudelleenvoiteluväli on 7 600 h/55 g (DE) ja 7 600 h/40 g
Voiteluohjekilvessä ilmoitetaan voiteluvälit asennustavan, (NDE):
ympäristön lämpötilan ja pyörintänopeuden mukaisesti.
Ensimmäisen käynnistyksen aikana tai laakerin voitelun (DE) RLI = 55 g/7 600 h*3*24 = 0,52 g/vrk
jälkeen voi esiintyä väliaikaista lämpötilan kohoamista noin (NDE) RLI = 40 g/7 600 h*3*24 = 0,38 g/vrk
10–20 tunnin ajan.
Laskentaesimerkki yhden automaattivoiteluyksikön
Joissakin moottoreissa voi olla poistuvan voiteluaineen
(kasetin) voiteluainemäärälle
kerääjä. Noudata laitteen erillisohjeita.
(DE) RLI = 55 g/7 600 h*24 = 0,17 g/vrk
A. Manuaalinen voitelu
(NDE) RLI = 40 g/7 600 h*24 = 0,13 g/vrk
Uudelleenvoitelu moottorin pyöriessä
– Jos voiteluaineen poistoaukot on varustettu tiivistystulpilla RLI = uudelleenvoiteluväli, DE = käyttöpää, NDE = N-pää
tai sulkuventtiilillä, poista ne voitelun ajaksi.
– Varmista, että voitelukanava on auki. 7.2.3 Voiteluvälit ja -määrät
– Purista suositeltu määrä voiteluainetta laakereihin.
– Anna moottorin pyöriä 1–2 tuntia varmistaaksesi, että Pystyasentoon asennettujen moottorien voiteluvälit ovat
ylimääräinen voiteluaine on poistunut. Sulje tiivistystulpilla puolet taulukon arvoista.
varustetut poistoaukot tai sulkuventtiili.
Ohjeena on seuraava taulukko, jossa esitetään voitelun
riittävyys L1-periaatteen mukaan. Lisätietoja käyttötunneista
korkeammissa lämpötiloissa saa tarvittaessa ABB:ltä.
Ohjeellinen kaava, jolla L1-arvot voidaan muuntaa karkeasti
L10-arvoiksi, on L10 = 2,0 x L1 manuaalivoitelulla.
Voiteluvälit perustuvat laakerin käyttölämpötilaan 80 °C

(ympäristön lämpötila +25 °C).
Nopeamman pyörimisen käyttö, esim. taajuusmuuttaja-
HUOM.! käyttö, tai pienempi nopeus raskaammalla kuormituksella
Ympäristön lämpötilan nousu nostaa laakerien edellyttää lyhyempää voiteluväliä.
lämpötilaa vastaavasti. Väliarvot tulee puolittaa
laakerin lämpötilan noustessa 15 °C, ja ne voidaan
VAROITUS!
kaksinkertaistaa laakerin lämpötilan laskiessa 15 °C.
Voiteluaineen ja laakerin suurinta sallittua
käyttölämpötilaa +110 °C ei saa ylittää.
Moottorin suurinta sallittua nopeutta ei saa ylittää.
Voiteluaineen
Runko- 3 600 3 000 1 800 1 500 1 000 500–900
määrä kW kW kW kW
koko r/min r/min r/min r/min r/min r/min
g/laakeri
Kuulalaakerit, voiteluväli käyttötunteina
112 10 kaikki 10 000 13 000 kaikki 18 000 21 000 kaikki 25 000 kaikki 28 000
132 15 kaikki 9 000 11 000 kaikki 17 000 19 000 kaikki 23 000 kaikki 26 500
160 25 ≤ 18,5 9 000 12 000 ≤ 15 18 000 21 500 ≤ 11 24 000 kaikki 24 000
160 25 > 18,5 7 500 10 000 > 15 15 000 18 000 > 11 22 500 kaikki 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 kaikki 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 kaikki 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 kaikki 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 kaikki 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 kaikki 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 kaikki 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 kaikki 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 kaikki 7 000
2801) 60 kaikki 2 000 3 500 – – – – – –
2801) 60 – – – kaikki 8 000 10 500 kaikki 14 000 kaikki 17 000
280 35 kaikki 1 900 3 200 – – – –
280 40 – – kaikki 7 800 9 600 kaikki 13 900 kaikki 15 000
315 35 kaikki 1 900 3 200 – – – –
355 35 kaikki 1 900 3 200 – – – –
400 40 kaikki 1 500 2 700 – – – –
450 40 kaikki 1 500 2 700 – – – –
Rullalaakerit, voiteluväli käyttötunteina

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 kaikki 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 kaikki 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 kaikki 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 kaikki 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 kaikki 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 kaikki 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 kaikki 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 kaikki 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 kaikki 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 kaikki 3 500
2801) 60 kaikki 1 000 1 750 – – – – – – –
2801) 70 – – – kaikki 4 000 5 250 kaikki 7 000 kaikki 8 500
280 35 kaikki 900 1 600 – – – –
315 35 kaikki 900 1 600 – – – –
355 35 kaikki 900 1 600 – – – –
400 40 kaikki – 1 300 – – – –
450 40 kaikki – 1 300 – – – –
1)
M3AA
7.2.4 Voiteluaineet Seuraavia voiteluaineita voidaan käyttää valurautaisissa
suurnopeusmoottoreissa, mutta ei sekoitettuina
litiumkompleksirasvoihin:
VAROITUS!
Älä sekoita eri voiteluaineita keskenään. – Klüber Klüber Quiet BQH 72-102 (polyureapohja)
Yhteensopimattomat voiteluaineet voivat aiheuttaa – Lubcon Turmogrease PU703 (polyureapohja).
laakerivaurion.
Jos muita voiteluaineita käytetään, tarkista valmistajalta,
että niiden laatu vastaa edellä mainittuja voiteluaineita.
Voitelussa on käytettävä vain erikoisesti kuulalaakereille Voiteluaineiden voiteluvälit perustuvat siihen, että käytetään
tarkoitettuja voiteluaineita, joiden ominaisuudet vastaavat edellä lueteltuja laadukkaita voitelulaineita. Muiden
seuraavia vaatimuksia: voiteluaineiden käyttäminen voi lyhentää voiteluväliä.
– laadukas litium-kompleksisaippua ja mineraali- tai
PAO-öljy
– perusöljyn viskositeetti 100–160 cST 40 °C:ssa
– kovuusluokka NLGI-aste 1,5–3 *)
– lämpötila-alue −30 °C...+120 °C, jatkuvasti.
*) Pystyasentoon asennetuille moottoreille ja kuumiin

olosuhteisiin suositellaan korkeampaa NLGI-astetta.
Edellä annetut voiteluainemääritykset ovat voimassa, jos

ympäristön lämpötila on välillä −30 °C...+55 °C ja laakerin
lämpötila on alle 110 °C. Muussa tapauksessa ota yhteys
ABB:n edustajaan, jolta saat tietoja sopivan voiteluaineen
valitsemisesta.
Oikeanlaatuisia voiteluaineita on saatavissa kaikilta

tärkeimmiltä voiteluainevalmistajilta.
Lisäaineistus on suotava, mutta voiteluaineen valmistajalta

on saatava kirjallinen takuu erityisesti EP-lisäaineista, että
ne eivät toimintalämpötila-alueella vahingoita laakerin tai
voiteluaineen ominaisuuksia.
VAROITUS!
EP-lisäaineisia voiteluaineita ei suositella korkeissa
laakerilämpötiloissa runkokokoluokissa 280 - 450.
Seuraavia laadukkaita voiteluaineita voidaan käyttää:

– Mobil Unirex N2 tai N3 (litiumkompleksipohja)
– Mobil Mobilith SHC 100 (litiumkompleksipohja)
– Shell Gadus S5 V 100 2 (litiumkompleksipohja)
– Klüber Klüberplex BEM 41-132 (erikoislitiumpohja)
– FAG Arcanol TEMP110 (litiumkompleksipohja)
– Lubcon Turmogrease L 802 EP PLUS (erikoislitiumpohja)
– Total Multiplex S2 A (litiumkompleksipohja)
– Rhenus Rhenus LKZ 2 (litiumkompleksipohja).
HUOM.!
Kaksinapaisissa suurnopeusmoottoreissa, joiden
nopeuskerroin (Dm x n, jossa Dm = keskimääräinen
laakerin halkaisija [mm] ja n = pyörimisnopeus, r/min)
on suurempi kuin 480 000, on käytettävä suur-
nopeusvoiteluaineita.
8. After Sales -tuki 9. Ympäristövaatimukset
Useimpien ABB:n moottoreiden äänenpainetaso ei ole yli
8.1 Varaosat 82 dB(A) (± 3 dB) 50 Hz:n taajuudella.
Ellei muuta mainita, varaosien on oltava alkuperäisosia tai Yksittäisten moottorien arvot on annettu vastaavissa tuote-
ABB:n hyväksymiä. esitteissä. 60 Hz:n sinimuotoisella syötöllä arvot ovat noin
Varaosia tilattaessa on ilmoitettava moottorin sarjanumero, 4 dB(A) suuremmat kuin tuote-esitteissä annetut 50 Hz:n
täydellinen tyyppimerkintä ja tuotekoodi. Nämä tiedot on arvot.
annettu arvokilvessä. Tietoja äänenpainetasoista taajuusmuuttajakäytöissä saat
ABB:ltä.
8.2 Purkaminen, kokoaminen Kun moottori(t) on hävitettävä tai kierrätettävä, on
ja uudelleenkäämintä noudatettava asianmukaisia menetelmiä sekä paikallisia
säädöksiä ja lakeja.
Uudelleenkääminnän saa suorittaa vain pätevä korjaamo.
Ota yhteyttä ABB:hen ennen savukaasun poistoon

tarkoitettujen moottorien ja muiden erikoismoottorien
uudelleenkäämintää.
8.3 Laakerit
Laakereista on pidettävä erityistä huolta.
Laakerit on poistettava ulosvetäjällä ja asennettava

lämmitettyinä tai erityistyökaluja käyttäen.
Laakereiden vaihto on kuvattu erillisessä ABB:n

tuotemyynnistä saatavassa ohjeessa.
Kaikkia moottorissa olevia ohjeita, kuten tarroja, on

noudatettava. Arvokilpeen merkittyjä laakerityyppejä ei saa
vaihtaa.
HUOM.!
Loppukäyttäjän tekemät korjaukset, joita valmistaja
ei ole erikseen hyväksynyt, vapauttavat valmistajan
vaatimustenmukaisuusvastuusta.
10. Vianmääritys
Nämä ohjeet eivät kata kaikkia laitteiston vaihtoehtoja tai
yksityiskohtia eivätkä anna tietoja kaikista mahdollisista
asennuksen, käytön tai huollon aikana ilmenevistä
tilanteista. Lisäohjeita saa ottamalla yhteyttä lähimpään
ABB:n myyntikonttoriin.
Moottorin vianetsintäkaavio
Moottorin huolto- ja vianetsintätoimenpiteitä saavat
suorittaa vain pätevät henkilöt, joilla on tarvittavat työkalut ja
välineet.
ONGELMA AIHEUTTAJA SUOSITELTAVA TOIMENPIDE

Moottori ei Sulake palanut Vaihda oikeantyyppinen ja nimellisarvoinen sulake.
käynnisty Ylikuormalaukaisu Tarkista ja kuittaa ylikuormalaukaisu käynnistimeltä.
Väärä syöttöjännite Tarkista, että syöttöjännite on arvokilven ja kuormituskertoimen
mukainen.
Virheellinen kytkentä Tarkista kytkennät moottorin mukana toimitetuista kytkentäkaavioista
ja arvokilvestä.
Katkos käämissä tai ohjauspiirissä Vian voi tunnistaa surisevasta äänestä, kun kytkin on suljettuna.
Tarkista löysät johtokytkennät ja varmista, että kaikki ohjauskytkimet
sulkeutuvat.
Mekaaninen vika Tarkista, että moottori ja käyttö pyörivät vapaasti.
Tarkista laakerointi ja voitelu.
Käämin oikosulku
Huono kosketus käämissä Vika aiheuttaa sulakkeiden palamisen. Moottori täytyy
käämiä uudelleen.
Irrota laakerikilvet ja etsi vika.
Viallinen roottori Tarkista roottoritankojen ja oikosulkurenkaiden kunto.
Moottori voi olla ylikuormitettu Vähennä kuormitusta.
Moottori Yhdessä vaiheessa voi olla Tarkista kytkennät katkosten varalta.
pysähtynyt jännitekatkos
Vääränlainen moottori sovellukseen Vaihda moottorityyppi tai -koko. Ota yhteys laitetoimittajaan.
Ylikuormitus Vähennä kuormitusta.
Pienjännite Varmista, että arvokilvessä ilmoitettua jännitettä on noudatettu.
Tarkista kytkennät.
Jännitekatkos Sulakkeet palaneet. Tarkista ylikuormitusrele, staattori ja painikkeet.
Moottori Syöttöjännitevika Tarkista, että vaihejohtimen, sulakkeiden ja ohjauspiirin kytkennät eivät
käynnistyy, mutta ole löysiä.
pysähtyy heti
Moottori ei saavuta Vääränlainen moottori sovellukseen Ota yhteys laitetoimittajaan, jotta voit valita oikean moottorin.
nimellisnopeuttaan Jännite moottorin liittimissä liian Käytä suurempaa jännitettä tai käynnistysmuuntajaa. Vähennä
alhainen jännitehäviöiden vuoksi kuormitusta.
Tarkista kytkennät. Tarkista kaapelien oikea koko.
Liian suuri kuorma käynnistettäessä Tarkista moottorin käynnistyminen "ilman kuormaa".
Roottori on rikki Tarkista oikosulkurenkaiden mahdolliset murtumat. Tarvitaan luultavasti
uusi roottori, koska korjaus on yleensä tilapäinen.
Katkos päävirtapiirissä Etsi vika testauslaitteella ja korjaa se.
ONGELMA AIHEUTTAJA SUOSITELTAVA TOIMENPIDE
Moottorin Ylikuormitus Vähennä kuormitusta.
kiihdytysaika on Liian alhainen jännite käynnistettäessä Tarkista mahdollinen suuri vastus. Varmista, että kaapelin koko on
liian pitkä, ja/tai riittävä.
virrankulutus on
liian suuri Viallinen oikosulkuroottori Vaihda roottori.
Liian pieni syöttöjännite Korjaa syöttöjännite.
Väärä Väärä vaihejärjestys Vaihda kytkentä moottorin liittimissä tai kytkintaulussa.
pyörimissuunta
Moottori Ylikuormitus Vähennä kuormitusta.
ylikuumenee Runko tai jäähdytysaukot voivat olla Avaa tuuletusaukot ja varmista, että ilmavirtaus moottorista on jatkuva.
likaiset tai tukossa, mikä estää riittävän
tuuletuksen
Moottorin yhdessä vaiheessa voi olla Tarkista kaikkien johdinten ja kaapelien kytkentä.
katkos
Maasulku Moottori täytyy käämiä uudelleen.
Epäsymmetrinen jännite Tarkista johtimet, kytkennät ja muuntajat.
moottoriliittimissä
Moottori tärisee Virheellinen linjaus Linjaa moottori uudelleen.
Moottorin alusta heikko Vahvista alustaa.
Kytkin epätasapainossa Tasapainota kytkin.
Käytettävä laite epätasapainossa Tasapainota laite.
Vialliset laakerit Vaihda laakerit.
Laakerit eivät ole linjassa Korjaa moottori.
Roottorin tasapainotus muuttunut Tasapainota roottori.
Roottorin ja kytkimen tasapainotukset Tasapainota kytkin tai roottori.
erilaiset (puoli kiilaa – täysi kiila)
Monivaiheinen moottori käy Tarkista kytkennät.
yksivaiheisena
Liian suuri aksiaalivälys Säädä laakerointi tai lisää välilevy.
Hankaava ääni Tuuletin hankaa laakerikilpeen tai Korjaa tuulettimen kiinnitys.
suojukseen
Moottori irronnut alustastaan Kiristä pultit.
Meluinen Ilmaväli on epätasainen Tarkista laakerikilvet ja laakerit.
käyntiääni Roottori epätasapainossa Tasapainota roottori.
Laakereiden Taipunut tai rikkoutunut akseli Vaihda roottori.
kuumeneminen Hihna on liian kireällä Vähennä hihnan kireyttä.
Hihnapyörät liian kaukana akselin Siirrä hihnapyörä lähemmäksi moottorin laakeria.
olakkeesta
Hihnapyörän halkaisija liian pieni Käytä halkaisijaltaan suurempia hihnapyöriä.
Moottori ei ole linjassa Korjaa linjaamalla käyttö uudelleen.
Liian vähän voiteluainetta Huolehdi laakerin riittävästä voitelusta ja voiteluaineen laadusta.
Voiteluaineen laadun heikkeneminen tai Poista vanha voiteluaine, pese laakerit huolellisesti ja vaihda uusi
epäpuhtaudet voiteluaine.
Liikaa voiteluainetta Vähennä voiteluaineen määrää.
Laakerin ylikuormitus Tarkasta linjaus sekä sivuttaisvoima ja aksiaalipaine.
Vioittunut laakeri Vaihda laakeri. Puhdista ensin laakeripesä huolellisesti.
Alçak Gerilim Motor
Kurulum, işletim, bakım ve emniyet kılavuzu
İçindekiler
1. Giriş .................................................................................................................................................... 161
1.1 Uygunluk Bildirimi ................................................................................................................................................................................161
1.2 Geçerlilik .....................................................................................................................................................................................................161
2. Emniyet değerlendirmeleri.............................................................................................................. 161
3. Taşıma ................................................................................................................................................ 162
3.1 Kabul kontrolü ........................................................................................................................................................................................162
3.2 Nakliye ve depolama ..........................................................................................................................................................................162
3.3 Kaldırma ......................................................................................................................................................................................................162
3.4 Motor ağırlığı ...........................................................................................................................................................................................162
4. Kurulum ve devreye alma ................................................................................................................ 163
4.1 Genel.............................................................................................................................................................................................................163
4.2 Bilyalı rulman dışında donanımları olan motorlar.............................................................................................................163
4.3 Yalıtım direnci kontrolü .....................................................................................................................................................................163
4.4 Temel ............................................................................................................................................................................................................163
4.5 Kaplinlerin ve kasnakların balansının alınması ve takılması ........................................................................................163
4.6 Motorun montajı ve kaplin ayarının yapılması ...................................................................................................................164
4.7 Radyal kuvvetler ve kayış tahrikleri .............................................................................................................................................164
4.8 Yoğuşma için tahliye tapalarına sahip motorlar.................................................................................................................164
4.9 Kablo ve elektriksel bağlantılar .....................................................................................................................................................164
4.9.1 Farklı yolverme yöntemlerine ilişkin bağlantılar ........................................................................................165
4.9.2 Yardımcı aksesuarların bağlantıları .....................................................................................................................165
4.10 Terminaller ve dönüş yönü..............................................................................................................................................................165
5. İşletim ............................................................................................................................................... 166
5.1 Genel.............................................................................................................................................................................................................166
Alçak gerilim motor kılavuzu, 3GZF500730-85 Rev F 02-2015 | ABB Motorları ve Generatörleri 159
6. Değişken hızlarda işletilen alçak gerilim motorlar ........................................................................... 167
6.1 Giriş ................................................................................................................................................................................................................167
6.2 Sargı yalıtımı .............................................................................................................................................................................................167
6.2.1 ABB konvertörler için sargı yalıtımı seçimi .....................................................................................................167
6.2.2 Tüm diğer konvertörlere ilişkin sargı izolasyonunun seçimi .............................................................167
6.3 Termal koruma .......................................................................................................................................................................................167
6.4 Rulman akımları .....................................................................................................................................................................................167
6.4.1 ABB konvertörleri için rulman akımlarının giderilmesi ..........................................................................167
6.4.2 Diğer konvertörler için rulman akımlarının giderilmesi ........................................................................168
6.5 Kablolama, topraklama ve EMC (Elektromanyetik Uyumluluk) ................................................................................168
6.6 İşletme hızı ................................................................................................................................................................................................168
6.7 Değişken hızlı uygulamalarda motorlar ..................................................................................................................................168
6.7.1 Genel.....................................................................................................................................................................................168
6.7.2 AC_8_ _ – serisi DTC kontrolü konvertörler ile motor yüklenebilirliği .........................................168
6.7.3 AC_5_ _ – serisi konvertörler ile motor yüklenebilirliği ........................................................................168
6.7.4 Diğer gerilim kaynağı PWM tipi konvertörler ile motor yüklenebilirliği......................................168
6.7.5 Kısa süreli aşırı yüklenmeler ....................................................................................................................................169
6.8 Motor plakaları ........................................................................................................................................................................................169
6.9 Frekans konvertörünün devreye alınması .............................................................................................................................169
7. Bakım ................................................................................................................................................. 170
7.1 Genel inceleme ......................................................................................................................................................................................170
7.1.1 Bekleme konumundaki motorlar ...................................................................................................................................170
7.2 Yağlama.......................................................................................................................................................................................................170
7.2.1 Kendinden yağlamalı rulmanlara sahip motorlar .....................................................................................170
7.2.2 Gresörlüklü rulmanlara sahip motorlar............................................................................................................171
7.2.3 Yağlama aralıkları ve miktarları..............................................................................................................................171
7.2.4 Yağlar ....................................................................................................................................................................................173
8. Satış sonrası Destek.......................................................................................................................... 174
8.1 Yedek parçalar .........................................................................................................................................................................................174
8.2 Parçalarına ayırma, birleştirme ve tekrar sarma ..................................................................................................................174
8.3 Rulmanlar ...................................................................................................................................................................................................174
9. Çevresel gereklilikler........................................................................................................................ 174
10. Sorun Giderme .................................................................................................................................. 175
160 ABB Motorları ve Generatörleri | Alçak gerilim motor kılavuzu, 3GZF500730-85 Rev F 02-2015
1. Giriş 2. Emniyet değerlendirmeleri
Motor, nitelikli, sağlık ve emniyet gereklilikleri ile ulusal mevzuatı
NOT!
bilen kişilerce kurulum ve bakım için tasarlanmıştır.
Motorun emniyetli ve uygun kurulumu, işletimi ve bakımı
için bu talimatlara uyulmalıdır. Bu talimatlar, motoru veya Kurulumda ve işletim sahasında kazaların önlenmesi için gerekli
bağlantılı ekipmanı kuran, işleten veya bakımını yapan emniyet ekipmanı, yerel yönetmeliklere göre sağlanmalıdır.
kişilerin dikkatine sunulmalıdır. Motor, nitelikli, sağlık ve
emniyet gereklilikleri ile ulusal mevzuatı bilen kişilerce
kurulum ve bakım için tasarlanmıştır. Bu talimatlara UYARI!
uyulmaması, yürürlükteki tüm garantileri geçersiz kılabilir. Acil stop kontrolleri yeniden başlatma kilitleriyle
donatılmalıdır. Acil stop sonrasında, yeni bir başlatma
komutu sadece yeniden başlatma kilidi kasten
1.1 Uygunluk Bildirimi resetlendiğinde etkili olabilir.
Motor makineye takıldığında, devreye alan tarafça tamamlanmış

ürünün 2006/42/EC no.lu Direktife (Makine) göre uygunluğu Dikkat edilmesi gerekenler:
sağlanmalıdır.
1. Motor üzerine çıkmayın / basmayın.
2. Motorun dış gövdesinin sıcaklığı normal işletim esnasında
1.2 Geçerlilik özellikle kapatma işleminden sonra dokunulmayacak kadar
sıcak olabilir.
Bu talimatlar, aşağıdaki ABB elektrik makine tipleri, hem motor
hem de generatör işletimi için geçerlidir. 3. Bazı özel motor uygulamaları ek talimatlar gerektirir (örn.
frekans konvertörü tarafından beslendiğinde).
seri MT*, MXMA, 4. Motorun dönen parçalarına temas etmeyin.
series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*, 5. Elektrik verilirken, terminal kutularını açmayın.
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*,
M2V*/M3V*
yapı büyüklükleri 56 - 450.
Ex motorları "patlayıcı atmosferler için alçak gerilim motorları

için ayrı bir kılavuz bulunmaktadır: Kurulum, işletim, bakım ve
emniyet kılavuzu (3GZF500730-47)
Özel uygulama ve/veya tasarım değerlendirmeleri nedeniyle

bazı makine tipleri için ilave bilgi gereklidir.
Aşağıdaki motorlar için ilave kılavuz mevcuttur:

– roller table motorları
– su soğutmalı motorlar
– duman tahliye motorları
– frenli motorlar
– yüksek ortam sıcaklıklarına uygun motorlar
– Gemilerin ve açık deniz birimlerinin güvertesinde kullanılan
denizcilik uygulamaları için motorlaredilen deniz
uygulamalarına yönelik motorlar
3. Taşıma Uygun kaldırma ekipmanının kullanılmasını ve kancaların
boyutlarının kaldırma mapaları için uygun olmasını sağlayın.
3.1 Kabul kontrolü Motora bağlı yardımcı ekipmana ve kablolara zarar verilmemesi
için özen gösterilmelidir.
Alımı takiben derhal motoru harici hasara karşı (örneğin mil
uçları, lanşlar ve boyalı yüzeyler gibi) kontrol edin, tespit Motoru palete sabitleyen nakliye kılavuzlarını çıkarın.
edildiğinde, gecikmeksizin taşıyıcıyı bilgilendirin.
ABB'den özel kaldırma talimatları alınabilir.
Tüm etiket değerlerini, özellikle gerilim ve sargı bağlantısı (yıldız
veya üçgen) bilgilerini kontrol edin. Rulman tipi, en küçük yapı
büyüklüğündeki motorlar hariç olmak üzere, tüm motorların UYARI!
motor etiketi üzerinde belirtilir. Kaldırma, montaj ya da bakım çalışması sırasında, gerekli
tüm güvenlik hususları göz önünde bulundurulacak ve
Değişken hızlı tahrik uygulaması durumunda, motorun ikinci kaldırılan yük nedeniyle kimsenin tehlikede olmamasına
motor etiketinde bulunan frekansa göre izin verilen maksimum özellikle dikkat edilecektir.
yüklenebilirliği kontrol edin.
3.2 Nakliye ve depolama 3.4 Motor ağırlığı

Motor her zaman iç mekanlarda (–20°C üzeri), kuru, titreşimsiz Toplam motor ağırlığı, farklı çıkış, montaj düzeni ve yardımcı
ve toz olmayan koşullarda saklanmalıdır. Nakliye esnasında, ekipmanlara bağlı olarak aynı gövde boyutundaki motorlar (mil
şoklardan, düşmelerden ve nemden kaçınılmalıdır. Diğer merkezinin yerden yüksekliği) arasında değişiklik gösterebilir.
şartlarda, lütfen ABB ile irtibata geçin.
Aşağıdaki tablo, motorların kendi temel sürümlerinde
Korunmamış işlenmiş yüzeyler (mil uçları ve lanşlar), korozyona gövde malzemesine bağlı olarak tahmini azami ağırlıkları
karşı işlemden geçirilmelidir. göstermektedir.
Yağ azalmasını önlemek için millerin düzenli olarak elle Tüm ABB motorlarına ait gerçek ağırlık, en küçük gövde
döndürülmesi tavsiye edilir. boyutundaki motorlar hariç olmak üzere (56 ve 63), motor
etiketinde gösterilmiştir
Isıtıcıların, takıldıkları takdirde, motordaki su yoğuşmasını
önlemek için kullanılmaları tavsiye edilir. Yapı büyüklüğü Alüminyum Pik döküm İlave.
fren için
Motor stok durumundayken, rulmanlara yönelik zarardan Ağırlık kg Ağırlık kg
kaçınmak amacıyla harici titreşimlere maruz kalmamalıdır. 56 4.5 - -
63 6 - -
Silindirik makaralı ve/veya açısal temaslı rulmanlara sahip 71 8 13 5
motorlar nakliye esnasında kilitleme cihazları ile donatılmalıdır. 80 14 20 8
90 20 30 10
3.3 Kaldırma 100 32 40 16
112 36 50 20
25 kg'dan ağır tüm ABB motorlarında kaldırma mapaları veya 132 93 90 30
gözlü cıvatalar bulunur. 160 149 130 30
180 162 190 45
Motorun kaldırılması için sadece motora ait kaldırma mapaları
200 245 275 55
ve gözlü cıvatalar kullanılmalıdır. Motor diğer ekipmana 225 300 360 75
bağlıyken, motoru kaldırmak için kullanılmamalıdırlar. 250 386 405 75
280 425 800 -
Yardımcı ekipmana (örneğin frenler, harici soğutma fanları) veya
315 - 1700 -
terminal kutularına ait kaldırma mapaları motorun kaldırılması
355 - 2700 -
için kullanılmamalıdır. Farklı çıkış, montaj düzenlemeleri ve
400 - 3500 -
yardımcı ekipman nedeniyle, aynı yapı büyüklüğüne sahip
450 - 4500 -
motorların ağırlık merkezi farklı olabilir.
Hasarlı kaldırma mapaları kullanılmamalıdır. Gözlü cıvataları veya Motorda harici fan bulunuyorsa, ağırlık için ABB ile irtibata geçin.
entegre kaldırma mapalarını, kaldırma öncesinde kontrol edin.
Kaldırma gözlü cıvataları, kaldırma öncesi sıkıştırılmalıdır.

Gerekirse, gözlü cıvatanın konumu, ara parça olarak uygun
pulların kullanılması ile ayarlanabilir.
4. Kurulum ve devreye alma
UYARI! UYARI!
Motoru veya tahrik edilen ekipmanı çalışmaya Elektrik çarpması riskini önlemek için, motor şasesi
başlamadan önce devre dışı bırakın ve kilitleyin. topraklanmalı ve sargılar ölçümden hemen sonra şase
üzerinden deşarj edilmelidir.
4.1 Genel Referans direnç değerine ulaşılmamışsa, sargı çok ıslaktır ve

Etiket değerlerinin tümü, motor koruması ve bağlantısının fırında kurutulması gerekir. Fırın sıcaklığı 12-16 saat boyunca
düzgün biçimde yapılmasını sağlamak üzere dikkatlice kontrol 90°C, ardından 6-8 saat boyunca 105°C olmalıdır.
edilmelidir.
Isıtma esnasında mevcutsa, tahliye deliği tapaları çıkarılmalıdır
ve kapatma valleri açık olmalıdır. Isıtma sonrasında, tapaların
4.2 Bilyalı rulman dışında tekrar takıldığından emin olun. Tahliye tapaları takılı olsa bile,
ön ve arka kapakların ve terminal kutusu kapaklarının kurutma
donanımları olan motorlar işlemi için sökülmesi tavsiye edilir.
Motorun montajı yapılmışsa, nakliye kilidini çıkarın. Motorun Deniz suyu ile ıslanmış sargıların tekrar sarılması gerekir.
milini, mümkünse serbest olarak dönmesini kontrol etmek üzere
elle çevirin.
4.4 Temel
Makaralı rulman bulunan motorlar: Temelin hazırlanması tamamen son kullanıcının
Mile hiçbir radyal kuvvet uygulamaksızın motorun çalıştırılması, sorumluluğundadır.
makaralı rulmana "kaymaya" bağlı olarak zarar verebilir.
Metal temeller, korozyonu önlemek için boyanmalıdır.
Açılı temas rulmanı bulunan motorlar: Temel düz, dengeli ve olası kısa devre güçlerine dayanacak
Mile dik yönde hiçbir eksenel kuvvet olmaksızın motorun kadar sağlam olmalıdır.
çalıştırılması, açılı temas rulmanına zarar verebilir.
Temel, motora titreşim aktarımını ve rezonans nedeni ile oluşan
titreşimleri önlemek üzere dizayn edilmiş olmalıdır.
UYARI!
Açılı rulmana sahip motorlar için, eksenel kuvvet hiçbir
suretle yön değiştirmemelidir. Cetvel
Rulman tipi, motor etiketinde belirtilmiştir.

Not: Motorun ayakları arasındaki
yükseklik farkı +/- 0,1 mm yi
Gresörlük bulunan motorlar: geçmemelidir
Motoru uzun depolama sonrasında veya ilk kez çalıştırmaya
başlarken, belirtilen yağ miktarını uygulayın.
Daha fazla ayrıntı için bkz. bölüm “7.2.2 Yağlanabilir rulmanlı

motorlar”.
Ayak konumu
Mil aşağıya bakacak şekilde dikey bir konumda bağlandığında,
yabancı maddelerin ve sıvıların havalandırma açıklıklarına
girmesini önlemek için motorda bir koruyucu kapak bulunması
gerekir. Bu, motora bağlı olmayan ayrı bir kapak ile de
sağlanabilir. Bu durumda, motorda uyarı etiketi bulunması 4.5 Kaplinlerin ve kasnakların
gerekir.
balansının alınması ve takılması
4.3 Yalıtım direnci kontrolü Standart olarak, motorun balansının alınması yarım kama
kullanılarak yapılmıştır.
Devreye almadan önce sargıların nemlendiğinden şüphe
ediliyorsa yalıtım direnci ölçülmelidir. Kaplin veya kasnaklar, kama yollarının işlenmesini takiben
mutlaka balans alma işlemine tabi tutulmalıdır. Balans
25 °C'ye göre düzeltilmiş yalıtım direnci hiçbir durumda 1 MΩ alma işlemi, motor için belirlenen balans alma yöntemi
(500 ya da 1000 VDC ile ölçülmüş) altında olamaz. Yalıtım direnci doğrultusunda yapılmalıdır.
değeri sıcaklıktaki her 20 °C artışla yarılanır. Tablo 1, istenilen
sıcaklığa yalıtım düzeltmesi uygulamak için kullanılabilir.
Kaplin ve kasnaklar, rulman ve contalara hasar vermeyen uygun 4.8 Yoğuşma için tahliye tapalarına
ekipman ve alet kullanılarak mile takılmalıdır.
sahip motorlar
Asla çekiç kullanılarak veya motor gövdesine bastırılan bir kol
kullanarak kaplini veya kasnağı takmayın. Tahliye deliklerinin ve tapalarının aşağı yöne baktığını kontrol
edin. Dikey konumlandırılmış motorlarda, tahliye tapaları yatay
konumda olabilir.
4.6 Motorun montajı ve kaplin
Sızdırmaz plastik tahliye tapalarına sahip makineler açık
ayarının yapılması konumda teslim edilir. Çok tozlu ortamlarda, tüm tahliye delikleri
kapatılmalıdır.
Motor etrafında serbest hava akışı için yeterince boşluğun
olmasını sağlayın. Fan kapağı ile duvar vb. arasında en az
fan kapağı hava girişinin ½'si kadar açıklık olması önerilir. Ek
bilgileri ürün kataloğundan ya da web sayfalarımızdaki boyut
4.9 Kablo ve elektriksel bağlantılar
çizimlerinden edinebilirsiniz: www.abb.com/motors&generators. Standart tek hızlı motorlardaki terminal kutusunda normalde altı
sargı terminali ve en az bir topraklama terminali bulunur.
Doğru hizalama, rulman, titreşim ve olası mil arızalarının
önlenmesi için esastır. Ana sargı ve topraklama terminaline ilaveten, terminal kutusu
ayrıca termistörlerin, ısıtıcıların veya diğer yardımcı aksesuarların
Uygun cıvataları veya saplamaları kullanarak motoru temele bağlantılarını içerebilir.
takın ve temel ile ayakların arasına şimleri yerleştirin.
Tüm ana kabloların bağlantısı için uygun kablo mapaları
Motoru uygun yöntemler kullanarak hizalayın. kullanılmalıdır. Yardımcı ekipmanlara ilişkin kablolar aynı şekilde
Mümkünse, tespit deliklerini delin ve tespit pimlerini bu kendi terminal bloklarına bağlanmalıdır.
konumlara takın. Motorlar sadece sabit / kalıcı kurulum için tasarlanmıştır. Aksi
Kaplin yarımının montaj doğruluğu: B aralığının 0,05 mm'den belirtilmediği takdirde, kablo girişi ölçüleri metriktir. Kablo
az olduğunu ve a1 ile a2 arasındaki farkın da 0,05 mm'den az rakorunun IP sınıfı en az terminal kutularınınki ile aynı olmalıdır.
olduğunu kontrol edin. Bkz. Tablo 2. Kurulum sırasında sertifikalı kablo göbeği ya da kablo
Cıvataların veya saplamaların son sıkıştırma işlemini takiben konnektörü kullanılmalıdır.
hizalamayı tekrar kontrol edin.
Ürün kataloglarında belirtilen şekilde, rulmanlar için izin verilen NOT!

yük değerlerini aşmayın. Kablolar IEC/EN 60079-0 ve yerel kurulum standartlarının
ilgili gereklilikleri karşılamak üzere mekanik olarak
Motorun yeterli hava akışına sahip olduğunu kontrol edin. korunmalı ve terminal kutusuna yakın olarak kelepçe ile
Yakındaki hiçbir nesnenin veya direkt güneş ışığının motora ilave bağlanmalıdır.
ısı yaymamasını sağlayın.
Flanşlı motorların (örn. B5, B35, V1), yapının lanşın dış yüzeyinde
yeterli hava akışına olanak sağladığından emin olun. Kullanılmayan kablo girişleri terminal kutusunun IP sınıfına göre
körleme elemanları ile kapatılmalıdır.
Koruma derecesi ve çapı, kablo rakoruna ilişkin dokümanlarda

4.7 Radyal kuvvetler ve kayış belirtilmiştir.
tahrikleri
UYARI!
Kayışlar, tahrik ekipmanı tedarikçisinin talimatlarına göre
Kablo girişlerinde uygun kablo rakorlarını ve
gerilmelidir. Ancak, ilgili ürün kataloglarında belirtilen (örn.
sızdırmazlarını, kablonun tipine ve çapına göre kullanın.
radyal rulman yüklemesi) azami kayış kuvvetlerini aşmayın.
UYARI! Topraklama, motora enerji verilmeden önce yerel yönetmeliklere

Aşırı kayış gerginliği yataklara hasar verecek ve mil göre yapılmalıdır.
hasarına yol açacaktır.
Gövde üzerindeki topraklama terminali PE'ye (koruyucu
topraklama) bir kablo ile IEC/EN 60034-1, Tablo 5'te gösterildiği
gibi bağlanmalıdır:
Koruyucu iletkenin minimum kablo kesit alanı Direkt-on-line starting (DOL) (direkt yolverme):
Y veya D sargı bağlantıları kullanılabilir.
Kurulum faz iletkenlerinin kesit İlgili koruyucu iletkenin minimum
alanı, S, [mm2] kesit alanı, SP, [mm2]
Örneğin, 690 VY, 400 VD, 690 V için Y bağlantısını ve 400 V için D
4 4 bağlantısını gösterir.
6 6
10 10 Yıldız/Üçgen başlatma (Y/D):
16 16
Bir D bağlantısı kullanılırken, besleme gerilimi mutlaka motorun
25 25
35 25
nominal gerilimine eşit olmalıdır.
50 25
Terminal bloğundan tüm bağlantıları çıkarın.
70 35
95 50 Diğer yolverme yöntemleri ve aralıklı başlatma koşulları:
120 70
S1 ve S2 tipi çalışma sınılarında, konvertör veya yumuşak
150 70
yolverici gibi diğer yol verme yöntemlerinin kullanılması
185 95
halinde, aygıtın, IEC 60079-0 standardındaki gibi “elektrik motoru
240 120
çalışırken güç sisteminden yalıtıldığı” ve termal korumanın isteğe
300 150
400 185
bağlı olduğu göz önünde bulundurmalıdır.
Ayrıca, elektrikli aparatların dışındaki topraklama veya ek 4.9.2 Yardımcı aksesuarların bağlantıları
bağlantı tesisleri en az 4 mm2 kesit alanına sahip bir iletkenin
efektif bağlantısını sağlayabilmelidir. Bir motor termistör veya diğer RTD'ler (Pt100, termal röleler vb.)
ile yardımcı cihazlarla teçhiz edilmişse, bunların uygun yollarla
Şebeke ve motor terminalleri arasındaki kablo bağlantısı kullanılması ve bağlanması tavsiye edilir. Bazı uygulamalar için,
kurulum için ulusal standartlarda ve motor etiketinde belirtilen termal koruma kullanılması zorunludur. Motor ile birlikte verilen
nominal akıma göre IEC/EN 60204-1 standardında belirtilen belgelerde daha detaylı bilgi bulunabilir. Yardımcı elemanlara ve
gereklilikleri karşılamalıdır. bağlantı parçalarına ilişkin bağlantı diyagramları terminal kutusu
içinde bulunabilir.
NOT!
Ortam sıcaklığı +50 °C'yi aştığında, en az +90 °C izin Termistörler için maksimum ölçüm gerilimi 2.5 V'tur. Pt100
verilen çalışma sıcaklığına sahip kablolar kullanılacaktır. için maksimum ölçüm akımı 5 mA'dir. Daha yüksek bir ölçüm
Ayrıca kurulum koşullarına bağlı diğer tüm dönüşüm gerilimi veya akımının kullanımı, okumalarda hatalara veya
faktörleri kablo boyutlandırmasında hesaba katılacaktır. sıcaklık algılayıcısında hasara yol açabilir.
Termal sensörlerin yalıtımı temel yalıtım gerekliliklerini karşılar.

Motor korumasının çevre ve hava koşullarına karşılık geldiğinden
emin olun. Örneğin, suyun motor ya da terminal kutularına
giremediğinden emin olun.
4.10 Terminaller ve dönüş yönü
Terminal kutularına ait sızdırmazlar, doğru IP sınıfı sağlamak
için sağlanan yuvalara doğru biçimde yerleştirilmelidir. Bu Mil, motora tahrik tarafı yönünden bakıldığı zaman saat
elemanların yanlış yerleştirilmesi, motora toz veya su girmesine yönünde döner ve hat fazı sırası - L1, L2, L3 - terminallere Tablo
neden olarak elektrik bulunan elemanların tutuşmasına neden 3'te gösterilen şekilde bağlanır.
olabilir. Dönüş yönünü değiştirmek için, besleme kablolarındaki iki
bağlantıyı birbiriyle değiştirin.
4.9.1 Farklı yolverme yöntemlerine ilişkin
Motor, tek yönlü bir soğutma fanına sahipse, bunun motor
bağlantılar üzerinde okla işaretlenen aynı yönde dönmesini sağlayın.
Standart tek hızlı motorlardaki terminal kutusunda normalde
altı sargı terminali ve en az bir topraklama terminali bulunur. Bu,
DOL veya Y/D yolvermenin kullanımına izin verir.
İki hızlı veya özel motorlar için, besleme bağlantısı terminal

kutusu içindeki veya motor el kitabındaki talimatlara uyulmalıdır.
Gerilim ve bağlantı değerleri motor etiketinde yer almaktadır.
5. İşletim
5.1 Genel
Motorlar, motor etiketinde aksi belirtilmedikçe, aşağıdaki koşullar
için tasarlanmıştır:
– Motorlar kalıcı olarak sabitlendikten sonra kullanılmalıdır.

– Normal ortam sıcaklığı -20°C - +40°C arasındadır.
– Maksimum rakım deniz seviyesinin 1000 m üzerindedir.
– Besleme voltajı ve frekansı çeşitliliği ilgili standartlarda
bahsedilen sınırları aşamaz. Tablo 4 (EN / IEC 60034-1,
paragraf 7.3, Zon A) uyarınca besleme voltajı toleransı ±%5 ve
frekans için ±%2'dir. Her iki aşırı değerin aynı anda oluşmasına
izin verilmez.
Motor sadece tasarlandığı uygulamalar için kullanılabilir.

Anma nominal değerleri ve işletim şartları motor etiketlerinde
gösterilmiştir. Buna ilaveten, bu el kitabının tüm gerekliliklerine
ve diğer ilgili talimatlar ile standartlara uyulmalıdır.
Bu sınırlar aşıldığı takdirde, motor verileri ve yapım verileri

kontrol edilmelidir. Daha fazla bilgi için lütfen ABB ile irtibata
geçin.
UYARI!
Verilen talimatların veya aparat bakımının göz ardı
edilmesi emniyeti tehlikeye atabilir ve sonucunda
motorun kullanımını engelleyebilir.
6. Değişken hızlarda işletilen alçak gerilim motorlar
6.1 Giriş 6.2.2 Tüm diğer konvertörlere ilişkin sargı
izolasyonunun seçimi
Kılavuzun bu kısmı, frekans konvertör beslemesinde kullanılan
motorlar için ilave talimatları içerir. Motor tek frekans konvertörü Gerilim stresleri aşağıdaki kabul edilen sınırların altında
kaynağından çalışmak üzere tasarlanmıştır ve paralel çalışan sınırlandırılmalıdır. Uygulamanın emniyetini sağlamak için lütfen
motorlar tek bir frekans konvertöründen çalışmaz. Konvertör sistem tedarikçinizle irtibata geçin. Olası filtrelerin etkisi, motor
üreticisi tarafından belirtilen talimatlar dikkate alınmalıdır. boyutlandırılırken dikkate alınmalıdır.
Özel uygulamalarda kullanılan veya özel dizayn edilmiş

motorların, sürücü ile kullanıma uygun olduğuna karar vermek
için ekstra bilgiye ihtiyaç duyulabilir. Bu durumda lütfen ABB ofisi
6.3 Termal koruma
ile iletişime geçiniz. Bu kılavuz ile kapsanan motorların çoğu, PTC termistörleri
ya da diğer tür RTD'ler ile teçhiz edilmiştir. Bunların frekans
konvertörlerine bağlanması tavsiye edilir. Bölüm 4.9.2'de daha
6.2 Sargı yalıtımı fazla bilgi edinebilirsiniz.
Değişken hızlı tahrikler, motor sargısındaki sinüs beslemeden

daha yüksek voltaj stresleri oluşturur. Bu nedenle, motorun
sargı yalıtımının yan sıra konvertör çıkışındaki filtre aşağıdaki
6.4 Rulman akımları
talimatlara göre boyutlandırılmalıdır. İzole rulmanlar veya rulman yapımları, ortak mod filtreleri, uygun
kablolama ile topraklama yöntemleri aşağıdaki talimatlara göre
6.2.1 ABB konvertörler için sargı yalıtımı seçimi ve tablo 6.1 ile birlikte kullanılmalıdır.
ABB AC_8_ _-serisi ve AC_5_ _-serisi diyotlu besleme ünitesine

sahip sürücülerin kullanılması (kontrolsüz DC gerilimi), sargı
6.4.1 ABB konvertörleri için rulman akımlarının
yalıtımının ve filtrelerin seçimi tablo 6.1'e göre yapılabilir: giderilmesi
Diyotlu besleme ünitesi olan AC_8_ _- ve AC_5_ _-serisi ABB
frekans konvertörlerinin kullanılması halinde, motorların içinde
zararlı rulman akımlarını önlemek için tablo 6.1'e göre olan
yöntemler kullanılmalıdır.
PN < 100 kW PN ≥ 100 kW ya da PN ≥ 350 kW ya da

IEC315 ≤ Yapı büyüklüğü ≤ IEC355 IEC400 ≤ Yapı büyüklüğü ≤ IEC450
UN ≤ 500 V Standart motor Standart motor Standart motor
+ İzole rulman + İzole rulman
+ Ortak mod filtresi
500V >UN ≤ 600V Standart motor Standart motor Standart motor
+ dU/dt –filtresi (reaktör) + dU/dt –filtresi (reaktör) + İzole rulman
VEYA + İzole rulman + dU/dt –filtresi (reaktör)
Güçlendirilmiş yalıtım VEYA + Ortak mod filtresi
Güçlendirilmiş yalıtım VEYA
+ İzole rulman Güçlendirilmiş yalıtım
+ İzole rulman
500V >UN ≤ 600V Standart motor Standart motor Standart motor
(kablo uzunluğu > 150 m) + İzole rulman + İzole rulman
600V >UN ≤ 690V Güçlendirilmiş yalıtım Güçlendirilmiş yalıtım Güçlendirilmiş yalıtım

+ dU/dt –filtresi (reaktör) + dU/dt –filtresi (reaktör) + İzole rulman
+ İzole rulman + dU/dt –filtresi (reaktör)
600V >UN ≤ 690V Güçlendirilmiş yalıtım Güçlendirilmiş yalıtım Güçlendirilmiş yalıtım
(kablo uzunluğu > 150 m) + İzole rulman + İzole rulman
Tablo 6.1 ABB konvertörler için sargı yalıtımı seçimi
Rezistör frenlemesi ile kontrollü besleme ünitelerine sahip konvertörlere ilişkin daha fazla bilgi için, lütfen ABB ile irtibata geçin.
NOT!
6.7 Değişken hızlı uygulamalarda
Alüminyum oksit kaplamalı iç ve/veya dış delikler veya motorlar
seramik silindir elemanlara sahip izole rulmanlar tavsiye
edilir. Alüminyum oksit kaplamalar ayrıca gözenekli
kaplamaya giren kiri ve nemi önleyecek bir sızdırmazla
6.7.1 Genel
ayrıca işleme tutulmalıdır. İzole rulmanın kesin tipi için, ABB'nin frekans konvertörleri ile, motorlar, ABB DriveSize
motor etiketine bakın. Rulman tipinin veya yalıtım boyutlandırma programı kullanılarak boyutlandırılabilir.
yönteminin ABB'nin izni olmaksızın değiştirilmesi yasaktır. Program, ABB internet sitesinden indirilebilir (www.abb.com/
motors&generators).
6.4.2 Diğer konvertörler için rulman akımlarının Diğer konvertörler tarafından sağlanan uygulama için, motorlar
manuel boyutlandırılmalıdır. Daha fazla bilgi için, lütfen ABB ile
giderilmesi irtibata geçin.
Kullanıcı, motoru ve tahrikli ekipmanı zararlı rulman
akımlarından korumakla sorumludur. Bölüm 6.4.1'de açıklanan Yüklenebilirlik eğrileri (veya yük kapasite eğrileri) nominal
talimatlar, kılavuz ilke olarak kullanılabilir, ancak etkinliği tüm besleme gerilimine dayanır. Düşük veya aşırı gerilimli koşullarda
durumlar için garanti edilemez. işletim, uygulamanın performansını etkiler.
6.7.2 AC_8_ _ – serisi DTC kontrolü konvertörler

6.5 Kablolama, topraklama ve EMC ile motor yüklenebilirliği
(Elektromanyetik Uyumluluk) Tablo 5a - 5d içinde sunulan yüklenebilirlik eğrileri, kontrolsüz
Uygun topraklama yapmak ve yürürlükteki EMC gerekliliklerine DC-gerilimi ve DTC kontrolüne sahip ABB AC_8_ _-serisi
uygunluğu sağlamak için, 30 kW üzeri motorlar, korumalı konvertörleri için geçerlidir. Tablolar, besleme frekansının bir
simetrik kablo ve EMC rakorları, örn. 360° dönme sağlayan kablo işlevi olarak motorların sürekli maksimum çıkış torkunu gösterir.
rakorları ile kablolanmalıdır. Çıkış torku, motorun nominal torkunun bir yüzdesi olarak
verilir. Değerler gösterge niteliğinde olup, kesin değerler talebe
Daha küçük motorlar için ayrıca simetrik ve korumalı kablolar istinaden verilebilir.
şiddetle önerilir. Rakorlara ilişkin talimatlarda açıklandığı üzere,
360° topraklama düzenlemesini tüm kablo girişlerinde yapın.
Kablo korumalarını, demetler halinde bükün ve terminal kutusu, NOT!
konvertör kabini vb içinde en yakın terminal/baraya bağlayın. Motor ve uygulamanın maksimum hızı aşılamaz!
NOT! 6.7.3 AC_5_ _ – serisi konvertörler ile motor

360° dönme sağlayan uygun kablo rakorları tüm yüklenebilirliği
sonlandırma noktalarında örn. motor, konvertör, olası
emniyet anahtarı vb kullanılmalıdır. Tablo 6a - 6d içinde sunulan yüklenebilirlik eğrileri, ABB AC_5_ _
-serisi konvertörleri için geçerlidir. Tablolar, besleme frekansının
bir işlevi olarak motorların sürekli maksimum çıkış torkunu
IEC 280 ve üstü gövdeye sahip motorlar için, motor gövdesi ile gösterir. Çıkış torku, motorun nominal torkunun bir yüzdesi
tahrik edilen ekipman, ortak bir çelik tabana takılmamışlarsa, olarak verilir. Değerler gösterge niteliğinde olup, kesin değerler
aralarında ilave potansiyel dengelemesi gereklidir. Bu durumda, talebe istinaden verilebilir.
çelik taban ile sağlanan bağlantının yüksek frekans iletkenliği,
örneğin bileşenler arasındaki potansiyel farkının ölçülmesi ile
kontrol edilebilir. NOT!
Motor ve uygulamanın maksimum hızı aşılamaz!
Frekans konvertörlerine ait topraklama ve kablolama hakkında
daha fazla bilgi, kılavuzun "Tahrik sisteminin topraklaması ve
kablolaması" bölümünde görülebilir (Kod: 3AFY 61201998). 6.7.4 Diğer gerilim kaynağı PWM tipi
konvertörler ile motor yüklenebilirliği
Kontrolsüz DC voltajı ve minimum 3 kHz (200…500 V)
6.6 İşletme hızı anahtarlama frekansı olan diğer konvertörlerde, bölüm 6.7.3'te
Motorun motor etiketinde veya ilgili ürün kataloğunda belirtilen bahsedilen boyutlandırma talimatları rehber olarak kullanılabilir.
nominal hızdan daha yüksek hızlar için, gerek en yüksek izin Ancak, gerçek termal yüklenebilirliğin daha düşük olabileceğine
verilebilir motor dönüş hızının gerekse tüm uygulamanın kritik dikkat edilmelidir. Konvertörün üreticisi veya sistem tedarikçisi
hızının aşılmamasını sağlayın. ile irtibata geçin.
NOT!
Bir motorun gerçek termal yüklenebilirliği, kılavuz
eğrilerinde gösterilenden daha düşük olabilir.
6.7.5 Kısa süreli aşırı yüklenmeler Konvertörün ayarlanması için gerekli tüm parametreler motor
ABB motorları sıklıkla geçici olarak aşırı yüklenebilir ayrıca plakalarından alınmalıdır. En sık biçimde ihtiyaç duyulan
aralıklı çalışmalarda kullanılabilir. Bu tür uygulamaların parametreler şunlardır:
boyutlandırılmasına ilişkin en uygun yöntem, DriveSize
programını kullanmaktır. – nominal gerilim
– nominal akım
– nominal frekans
6.8 Motor plakaları – nominal hız
– nominal güç
ABB motorlarının değişken hızlı uygulamalarda kullanılması
genelde ek motor plakaları gerektirmez. Konvertörün işletime
alınması için gereken parametreler ana motor etiketinde NOT!
bulunabilir. Bununla birlikte bazı özel uygulamalarda motorlara Eksik veya yanlış bilgi durumunda, doğru ayarları
değişken hızlı uygulamalar için ek plaka takılabilir. Bunlar sağlamadan motoru çalıştırmayın!
aşağıdaki bilgileri içerir:
– hız aralığı ABB, uygulamanın emniyetinin artırılması için konvertör

– güç aralığı tarafından sağlanan tüm uygun koruyucu özelliklerin
– gerilim ve akım aralığı kullanılmasını tavsiye etmektedir. Konvertörler genellikle
– tork tipi (sabit veya ikinci derece - kuadratik) aşağıdaki özellikleri sunarlar (özelliklerin adları ve kullanılabilirliği
– ve konvertör tipi ve gerekli minimum anahtarlama frekansı konvertörün üreticisine ve modeline bağlıdır):
– minimum hız
– maksimum hız
6.9 Frekans konvertörünün devreye – hızlanma ve yavaşlama zamanları
alınması – maksimum akım
– maksimum tork
Frekans konvertörünü devreye alma işlemi, frekans konvertörü – arıza koruması
talimatlarına ve yerel kanun ile yönetmeliklere göre yapılmalıdır.
Uygulama tarafından ortaya çıkan gereklilikler ve sınırlamalar da
ayrıca dikkate alınmalıdır.
7. Bakım 7.2 Yağlama
UYARI! UYARI!
Motora bağlı ısıtıcılarda enerji olabilir. Tüm dönen parçalara dikkat edin!
7.1 Genel inceleme UYARI!

Yağ deri tahrişi ve göz yanmasına sebep olabilir. Yağ
1. Motoru düzenli aralıklarla, yılda en az bir kez muayene edin.
üreticisi tarafından belirtilen tüm emniyet önlemlerine
Kontrollerin sıklığı, ortam havasının nemine, yerel hava
uyun.
şartlarına vb. bağlıdır. Bu başlangıçta deneysel olarak tespit
edilebilir ve ardından buna kesin biçimde uyulmalıdır.
2. Motoru temiz tutun ve serbest havalandırma akışını sağlayın. İlgili ürün kataloglarında ve daha küçük gövde boyutundakiler
Motor tozlu ortamda kullanılıyorsa, havalandırma sistemi hariç tüm motorların motor etiketlerinde rulman tipleri
düzenli olarak kontrol edilmeli ve temizlenmelidir. belirtilmiştir.
3. Mil contalarının durumunu kontrol edin (örn. V halka veya Güvenirlik, rulman yağlama aralıkları için hayati bir husustur. ABB
radyal conta) ve gerekirse değiştirin. esas olarak yağlama için L1-prensibini (örn. motorların %99'unun
4. Bağlantıların ve montaj cıvatalarının durumunu kontrol edin. ömrünü tamamlayacağı kesindir) kullanır.
5. Olağandışı bir gürültüyü dinleyerek, vibrasyon ölçümü,

rulman sıcaklığı, harcanan yağın muayenesi veya SPM rulman 7.2.1 Kendinden yağlamalı rulmanlara sahip
izlemesi yoluyla rulman durumunu kontrol edin. Hesaplanmış motorlar
/ tahmini ömürleri bitmeye yakın olan rulmanlara özellikle Rulmanlar genellikle 1Z, 2Z, 2RS veya benzer kendinden
dikkat edin. yağlamalı rulmanlardır.
Aşınma belirtileri görüldüğünde, motoru parçalarına ayırın, Kılavuz olarak, 250 gövdeye kadar olan boyutlara ilişkin yeterli
parçaları kontrol edin ve gerekirse değiştirin. Rulmanlar yağlama, L1'ye göre aşağıdaki sürelerde gerçekleştirilebilir. Daha
değiştirilirken, yeni parçalar, orijinal parçalar ile aynı tipte yüksek ortam sıcaklıklarında çalışma için, lütfen ABB ile irtibata
olmalıdır. Mil sızdırmazları değiştirilirken, orijinaller ile aynı geçin. L1 değerlerinin kabaca L10 değerlerine değiştirilmesine
nitelikte ve karakteristikteki sızdırmazlar ile değiştirilmelidir. yönelik bilgilendirici formül: L10 = 2,0 x L1.
IP 55 motoru söz konusu olduğunda ve motor bir tapası kapalı 25 ila 40°C arasındaki ortam sıcaklıklarında kendinden yağlamalı
biçimde teslim edildiğinde, tahliye tapalarının yoğuşan sıvının rulmanlar için görev / çalışma saatleri şöyledir:
çıkışına ilişkin yolun engellenmemesi ve yoğuşan sıvının
motordan çıkması için periyodik olarak açılması tavsiye edilir. Bu Çalışma Çalışma
işlem motor dururken ve üzerinde çalışmak için emniyetli hale Yapı Kutup saatleri saatleri
getirildikten sonra yapılmalıdır. büyüklüğü sayısı 25° C'de 40° C'de
56 2 52 000 33 000
7.1.1 Bekleme konumundaki motorlar 56 4-8 65 000 41 000
63 2 49 000 31 000
Motor bir gemide veya diğer bir ortamda daha uzun bir süre 63 4-8 63 000 40 000
bekleme konumunda kalacaksa, aşağıdaki tedbirler alınmalıdır: 71 2 67 000 42 000
71 4-8 100 000 56 000
1. Mil düzenli olarak 2 haftada (raporlanarak) bir sistem başlatma
80-90 2 100 000 65 000
yoluyla döndürülmelidir. Başlatma herhangi bir nedenle
80-90 4-8 100 000 96 000
mümkün değilse, en azından haftada bir kez milin farklı
100-112 2 89 000 56 000
bir konuma gelmesi için elle döndürülmesi gerekir. Diğer
100-112 4-8 100 000 89 000
araçların ekipmanı nedeniyle oluşan titreşimler, düzenli
132 2 67 000 42 000
işletim / elle döndürme yoluyla engellenebilecek rulman
karıncalanmalarına neden olacaktır. 132 4-8 100 000 77 000
160 2 60 000 38 000
2. Rulman, her yıl mil döndürülürken mutlaka yağlanmalıdır 160 4-8 100 000 74 000
(raporlanacak). Motor, tahrik ucunda bir makaralı rulmanla 180 2 55 000 34 000
birlikte sağlanmışsa, mil döndürülmeden önce nakliye 180 4-8 100 000 70 000
kilidi çıkarılmalıdır. Nakliye kilidi, taşıma durumunda tekrar 200 2 41 000 25 000
takılmalıdır. 200 4-8 95 000 60 000
225 2 36 000 23 000
3. Rulmanın arızalanmasını önlemek üzere tüm titreşimlerden
225 4-8 88 000 56 000
kaçınılmalıdır. Motor talimat kılavuzundaki devreye alma
250 2 31 000 20 000
ve bakıma ilişkin tüm talimatlara uyulmalıdır. Garanti, bu
250 4-8 80 000 50 000
talimatlara uyulmadığı takdirde sargı ve rulman hasarlarını
kapsamayacaktır. Veriler 60 Hz'e kadar geçerlidir.
7.2.2 Gresörlüklü rulmanlara sahip motorlar Otomatik yağlama sistemi için yağ miktarı hesaplama
örneği
Yağlama bilgi plakası ve genel yağlama tavsiyesi Merkezi yağlama sistemi: 50 Hz şebekedeki IEC M3_P 315_ 4
Motor bir yağlama bilgi plakası ile teçhiz edilmişse, verilen kutuplu motor, Tabloya göre yağlama aralığı 7600 saat/55 g (DE)
değerlere uyun. ve 7600 saat/40 g (NDE) şeklindedir:
Montaj, ortam sıcaklığı ve rotasyon hızına göre yağlama aralıkları (DE) RLI = 55 g/7600h*3*24 = 0,52 g/gün
yağlama bilgi plakasında tanımlanmıştır.
(NDE) RLI = 40 g/7600*3*24 = 038 g/gün
İlk başlatma esnasında veya rulman yağlamasını takiben, geçici
sıcaklık artışı yaklaşık 10 ila 20 saat boyunca görülebilir. Tekli otomatik yağlama ünitesi (kartuş) için yağ miktarı
Bazı motorlar, eski yağ için kolektör ile teçhiz edilebilir. Ekipman hesaplama örneği
için verilen özel talimatlara uyun. (DE) RLI = 55 g/7600h*24 = 0,17 g/gün
A. Manuel yağlama (NDE) RLI = 40 g/7600*24 = 0,13 g/gün
Motor çalışırken yağlama RLI = Yağlama aralığı, DE = Tahrik ucu, NDE = Tahrik edilmeyen uç
– Yağ boşaltma tapasını çıkarın veya mevcutsa kapatma valfini
açın. 7.2.3 Yağlama aralıkları ve miktarları
– Yağlama kanalının açık olduğundan emin olun
– Belirtilen miktarda yağı rulmana enjekte edin. Dikey motorlara ilişkin yağlama aralıkları, aşağıda gösterilen
– Aşırı miktardaki yağın tümünün rulmandan boşaltılması için tablodaki değerlerin yarısıdır.
motorun 1-2 saat çalışmasına izin verin. Yağ boşaltma tapasını
veya mevcutsa kapatma valfini kapatın. Kılavuz olarak, yeterli yağlama, L1'ye göre aşağıdaki sürelerde
gerçekleştirilebilir. Daha yüksek ortam sıcaklıklarında çalışma için,
Motor bekleme konumundayken yağlama lütfen ABB ile irtibata geçin. L1 değerlerini kabaca L10 değerlerine
Motorlar çalışırken rulmanların yağlanması mümkün değilse, değiştirmek için bilgilendirici formül, manuel yağlama ile
yağlama motor bekleme konumundayken yapılabilir. L10 = 2.0 x L1.
– Bu durumda, sadece yağın yarısını kullanın ve birkaç dakika
boyunca tam devirde motoru çalıştırın. Yağlama aralıklarında, rulman işletim sıcaklığı 80°C esas alınır
– Motor durdurulduğunda, rulmana belirtilen miktardaki yağın (ortam sıcaklığı +25°C).
kalanını uygulayın.
– 1-2 saatlik çalışma sonrasında, yağ boşaltma tapasını veya
mevcutsa kapatma valfini kapatın. NOT!
Ortam sıcaklığındaki artış rulmanların sıcaklığında da
B. Otomatik yağlama artışa neden olur. Rulman sıcaklığındaki 15°C'lik bir artış
için yağlama aralığı değerlerinin yarısı alınmalıdır ve
Yağ boşaltma tapası kalıcı olarak çıkarılmalıdır veya takılıysa rulman sıcaklığındaki 15°C'lik azalma için yağlama aralığı
kapama valfi açılmalıdır. değerleri iki kat artırılabilir.
ABB sadece elektromekanik yağlama sistemlerin kullanımını
tavsiye etmektedir.
Daha yüksek hızda işletim, örn. frekans konvertörü
Tabloda belirtilen her bir yağlama aralığına ait yağ miktarı, uygulamalarında, veya ağır yükte daha düşük hız için yağlama
merkezi yağlama sistemi kullanılıyorsa üç ile çarpılmalıdır. Daha aralıklarının daha kısa tutulması gerekir.
küçük otomatik yağlama ünitesi kullanılması durumunda (motor
başına bir veya iki kartuş), normal yağ miktarı kullanılabilir.
UYARI!
2 kutuplu motorlar yeniden yağlandığında, Yağlayıcılar Yağ ve rulmanların maksimum işletim sıcaklığı +110°C'yi
bölümünde 2 kutuplu motorlara ilişkin yağlayıcı tavsiyelerine aşmamalıdır.
dair not dikkate alınmalıdır. Motorun tasarlanan maksimum hızı aşılmamalıdır.
Kullanılan yağ otomatik yağlama için uygun olmalıdır. Otomatik

yağlama sistemi tedarikçisinin ve yağ üreticisinin tavsiyeleri
kontrol edilmelidir.
Gres 3600 3000 1800 1500 1000 500-900
Yapı
miktarı kW devir/ devir/ kW devir/ devir/ kW devir/ kW devir/
büyüklüğü
g/yatak dakika dakika dakika dakika dakika dakika
Bilyalı rulmanlar, çalışma saati cinsinden yağlama aralıkları
112 10 tümü 10 000 13 000 tümü 18 000 21 000 tümü 2 5 000 tümü 28 000
132 15 tümü 9 000 11 000 tümü 17 000 19 000 tümü 23 000 tümü 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 tümü 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 tümü 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 tümü 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 tümü 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 tümü 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 tümü 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 tümü 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 tümü 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 tümü 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 tümü 7 000
2801) 60 tümü 2 000 3 500 - - - - - - -
2801) 60 - - - tümü 8 000 10 500 tümü 14 000 tümü 17 000
280 35 tümü 1 900 3 200 - - - -
280 40 - - tümü 7 800 9 600 tümü 13 900 tümü 15 000
315 35 tümü 1 900 3 200 - - - -
315 55 - - tümü 5 900 7 600 tümü 11 800 tümü 12 900
355 35 tümü 1 900 3 200 - - - -
355 70 - - tümü 4 000 5 600 tümü 9 600 tümü 10 700
400 40 tümü 1 500 2 700 - - - -
400 85 - - tümü 3 200 4 700 tümü 8 600 tümü 9 700
450 40 tümü 1 500 2 700 - - - -
450 95 - - tümü 2 500 3 900 tümü 7 700 tümü 8 700
Makaralı rulmanlar, çalışma saatleri cinsinden yağlama aralıkları

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 tümü 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 tümü 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 tümü 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 tümü 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 tümü 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 tümü 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 tümü 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 tümü 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 tümü 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 tümü 3 500
2801) 60 tümü 1 000 1 750 - - - - - - -
2801) 70 - - - tümü 4 000 5 250 tümü 7 000 tümü 8 500
280 35 tümü 900 1 600 - - - -
280 40 - - tümü 4 000 5 300 tümü 7 000 tümü 8 500
315 35 tümü 900 1 600 - - - -
315 55 - - tümü 2 900 3 800 tümü 5 900 tümü 6 500
355 35 tümü 900 1 600 - - - -
355 70 - - tümü 2 000 2 800 tümü 4 800 tümü 5 400
400 40 tümü - 1 300 - - - -
400 85 - - tümü 1 600 2 400 tümü 4 300 tümü 4 800
450 40 tümü - 1 300 - - - -
450 95 - - tümü 1 300 2 000 tümü 3 800 tümü 4 400
1)
M3AA
7.2.4 Yağlar Aşağıdaki yağlar yüksek hızlı pik döküm motorlarda kullanılabilir,
ancak lityum kompleks bazlı yağlarla karıştırılmamalıdır:
UYARI! – Klüber Klüber Quiet BQH 72-102 (poliüre taban)

Farklı tipteki yağları karıştırmayın. – Lubcon Turmogrease PU703 (poliüre bazlı)
Uygun olmayan yağlar rulman hasarına neden olabilir.
Diğer yağlayıcılar kullanılırsa, niteliklerin yukarıda bahsedilen
yağlayıcılar karşılık geldiğini üreticilerle kontrol edin. Yağlama
Yağlama yapılırken, sadece aşağıdaki özelliklere sahip özel bilyalı aralığı için, yukarıda listelenen yüksek performanslı yağlar esas
rulman yağını kullanın: alınır. Başka yağların kullanılması durumunda, yağlama aralığı
kısalabilir.
– lityum kompleks sabunu ve mineralli veya PAO yağlı iyi kalite
yağ
– baz yağ viskozitesi 40°C'de 100-160 cST
– yoğunluk NLGI derecesi 1,5 - 3 *)
– sıcaklık aralığı –30 °C - +120 °C, sürekli
*) Skalanın daha katı ucu dikey montajı motorlar ya da sıcak

koşullar için önerilir.
Yukarıda bahsedilen yağlama özelliği, ortam sıcaklığı –30°C

üzerinde veya +55°C altında ise ve rulman sıcaklığı 110°C altında
ise geçerlidir; aksi takdirde uygun yağ için ABB'ye danışın.
Doğru özelliklere sahip gres yağı, tüm büyük yağ üreticilerinde

bulunur.
İlave katkılar tavsiye edilir, ancak yazılı garanti mutlaka bir

yağlayıcı üreticisinden, özellikle ilave katkıların rulmanlara
hasar vermediğine veya yağlayıcıların özelliklerinin işletim
sıcaklık aralığında olduğuna dair EP ilave katkıları ile ilgili olarak
alınmalıdır.
UYARI!
EP ilave katkılarını içeren yağlar 280 ila 450 gövde
boyutlarında yüksek rulman sıcaklıklarında tavsiye
edilmez.
Aşağıdaki yüksek performanslı yağlar kullanılabilir:

– Mobil Unirex N2 ya da N3 (lityum kompleks taban)
– Mobil Mobilith SHC 100 (lityum kompleks taban)
– Shell Gadus S5 V 100 2 (lityum kompleks taban)
– Klüber Klüberplex BEM 41-132 (özel lityum taban)
– FAG Arcanol TEMP110 (lityum kompleks taban)
(özel lityum taban)
– Total Multiplex S2 A (lityum kompleks taban)
– Rhenus Rhenus LKZ 2 (lityum kompleks taban)
NOT!
Hız faktörünün 480.000'den yüksek olduğu yüksek hızlı 2
kutuplu motorlar için her zaman yüksek hızlı gres
kullanın (Dm x n olarak hesaplanan; Dm = ortalama
rulman çapı, mm; n = rotasyon hızı, r/dak).
8. Satış sonrası Destek 9. Çevresel gereklilikler
ABB motorlarının birçoğu 50 Hz'de 82 dB(A) (± 3 dB) seviyesini
8.1 Yedek parçalar aşmayan bir ses basınç seviyesine sahiptir.
Yedek parçalar aksi belirtilmediği sürece orijinal ve ABB Belirli motorlara ilişkin değerler, ilgili ürün kataloglarında
tarafından onaylanmış olmalıdır. bulunabilir. 60 Hz sinüzoidal beslemede, değerler ürün
Yedek parçalar sipariş edilirken, motor seri numarası, tam kataloglarındaki 50 Hz değerle karşılaştırıldığında yaklaşık
tip tanımı ve ürün kodu motor etiketinde yazılan şekilde 4 dB(A) daha yüksektir.
belirtilmelidir. Frekans konvertörü beslemesindeki ses basınç seviyeleri için,
lütfen ABB ile irtibata geçin.
8.2 Parçalarına ayırma, birleştirme Motorların kazınması ve geri dönüştürülmesi gerektiğinde,
ve tekrar sarma uygun yollar, yerel yönetmelikler ve yasalar izlenmelidir.
Sargı işlemi her zaman nitelikli tamir atölyesi tarafından

yapılmalıdır.
Duman tahliye ve diğer özel motorlar, ABB ile irtibata

geçilmeden sarılmamalıdır.
8.3 Rulmanlar
Rulmanlara özellikle dikkat edilmelidir.
Rulmanlar çektirme aletleri çıkarılmalı ve ısıtılarak veya özel

aletler kullanılarak takılmalıdır.
Rulman değişimi, ABB Satış Ofisinde mevcut olan ayrı bir talimat
kitapçığında detaylı olarak açıklanmıştır.
Etiket gibi motor üzerinde bulunan yönergelere uyulmalıdır.

Motor etiketindeki rulman tipleri değiştirilmemelidir.
NOT!
Üretici tarafından açıkça onaylanmadığı sürece, kullanıcı
tarafından gerçekleştirilen her türlü onarım üreticinin
sorumluluğunu geçersiz kılar.
10. Sorun Giderme
Bu talimatlar, ekipmana ait tüm detayları veya değişiklikleri
kapsamamakta ve kurulum, işletim veya bakım ile bağlantılı
olarak karşılanacak her tür olası koşulu sağlamamaktadır. İlave
bilgiye ihtiyaç duyulduğunda, lütfen en yakın ABB Satış Ofisi ile
irtibata geçin.
Motor sorun giderme şeması

Motor servisi ve sorun giderme işlemi uygun alet ve ekipmana
sahip nitelikli şahıslar tarafından yapılmalıdır.
SORUN NEDEN YAPILMASI GEREKEN

Motor çalışmıyor Yanmış sigortalar Sigortaları uygun tip ve değerdeki sigortalarla değiştirin.
Aşırı yük tetiklemeleri Yol vericideki aşırı yüklemeyi kontrol edin ve resetleyin.
Uygun olmayan güç beslemesi Beslenen gücün motor etiketi ile yük faktörüne uyduğunu
görmek için kontrol edin.
Uygun olmayan hat bağlantıları Motorla birlikte verilen diyagramlara göre bağlantıları kontrol edin.
Sargı veya kontrol anahtarında Anahtar kapatıldığında bir uğultu sesi ile belirlenir. Gevşek kablo
açık devre bağlantılarını kontrol edin ve tüm kontrol kontaklarının kapalı olduğundan
emin olun.
Mekanik arıza Motorun ve tahrikin serbest biçimde döndüğünü tespit etmek için kontrol
edin.
Rulmanları ve yağlamayı kontrol edin.
Kısa devre olmuş stator
Zayıf stator bobini bağlantısı Yanık sigortalarla belirlenir. Motor tekrar sarılmalıdır.
Kapakları sökün ve arızayı tespit edin.
Rotor arızalı Kırık çubuk veya uç halkaları arayın.
Motor aşırı yüklenmiş olabilir Yükü azaltın.
Motor hız Tek faz açık olabilir Açık faz için hatları kontrol edin.
kaybediyor Yanlış uygulama Tip ve boyutu değiştirin. Ekipman tedarikçisine danışın.
Aşırı yük Yükü azaltın.
Alçak gerilim Motor etiketinde belirtilen geriliminin sağlandığından emin olun. Bağlantıyı
kontrol edin.
Açık devre Sigortalar yanmış. Aşırı yük rölesini, statoru ve düğmeleri kontrol edin.
Motor çalışıyor ve Güç arızası Hattaki sigortalara ve kontrole giden gevşek bağlantıları kontrol edin.
ardından duruyor
Motor nominal hıza Düzgün biçimde uygulanmamış Uygun tip için ekipman tedarikçisine danışın.
ulaşamıyor Motor terminallerindeki gerilim, gerilim Daha yüksek gerilim veya transformatör terminalleri kullanın veya yükü
düşümü nedeniyle çok düşük azaltın.
Bağlantıları kontrol edin. İletkenleri uygun boyut bakımından kontrol edin.
Başlama yükü çok yüksek Motorun başlatma yükünü "yüksüz" konuma göre kontrol edin.
Kırık rotor çubukları veya gevşek rotor Halkaların yanında kırıkları kontrol edin. Yeni bir rotor gerekebilir, çünkü
onarım işlemleri genellikle geçici çözümdür.
Açık primer devresi Test cihazıyla arızayı tespit ve tamir edin.
SORUN NEDEN YAPILMASI GEREKEN
Motor hızlanması Aşırı yük Yükü azaltın.
çok uzun zaman Başlatmada alçak gerilim Yüksek direnç olup olmadığını kontrol edin. Yeterli kablo boyutunun
alıyor ve/veya kullanıldığından emin
yüksek akım çekiyor olun.
Arızalı sincap kafesli rotor Yeni bir rotorla değiştirin.
Uygulanan gerilim çok düşük Güç beslemesini onarın.
Yanlış dönüş yönü Yanlış faz sırası Motorda veya dağıtım panosunda bağlantıları ters çevirin.
Motor çalışırken aşırı Aşırı yük Yükü azaltın.
ısınıyor Gövde veya havalandırma açıklıkları Havalandırma deliklerini açın ve motordan sürekli bir hava
kirli ve motorun uygun havalandırması akışı olup olmadığını kontrol edin.
engelleniyor olabilir
Motorun bir fazı açık olabilir Tüm uçların iyi bağlandığından emin olmak için kontrol edin.
Topraklanmış sargı Motor tekrar sarılmalıdır.
Dengesiz terminal gerilimi Hatalı uçları, bağlantıları ve transformatörleri kontrol edin.
Motor titreşim Motor yanlış hizalanmış Tekrar hizalayın.
yapıyor Zayıf destek Tabanı güçlendirin.
Kaplin dengesiz Kaplini balanse edin.
Tahrik edilen ekipman dengesiz Tahrik ekipmanının tekrar balanse edin.
Arızalı rulmanlar Rulmanları değiştirin.
Rulmanlar hizada değil Motoru onarın
Dengeleme ağırlıkları değişmiş Rotoru tekrar balanse edin.
Rotor ve kaplin balansı arasında Kaplini veya rotoru tekrar balanse edin.
uyumsuzluk (yarım kama - tam kama)
Polifaz motor tek fazda çalışıyor Açık devre olup olmadığını kontrol edin.
Aşırı uç boşluğu Rulmanı ayarlayın veya şim koyun.
Sürtünme sesi Fan arka rulman kapağına veya fan Fan montajını düzeltin.
kapağına sürtüyor
Yatak plakasında gevşeklik Tutucu cıvataları sıkıştırın.
Gürültülü işletim Hava boşluğu üniform değil Motor kapak geçmelerini veya rulman geçmelerini kontrol edin ve düzeltin.
Rotor dengesiz Rotoru tekrar balanse edin.
Rulmanlar sıcak Mil bükülmüş veya esnemiş Mili düzeltin veya değiştirin.
Aşırı kayış çekmesi Kayış gerginliğini azaltın.
Kasnaklar, mil desteğinden çok uzakta Kasnağı motor rulmanının yakınına getirin.
Kasnak çapı çok küçük Daha büyük kasnak kullanın.
Yanlış hizalama Tahriki yeniden hizalayarak düzeltin.
Yetersiz yağ Rulmanda uygun kalite ve miktarda yağın bulunmasını sağlayın.
Yağın bozulması veya kirlenmesi Eski yağı tahliye edin, rulmanları kerosenle tamamen yıkayın ve yeni yağı
koyun.
Aşırı yağ Yağ miktarını azaltın, rulman yarıdan fazla dolu olmamalıdır.
Aşırı yüklenmiş rulman Hizalamayı, yan ve uç baskısını kontrol edin.
Kırık bilya veya kaba yüzeyler Rulmanı değiştirin, önce gövdeyi iyice temizleyin.
11. Figures Key
X-axis: Winding temperature, Celsius Degrees
Y-axis: Insulation Resistance Temperature Coefficient, ktc
100 1) To correct observed insulation resistance, Ri, to 40 °C
multiply it by the temperature coefficient ktc. Ri 40 °C = Ri x
50
Passfeder
x-Achse: Wicklungstemperatur, Grad Celsius
y-Achse: Temperaturkoeffizient des Isolationswiderstandes, ktc
1) Zur Korrektur des ermittelten Isolationswiderstandes,
10 Ri, bis 40 °C, multiplizieren Sie ihn mit dem
Temperaturkoeffizient ktc. Ri 40 °C = Ri x
5
Légende
Axe X : Température du bobinage, degrés Celsius
Axe Y : Coefficient de température de la résistance d'isolation,
ktc
1.0 1) Pour corriger la résistance d'isolation observée, Ri,
à 40 °C, la multiplier par le coefficient de température
0.5 ktc. Ri 40 °C = Ri x
Clave
Eje X: Temperatura de devanado, grados centígrados
1)
Eje Y: Coeficiente de temperatura de resistencia de
0.1 aislamiento, ktc
1) Para corregir una resistencia de aislamiento observada, Ri, a
0.05 40 °C, multiplíquela por el coeficiente de temperatura
ktc. Ri 40 °C = Ri x
-10 0 10 20 30 40 50 60 70 80 90 100 Legenda

Asse X: Temperatura dell'avvolgimento, in gradi Celsius
Figure 1. Diagram illustrating the insulation resistance Asse Y: Coefficiente di temperatura della resistenza
dependence from the temperature and how to correct the d'isolamento, ktc
measured insulation resistance to the temperature of 40 °C. 1) Per correggere la resistenza d'isolamento osservata,
Ri, per 40 °C, moltiplicarla per il coefficiente di temperatura ktc.
Abb. 1. Diagramm, das die Abhängigkeit des Ri 40 °C = Ri x
Isolationswiderstandes von der Temperatur anzeigt und angibt,
wie der gemessene Isolationswiderstand für die Temperatur Explicação
von 40 °C korrigiert wird. Eixo X: Temperatura dos enrolamentos, Graus Celsius
Eixo Y: Coeficiente de Temperatura da Resistência de
Figure 1. Diagramme illustrant la dépendance de la résistance Isolamento, ktc
d'isolation à la température et la façon de corriger la résistance 1) Para corrigir a resistência de isolamento observada, Ri, para
d'isolation mesurée à la température de 40 °C. 40 °C, deverá ser multiplicada pelo coeficiente de temperatura
ktc. Ri 40 °C = Ri x
Figura 1. Diagrama que ilustra la dependencia de la resistencia
de aislamiento respecto a la temperatura y cómo corregir la Nyckel
resistencia de aislamiento medida a la temperatura de 40 °C. X-axeln: Lindningstemperatur, grader Celsius
Y-axeln: Isolationsresistans, temperaturkoefficient, ktc
Figura 1. Diagramma che mostra la resistenza d'isolamento 1) För att korrigera observerad isolationsresistans, Ri,
in funzione della temperatura e come correggere la resistenza till 40 °C ska den multipliceras med temperaturkoefficienten
d'isolamento misurata per la temperatura di 40 °C. ktc. Ri 40 °C = Ri x
Figur 1. I schemat visas isolationsresistansens beroende av Selitys

temperaturen och hur den uppmätta isolationsresistansen X-akseli: Käämin lämpötila, celsiusastetta
korrigeras till en temperatur på 40 °C. Y-akseli: Eristysvastuksen lämpötilakerroin, ktc
1) Korjaa havaittu eristysvastus, Ri, 40 °C:n lämpötilaan
Kuva 1. Kaavio, joka kuvaa, miten eristysvastus riippuu kertomalla se lämpötilakertoimella ktc. Ri 40 °C = Ri x
lämpötilasta ja miten mitattu eristysvastus korjataan 40 °C:n
lämpötilaan
Tuş
X ekseni: Sargı sıcaklığı, Santigrat Derece
Tablo 1. Yalıtım direncinin sıcaklık ile olan bağıntısını ve ölçülen
Y ekseni: Yalıtım Direnci Sıcaklık Katsayısı, ktc
yalıtım direncinin 40 °C sıcaklığa göre nasıl düzeltileceğini gösteren
1) Gözlenen yalıtım direncini düzeltmek için, Ri, 40 °C'ye ktc sıcaklık
diyagram.
katsayısı ile çarpın. Ri 40 °C = Ri x
Figure 2. Mounting of half-coupling or pulley
a1 b
Abb. 2. Montage von Kupplungshälften und
Riemenscheiben
Figure 2. Montage d'un demi-accouplement

ou d'une poulie
Figura 2. Montaje de acoplamiento o polea
Figure 2. Montaggio di semigiunto o puleggia
Figura 2. Montagem dos meios-acoplamentos ou polias
Figur 2. Montering av kopplingshalva eller remskiva
Kuva 2. Kytkinpuolikkaan tai hihnapyörän kiinnittäminen
a2 Tablo 2. Yarım kaplin veya kasnağın montajı
Figure 3. Connection of terminals for main supply
Abb. 3. Anschlussklemmen für Hauptversorgung
Figure 3. Raccordement des bornes pour l'alimentation principale
Figura 3. Conexión de terminales de la alimentación principal
Figura 3. Collegamento dei morsetti per l'alimentazione di rete
Figura 3. Ligação de terminais para alimentação
Figur 3. Anslutning av terminaler för elnätet
Kuva 3. Verkkosyötön liitäntöjen muodostaminen
Tablo 3. Ana besleme için terminal bağlantıları
Y Key
1.10
X axis frequency p.u.
Y axis voltage p.u.
1 zone A
2 zone B (outside zone A)
3 rating point
1.05
Passfeder
x-Achse Frequenz p.u.
1.03
1
y-Achse Spannung p.u.
1 Zone A
3
1.09
2 Zone B (außerhalb Zone A)
X 3 Bewertungspunkt
0.95 0.98 1.00 1.02
2 Légende
0.93 Axe X fréquence p.u.
Axe Y tension p.u.
1 zone A
0.95
2 zone B (hors zone A)
3 point nominal
Clave
Eje X frecuencia p.u.
0.90 Eje Y tensión p.u.
1 zona A
2 zona B (fuera de la zona A)
3 punto nominal
Figure 4. Voltage and frequency deviation
Legenda
in zones A and B
Asse X frequenza p.u.
Asse Y tensione p.u.
Abb. 4. Spannungs- und Frequenzabweichung 1 zona A
in den Zonen A und B 2 zona B (fuori dalla zona A)
3 punto nominale
Figure 4. Écart de tension et de fréquence Explicação

dans les zones A et B Eixo X frequência p.u.
Eixo Y tensão p.u.
1 zona A
Figura 4. Desviación de tensión y frecuencia
2 zona B (fora da zona A)
en zonas A y B 3 ponto de avaliação
Figura 4. Deviazione di tensione e frequenza Nyckel

X-axeln frekvens p.u.
nelle zone A e B
Y-axeln spänning p.u.
1 zon A
Figura 4. Desvio de tensão e frequência 2 zon B (utanför zon A)
nas zonas A e B 3 märkpunkt
Selitys
Figur 4. Spännings- och frekvensavvikelse X-akseli taajuus yksikköä kohti
i zoner A och B Y-akseli jännite yksikköä kohti
1 vyöhyke A
2 vyöhyke B (vyöhykkeen A ulkopuolella)
Kuva 4. Jännite- ja taajuuspoikkeama
3 arvopiste
vyöhykkeillä A ja B
Tuş
Tablo 4. Zon A ve B'de voltaj ve frekans sapması X ekseni frekans p.u.
Y ekseni voltaj p.u.
1 zon A
2 zon B (zon A dışında)
3 değerlendirme noktası
Guideline loadability curves with converters with DTC control
Richtlinie Belastbarkeitskurven mit Frequenzumrichtern mit DTC-Regelung
Courbes de capacité de charge de référence avec convertisseurs à contrôle DTC
Curvas indicativas de capacidad de carga con convertidores dotados de control de DTC
Curve di funzionamento con alimentazione da convertitore di frequenza, controllo DTC
Curvas de capacidade de carga orientadoras com conversores com controlo DTC
Riktlinjer: lastbarhetskurvor för omriktare med DTC-styrning
Ohjeelliset kuormitettavuuskäyrät DTC-ohjatuilla taajuusmuuttajilla
DTC kontrollü konvertörler ile kılavuz yüklenebilirlik eğrileri
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat/Tablolar 5a, 5b, 5c, 5d
Conventer with DTC control, 50/60 Hz, temperature rise B/F

Convertisseur à contrôle DTC, 50/60 Hz, élévation de température B/F
Convertidor con control de DTC, 50/60 Hz, aumento de temperatura B/F
Convertitore con controllo DTC, 50/0 Hz, sovra-temperatura classe B/F
Conversor com controlo DTC, 50/60 Hz, aumento de temperatura B/F
Omriktare med DTC-styrning, 50/60 Hz, temperaturstegring B/F
DTC-ohjattu taajuusmuuttaja, 50/60 Hz, lämpötilan nousu B/F
DTC kontrollü konverter, 50/60 Hz, sıcaklık artışı B/F
Figure 5a Figure 5b
Figure 5c Figure 5d
Guideline loadability curves with other voltage source PWM type
Belastbarkeitskurven als Richtlinie für PWM-Frequenzumrichter mit anderen Spannungsquellen
Courbes de capacité de charge de référence avec d’autres convertisseurs PWM de source de tension
Curvas indicativas de capacidad de carga con otros convertidores de fuente de tensión de tipo PWM
Curve di funzionamento con convertitori di frequenza PWM
Curvas de capacidade de carga orientadoras com outros conversores de alimentação tipo PWM
Riktlinjer: belastbarhetskurvor för annan spänningsomriktare av PWM-typ
Ohjeelliset kuormitettavuuskäyrät muilla PWM-tyyppisillä jännitelähdetaajuusmuuttajilla
Diğer voltaj kanyağı PWM tipi ile kılavuz yüklenebilirlik eğrileri
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat/ Tablolar 6a, 6b, 6c, 6d
Other voltage source PWM type converter, 50/60 Hz, temperature rise B/F
PWM-Frequenzumrichter mit anderen Spannungsquellen, 50/60 Hz, Temperaturanstieg B/F
Autre convertisseur PWM de source de tension, 50/60 Hz, élévation de température B/F
Otro convertidor de fuente de tensión de tipo PWM, 50/60 Hz, aumento de temperatura B/F
Convertitore PWM, 50/60 Hz, sovra-temperatura classe B/F
Outros conversores de alimentação tipo PWM, 50/60 Hz, aumento de temperatura B/F
Annan spänningsomriktare av PWM-typ, 50/60 Hz, temperaturstegring B/F
Muu PWM-tyyppinen jännitelähde-taajuusmuuttaja, 50/60 Hz, lämpötilan nousu B/F
Diğer voltaj kaynağı PWM tipi konverter, 50/60 Hz, sıcaklık artışı B/F
Figure 6a Figure 6b
Figure 6c Figure 6d
Contact us
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9.5 MANUALE MANOMETRI
IOM_14479_2 (09.16) Pages 38/59

1. Avvertenze di sicurezza co con manicotto e dado girevole. Se un misuratore
di pressione dovesse possedere un dispositivo
Istruzioni di esercizio Prima di procedere al montaggio, alla messa di sfiato, questo deve essere protetto in maniera che
in funzione e all'esercizio, fare assolutamente non si possa intasare o chiudere da parte di compo-
Misuratori di
pressione meccanici
! attenzione che venga selezionato il giusto
strumento dal punto di vista del campo di
misurazione e dell‘esecuzione e che, in
nenti dell‘apparecchio o a causa di sporcizia.
In misuratori di pressione di sicurezza (riconoscibili dal-
la k ) bisogna fare attenzione che la zona libera dietro
funzione delle condizioni di misurazione vigenti local-
alla parete posteriore sganciabile sia di almeno 15 mm.
mente, venga scelto il materiale giusto per i componen-
Esempi: ti a contatto con il fluido di misurazione (a causa della
possibilità di corrosione). Rispettare i limiti di sollecita-
2.1 Requisiti per il montaggio
zione, al fine di garantire la precisione di misurazione e
la durata. Dati tecnici: vedere la scheda tecnica al sito Se la tubazione verso il misuratore non dovesse essere
www.wika.de sufficientemente stabile a garantire un'applicazione
senza scossoni, si raccomanda (eventualmente tramite
Il montaggio e la manutenzione degli strumenti devono
Tipo 732.14, un tubo capillare flessibile) di eseguire il fissaggio me-
essere eseguiti solo da parte di personale qualificato
capacità di sovraccarico diante dei supporti per misuratori. Se non è possibile
istruito ed autorizzato dal gestore dell‘impianto.
sino a 400 bar evitare scossoni nemmeno con idonee installazioni,
Tipo 432.36, In caso di fluidi di misurazione pericolosi, quali p.e. allora si raccomanda di usare apparecchi con cariche a
capacità di sovraccarico ossigeno, acetilene e fluidi infiammabili o velenosi a riempimento di liquido. Gli apparecchi devono essere
sino a 400 bar come anche in impianti di refrigerazione, compressori protetti da sporcizia e da forti oscillazioni della tempe-
ecc. devono essere osservate, oltre alle regole gene- ratura ambiente. Rispettare la EN 837-2 „Raccoman-
Tipo 213.40
ralmente riconosciute, anche le prescrizioni in materia dazioni per la scelta ed il montaggio di misuratori di
attualmente vigenti. pressione“.
Dopo un incendio all'esterno è possibile che soprattutto
in corrispondenza dei collegamenti effettuati con sal-
dobrasatura fuoriesca del fluido di misurazione. Prima 3.
Temperature ambientali e di esercizio
di rimettere in servizio l‘impianto, tutti gli apparecchi ammesse
devono essere controllati ed eventualmente sostituiti. L'applicazione del misuratore di pressione deve essere
Avvertenze secondo la direttiva sugli In caso di mancata osservanza delle relative prescrizio- eseguita in maniera tale da non superare né per
ni vi è il rischio di seri infortuni e/o di danni materiali. eccesso né per difetto i limiti ammessi di temperatura
apparecchi a pressione 97/23/CE
del fluido da misurare o dell'ambiente. Tenere in consi-

Come dall'articolo 1, capoverso 2.1.4, i misuratori di derazione l'influenza della temperatura sulla precisione
pressione sono dei "Componenti di equipaggiamento 2. Attacco al processo della misurazione.
a ritenzione di pressione". Come previsto dalle regole tecniche generali per

Il volume dell'alloggiamento in pressione di misuratori misuratori di pressione (p.e. EN 837-2). Al momento di
avvitare gli apparecchi, la forza necessaria a tale ope- 4. Stoccaggio
di pressione WIKA è < 0,1 L
razione non deve essere trasmessa sull'alloggiamento Sino al momento del montaggio, conservare i misurato-

La marcatura CE viene effettuata secondo il ma solo sulle superfici previste della chiave utilizzando ri di pressione nella confezione originale per proteggerli
gruppo fluidi 1G secondo Appendice 2, Diagramma 1 a sempre e solo un utensile idoneo. da danni meccanici.
partire da una pressione ammessa di esercizio > 200 bar Il campo di temperatura per lo stoccaggio va da -40 °C
a +70 °C.
Gli apparecchi non contrassegnati vengono prodotti ontaggio con
M
secondo l‘articolo 3, capoverso 3 secondo „buona Proteggere i misuratori da umidità e da polvere.
chiave fissa
pratica ingegneristica“.
Norme applicate 5. Manutenzione / Riparazioni
Per sigillare gli attacchi del misuratore di pressione
EN 837-1
Misuratori di pressione con molle a tubo,
con filetto cilindrico in corrispondenza della superficie Gli apparecchi non necessitano di manutenzione. La
dimensioni, tecnica di misurazione, requisiti
e collaudo. di tenuta  devono essere usate guarnizioni piatte, precisione di misurazione del misuratore di pressione
EN 837-2
Misuratori di pressione, raccomandazioni dischi sigillanti o guarnizioni profilate WIKA. Nel caso di deve essere verificata regolarmente mediante idonei
per la scelta ed il montaggio. filetti conici (p.e. filetti NPT) la tenuta viene eseguita sul controlli. Il controllo o la ricalibrazione devono essere
EN 837-3
Misuratori di pressione con molle a piastra e filetto ‚ mediante sigillanti supplementari, come p.e. effettuati da personale addestrato in possesso del
capsula dimensioni, tecnica di misurazione, del nastro di PTFE (EN 837-2). giusto equipaggiamento.
requisiti e collaudo.
Superficie della Dei residui di fluido di misurazione all'interno
WIKA Alexander Wiegand GmbH & Co. KG
Alexander-Wiegand-Straße 30
63911 Klingenberg • Germania
chiave
Superficie di tenuta 
Sigillatura
del filetto  ! di misuratori di pressione smontati possono
mettere a rischio la salute umana,
danneggiare l'ambiente e le apparecchiature.
Telefono (+49) 93 72/132-0
Adottare gli opportuni provvedimenti precauzionali.
08/2006
Telefax (+49) 93 72/132-406 La coppia di serraggio dipende dalla guarnizione utiliz-

E-Mail info@wika.de zata. Per portare il misuratore nella posizione in cui si
www.wika.de lascia meglio leggere, si raccomanda di usare un attac- Con riserva di modifiche tecniche.
Misura di pressione
meccanica
Manometro a molla tubolare

Versione in acciaio inox
Modelli 232.50, 233.50
Scheda tecnica WIKA PM 02.02
per ulteriori omologazi-

oni vedi pagina 2
Applicazioni
■ Con cassa a riempimento di liquido per applicazioni con
carichi di pressione altamente dinamici o vibrazioni 1)
■ P4r lu838 066r4ss8v8 60ssos8 4 l8qu838 non 0lt0m4nt4 v8s2os8
o cristallizzanti, anche in ambienti aggressivi
■ Industria di processo: Chimica/petrolchimica, centrali
4l4ttr8274, 8n3ustr80 m8n4r0r80, ons7or4 4 ofs7or4,
tecnologia ambientale, costruzione di macchine e
impiantistica generale
Caratteristiche distintive
■ Eccellente stabilità a lungo termine e resistenza agli urti
■ Costruzione interamente in acciaio inox
■ Approvato da German Lloyd, Gosstandart e DVGW
■ C0mp8 s20l0 ino 0 ... . 10r Manometro a molla tubolare modello 232.50
Descrizione Pressione di lavoro

DN : St0t820: / x v0lor4 38 5on3o s20l0
Esecuzione Fluttu0nt4: / x v0lor4 38 5on3o s20l0
EN 837-1 Br4v4 p4r8o3o: v0lor4 38 5on3o s20l0
Dimensione nominale in mm DN , : St0t820: v0lor4 38 5on3o s20l0
, , Fluttu0nt4: . x v0lor4 38 5on3o s20l0
Br4v4 p4r8o3o: , x v0lor4 38 5on3o s20l0
Classe di precisione
DN : , Temperature consentite
DN , : , Am184nt4: - ... + °C s4nz0 r84mp8m4nto 38 l8qu83o
- ... + °C m0nom4tr8 0 r84mp8m4nto 38 6l824r8n0 1)
Campi scala
Flu83o: + °C m0ss8mo s4nz0 r84mp8m4nto 38 l8qu83o
DN : ... 0 ... . 10r
+ °C m0ss8mo 2on r84mp8m4nto 38 l8qu83o 1)
DN : ... , 0 ... . 10r
DN : ... , 0 ... . 10r Inluenza della temperatura
o tutti gli altri campi equivalenti per vuoto o combinazione di In 20so 38 38f4r4nz0 tr0 l0 t4mp4r0tur0 38 r854r8m4nto + °C
pressione e vuoto e quella del sistema di misura: max. ± 0,4 %/10 K del rispetti-
vo v0lor4 38 5on3o s20l0.
Grado di protezione
1) Modello 233.50 IP 2on5orm4 0 EN / lEC
S27430 t42n820 WIKA PM . ∙ / Pagina 1 di 3
Schede tecniche di prodotti analoghi:

Acciaio inox; esecuzione di sicurezza; modello 232.30; vedere la scheda tecnicaPM 02.04
Versione standard Versioni speciali
Attacco al processo Manometri per impianti ad ammoniaca (DN 100 e 160)

A22808o 8nox L DN : . , Con s20l0 38 t4mp4r0tur0 p4r r45r864r0nt4 R NH 8n °C,
Att022o 0l pro24sso 8n54r8or4 LM o 0tt022o 0l pro24sso C0mp8 s20l0: - ... ... 10r o - ... ... 10r
post4r8or4 4224ntr82o LBM , 0tt022o 0l pro24sso post4r8or4
24ntr0l4 CBM DN
DN : G ¼ B m0s278o , 2780v4 mm
DN , : G ½ B, 2780v4 mm
Elemento di misura
Conformità CE
A22808o 8nox AISI L
< 10r: 5orm0 0 C Direttiva PED
10r: 5orm0 4l82o830l4 97/23/EC, PS > 200 bar; modulo A, accessorio di pressione
Movimento Direttiva ATEX 1)

Acciaio inox T8po 38 prot4z8on4 0nt834l06r0nt4 2 , s82ur4zz0 2ostrutt8v0
Quadrante
Alluminio, bianco, scritte in nero, Omologazioni
DN 2on 54rmo sullo z4ro
■ GL, 8m10r20z8on8, 2ostruz8on8 n0v0l8 4s. ofs7or4 ,
Indice
Germania
Alluminio, nero
■ GOST, t42nolo680 38 m8sur0z8on4/m4trolo680, Russ80
■ GOST-R, 24rt8i20to 3'8mport0z8on4, Russ80
Cassa
■ DVGW, s82ur4zz0 4s. s82ur4zz0 4l4ttr820,
A22808o 8nox, 2on 5oro 38 s20r82o sull0 28r2on54r4nz0 34ll0
sovraccaricabilità, ...), Germania
20ss0, or4 DN 4 sul r4tro 34ll0 20ss0 DN 4 ,
■ KBA, automotive, Comunità europea
C0mp8 s20l0 ... 10r 2on v0lvol0 38 2omp4ns0z8on4 p4r
■ CRN, s82ur4zz0 4s. s82ur4zz0 4l4ttr820, sovr0220r82018l8tà,
si0to 20ss0
...), Canada
■ KOSHA, t8po 38 prot4z8on4 0nt834l06r0nt4 8 - s82ur4zz0
Trasparente
intrinseca, Corea del Sud
Vetro multistrato di sicurezza
DN : pol820r1on0to
Anello
Certiicati 1)
Anello a baionetta, in acciaio inox
■ Proto2ollo 38 prov0 . 2on5orm4 0 EN 4s.
pro3uz8on4 0llo st0to 34ll'0rt4, 24rt8i20z8on4 348 m0t4r80l8,
Riempimento di liquido (per modello 233.50)
pr428s8on4 3'8n3820z8on4
Glicerina 99,7 %
■ C4rt8i20to 3'8sp4z8on4 . 2on5orm4 0 EN 4s.
pr428s8on4 3'8n3820z8on4
Opzioni 1) Opzione
■ Altre connessioni al processo P4r l4 omolo60z8on8 4 8 24rt8i20t8, 2onsult0r4 8l s8to 8nt4rn4t

■ Gu0rn8z8on8 mo34llo . , v438 s27430 t42n820 AC .
■ Montaggio su separatori, vedi catalogo riassuntivo DS
■ S8st4m0 38 m8sur0 Mon4l mo34llo x. , non 2on 0tt022o
0l pro24sso post4r8or4 DN
■ Sistema di misura in acciaio inox 1.4571
■ Flangia per montaggio a pannello o parete, acciaio inox
■ Flangia per montaggio a pannello, acciaio inox lucidato
■ Fl0n680 tr80n6ol0r4, 022808o 8nox, lu2830to, 2on st0f0
■ T4mp4r0tur0 0m184nt4 - °C: r84mp8m4nto 8n ol8o s8l82on82o
■ In3820tor4 38 l8m8t4 0 DN 4 , v438 s27430 t42n820
SP 09.03
■ Manometro con contatti elettrici, vedi modello PGS23.1x0,
scheda tecnica PV 22.02
■ Manometro con segnale in uscita elettrico, vedi modello
PGT . / , s27430 t42n820 PV .
Pagina 2 di 3 S27430 t42n820 WIKA PM . ∙ /

Dimensioni in mm
Versione standard
Attacco al processo inferiore (LM)
10r 2on v0lvol0 38 si0to

> 10r s4nz0 v0lvol0 38 si0to
.
DN 63, attacco al processo posteriore centrale (CBM) DN 100, 160, attacco al processo posteriore eccentrico (LBM)
10r 2on v0lvol0 38 si0to 14112247.01 10r 2on v0lvol0 38 si0to
1520814.03
> 10r s4nz0 v0lvol0 38 si0to > 10r s4nz0 v0lvol0 38 si0to
DN Dimensioni in mm Peso in kg
a b b1 b2 D1 D2 e f G h ±1 SW Modello 232.50 Modello 233.50
63 9,5 33 33 57 11,5 - G¼B 54 14 , 0,20
100 15,5 49,5 49,5 83 101 99 17,5 30 G½B 87 22 , 0,90
160 15,5 49,5 2) 49,5 2) 83 1) 159 17,5 50 G½B 118 22 1,10 2,00
Attacco al processo per EN 837-1 / 7.3
P8ù mm 2on 20mp8 s20l0 10r
P8ù mm 2on 20mpo s20l0 10r
Informazioni per l'ordine

Modello / Dimensione nominale / Campo scala / Dimensioni attacco / Posizione attacco / Opzioni
10/2014 IT based on 08/2014 EN
© 2000 WIKA Alexander Wiegand SE & Co. KG, tutti i diritti riservati.
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C8 r8s4rv80mo 8l 38r8tto 38 0pport0r4 mo38i274 0ll4 sp428i274 t42n8274 43 08 m0t4r80l8.
S27430 t42n820 WIKA PM . ∙ / Pagina 3 di 3
WIKA Italia Srl & C. Sas

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9.6 MANUALE COOLER
IOM_14479_2 (09.16) Pages 39/59

aerospace
climate control
electromechanical
filtration
fluid & gas handling
hydraulics
pneumatics
process control
sealing & shielding
Air Oil Coolers

LOC Cooling System for industrial Use
Installation and servicing manual
Catalogue HY10-6003-UM/EU Installation and servicing manual
Air Oil Coolers, LOC
B
C
A
1
LOC A B
AIR OIL COOLER
C D
2
5
1/ 2 A
B
LOC
AIR OIL COOLER B
1/ 2 A
A
13
Catalogue HY10-6003-UM/EU
2 Parker Hanniin Corporation

Hydraulics Group
Y-koppling D-koppling
Y-connection D-connection
Y-Anschluss D-Anschluss
Connexion en Y Connexion en D
Conexión en Y Conexión en D

Hydraulics Group
LOC LOC CO OLE

R
LER OIL
COO AIR
OIL
AIR
7 8
LOC IL CO
OLE
R
O
AIR
9 10
11 A 11 B 12

Hydraulics Group
F
E
C
B D
A
G
K
H
I
J
Komponentförteckning Komponentenverzeichnis Lista de piezas

A Elmotor A Elektromotor A Motor eléctrico
B Motorfäste B Motorhalterung B Soporte de motor
C Fläktgaller C Schutzgitter C Rejilla de protección ventilador
D Fläktenhet* D Lüftereinheit* D Ventilador completo*
E Fläkthus E Lüftergehäuse E Caja del ventilador
F Kylelement F Kühlelement F Radiador
G Pluggar och gummistålbrickor G Stopfen und Gummistahlscheiben G Tapón ciego con junta metalbuna
H Fötter H Füße H Patas
I Slang med anslutningar I Schlauch mit Anschlüssen I Flexible hidráulico con conexiones
J Konsol J Konsole J Consola del motor
K Pump K Pumpe K Bomba
* Utförandet, fast eller löst nav, varierar * Die Ausführung mit starrer oder loser * El asiento del ventilador, fijo o desmontable,
med typ av kylarsystem. Nabe hängt vom Kühlermodell ab. dependerá del tipo de sistema de
refrigeración.
Part list Liste des composants
A Electric motor A Moteur électrique
B Motor attachment B Support moteur
C Fan guard C Grille ventilateur
D Fan unit* D Hélice complète*
E Fan housing E Caisson ventilateur
F Cooler matrix F Radiateur
G Plugs and rubber steel washers G Bouchons et joints à lèvres
H Feet H Pieds
I Hose with connections I Flexible avec connections
J Bracket J Chaise
K Pump K Pompe
* The design, fixed or detachable hub, is * La conception, moyeu fixe ou non fixe, varie
depending on type of cooling system. suivant le type du système de refroidissement.

Hydraulics Group
A B C D
E
H
G
G
Tillval Tillval Sonderzubehör

Sonderzubehör Opciones Opciones
B S-Bypass, enpassage* B S-Bypass, Einzeldurchlauf* B By-pass tipo S, 1 paso*
C Dammskydd C Staubschutz C Filtro antipolvo
D Stenskydd D Steinschutz D Protección piedras
E T-Bypass, tvåpassage* E T-Bypass, Doppeldurchlauf* E By-pass tipo T, 2 pasos*
F Termokontakt F Thermokontakt F Termocontacto
H Tryckfallsindikatorer H Differenzdruckanzeigen H Dispositivo de presión diferencial
I Filterenhet I Filter I Conjunto iltro
* Kan fås som tryckstyrd eller temperatur- * Mit Drucksteuerung oder Temperatur- * Disponible como bypass controlado por pre
och tryckstyrd bypass. und Drucksteuerung lieferbar. ción o por temperatura y presión
Tillbehör Zubehör Accesorios

A Lyftöglor A Hebeösen A Cáncamos de elevación
G Vibrationsdämpare G Vibrationsdämpfer G Silent blocs
Options Equipements en option

B S by-pass, single-pass* B Bypass type S, modèle 1 passe*
C Dust guard C Filtre antipoussière
D Stone guard D Grille de protection
E T by-pass, two-pass* E Bypass type T, modèle 2 passes*
F Thermo contact F Thermocontact
H Pressure drop indicator H Inidcateurs de comatage
I Filter unit I Filtre
* Pressure controlled or temperature and * Disponsible comme bypass commandé par
pressure controlled by-pass valves are availble. pression ou par température et pression
Accessories Accessoires
A Lifting eye A Anneaux de levage
G Vibration dampener G Patins antivibratoires

Hydraulics Group
Contents Air Oil Coolers, LOC
Inledning 8
Säkerhetsföreskrifter 8
Beskrivning 8
Installation 9
Handhavande 9 SE
Förebyggande underhåll 10
Underhåll 10
Tekniska data 13
Försäkran om överensstämmelse 14
Introduction 15
Safety instructions 15
Description 15
Installation 16
Handling 16 GB
Preventive maintenance 17
Maintenance 17
Technical speciication 20
Declaration of conformity 21
Einleitung 22
Sicherheitsvorschriften 22
Beschreibung 23
Installation 23
Bedienung 24 DE
Vorbeugende Wartung 24
Wartung 25
Technische Daten 27
Konformitätserklärung 28
Introduction 29
Consignes de sécurité 29
Description 30
Installation 30
Consignes d’emploi 31 FR
Entretien préventif 31
Entretien 32
Caractéristiques techniques 35
Déclaration de conformité 36
Introducción 37
Instrucciones de seguridad 37
Descripción 38
Instalación 38
Modo de empleo 39 ES
Mantenimiento preventivo 39
Mantenimiento 40
Características técnicas 43
Declaración de conformidad 44

Hydraulics Group
Inledning/Säkerhetsföreskrifter/Beskrivning Air Oil Coolers, LOC
Inledning Övergripande föreskrifter

Denna anvisning är avsedd att vara ett hjälpmedel vid installation, Lyft
användning och underhåll av LOC kylsystem. Varning Kläm-/krossrisk. För att undvika personskador vid
Förvara anvisningen så att den alltid inns till hands. lyft är det viktigt att använda rätt lyftmetod. Kontrollera att
Ersätt omedelbart en förlorad anvisning. den lyftanordning och de lyftdon som används är felfria och
Läs igenom anvisningen och varningstexterna noggrant och se till godkända för kylsystemets vikt.
att förstå innehållet innan du använder kylsystemet.
Installation
På så sätt får du ut mesta möjliga av ditt kylsystem och felaktig
användning undviks. Fara Risk för elchock. Elektrisk anslutning får endast
Endast för ändamålet utbildad personal får installera, handha och utföras av behörig elektriker!
underhålla kylsystemet. Drift, hantering och underhåll
Parker förbehåller sig rätten till tekniska ändringar.
Varning Risk för personskada. Koppla alltid bort
Avsedd användning drivkällan för motorn innan underhåll.
LOC kylsystem är avsett för kylning och rening (tillval) av olja i
hydraulsystem för industriella applikationer. Varning Risk för personskada. Se till att systemet är
trycklöst innan hydraulanslutningar kopplas bort.
Garanti och reklamation
Vid haveri, kontakta Parker. Parker ansvarar inte för LOC kylsys- Varning Risk för allvarlig brännskada. Vid drift kan
tem efter egenhändiga reparationer och/eller modiieringar. kylsystemet bli mycket varmt. Vidrör ej kylsystemet
förrän det har svalnat.
Försiktighet Klämrisk. Kylsystemet kan styras via en
Säkerhetsföreskrifter termokontakt. Fläkten startar då automatiskt vid upp-
Installatör och brukare ska känna till, förstå och beakta varningar nådd temperatur. Var försiktig vid vistelse nära roterande
eller upplysningar som anges på dekaler, skyltar och i denna komponenter.
anvisning.
Försiktighet Risk för förgiftning. Förbrukad olja skall
Varningsnivåer och uppmärksamhetstexter... lämnas på därför avsedd depå för att inte orsaka skada
på person, egendom eller miljö.
...gällande personlig säkerhet
Uppmärksamhetstexter, som har med personlig säkerhet att Viktigt Statisk elektricitet. Fläktar alstrar statisk elektricitet.
göra, är klassade i tre nivåer, enligt nedan, beroende på hur all- Undvik känslig utrustning (elektronik m.m.) i systemets omedelbara
varliga följderna av en olycka kan bli. närhet.
Antistatiska läktar inns att beställa.
Fara anger att en olycka kommer att inträffa om
föreskriften inte följs. Olyckan leder till allvarlig personskada Anm! Använd hörselskydd vid vistelse under en längre tid i när-
eller möjligen dödsfall. heten av ett kylsystem i drift.
Varning anger att en olycka kan komma att inträffa om Varningsdekal
föreskriften inte följs. Olyckan kan leda till allvarlig person- Nedanstående dekal är fäst på LOC kylsystem vid leverans.
skada eller möjligen dödsfall. Varning! Heta ytor! Använd hörselskydd! Roterande läkt!
(art.nr. 500029 – 70 x 30 mm alt.
Försiktighet anger att en olycka kan komma att inträffa art.nr. 5000291 – 120 x 50 mm) Se Bild 1.
om föreskriften inte följs. Olyckan kan leda till personskada.
...gällande övrig säkerhet
Uppmärksamhetstexter som har med övrig säkerhet (egendom, Beskrivning
process eller omgivning) och handhavande att göra är klassade
enligt följande: LOC kylsystem består i huvudsak av en luftoljekylare, en
växelströmsmotor samt en lågtryckspump ur vår QPM-serie.
Viktigt anger att en olycka kan komma att inträffa om föreskrif- Kylsystemet kan med fördel även förses med en ilterenhet för
ten inte följs. Olyckan kan leda till skada på egendom, process rening av oljan.
eller omgivning. LOC kylsystem inns med kyleffekt 2,7 - 44,8 kW samt med
...gällande tilläggsinformation nominellt oljelöde 20-80 l/min.
Tilläggsinformation markeras enligt följande: Märkskylt kylsystem
Anm! Anger extra information som kan underlätta förståelse för, Kylsystemets märkskylt är placerad på läkthuset. Se Bild 2.
eller utförande av, ett visst moment.
På märkskylten inns information om:
A – Artikelnummer
B – Artikelbenämning
C –Serienummer
D – Leveransdatum
(år och vecka, t.ex. 1018, dvs år 2010 och vecka 18).
Ersätt skadad eller saknad skylt omedelbart.
Märkskylt filterenhet
På ilterenhetens märkskylt inns följande information:
• Artikelnummer på ilterpatron
• Benämning på ilterpatron (04” HP).

Hydraulics Group
Installation/Handhavande Air Oil Coolers, LOC
Installation Elektrisk anslutning
Lyft Fara Risk för elchock. Elektrisk anslutning får endast utföras
av behörig elektriker!
Varning Kläm-/krossrisk. För att undvika personskador vid
lyft är det viktigt att använda rätt lyftmetod. Kontrollera att Innan inkoppling av motorn till elnätet, se till att uppgifterna på
den lyftanordning och de lyftdon som används är felfria och motorns märkskylt överensstämmer med nätets spänning och
godkända för kylsystemets vikt. frekvens.
Elmotorn ska installeras i enlighet med allmänt gällande regler och
LOC kylsystem är från och med storlek 033 förberedda för lyftög- elsäkerhetsföreskrifter och måste installeras av en behörig elektriker.
lor. Lyftöglor inns att beställa som tillbehör.
Försiktighet Var noggrann vid inkoppling. Felaktig
Montering inkoppling, skadade kablar, etc. kan ge upphov till
Försiktighet Risk för personskador. Se till att kyl systemets strömförande komponenter och fel rotationsriktning på
alla delar är ordentligt ixerade. motor, läkt och pump. Se Bild 6.
Parker rekommenderar att installera LOC kylsystem horisontellt, Viktigt Elmotorns märkström får inte överskridas, se märkplåt på
stående på kylsystemets fötter. För att undvika personskador, se elmotorn.
alltid till att kylsystemet är ordentligt fastsatt. Anm! Parker rekommenderar att använda överströmsskydd för
För att uppnå god luftgenomströmning och därmed bästa möjliga elmotorn.
kyleffekt och lägsta möjliga ljudtrycksnivå, lämna ett utrymme
motsvarande åtminstone halva elementhöjden fritt framför och I mycket fuktig miljö, speciellt i samband med intermittent
bakom kylsystemet. Se Bild 3. drift, kan kondens vatten bildas i elmotorn. Vissa elmotorer är
Om systemet är utrustat med ilterenhet, se till att ett utrymme försedda med pluggade hål som kan användas som utlopp för
motsvarande ilterpatronens storlek lämnas fritt över iltret för att eventuellt kondensvatten. Beroende på elmotorns placering bör
förenkla vid byte av ilterpatron. Se Bild 3. dräneringspluggarna avlägsnas.
Ljudtrycksnivån kan uppgå till 57-86 dB(A) LpA vid 1 m avstånd LOC kylsystem kan förses med termokontakt för temperaturlarm.
under normala driftsförhållanden. Olämplig placering av Fläkten startar då automatiskt vid uppnådd temperatur. Använd
kylsystemet, eller drift under extrema förhållanden, kan orsaka relä vid högre belastning än vad som är tillåtet för termokontakten.
förhöjd ljud trycksnivå och sämre kyleffekt.
Viktigt Termokontakten får ej användas för att direkt styra elmotorn.
För att förhindra att tanken töms vid byte av ilterpatron, bör
kylsystemets vätskenivå vara högre än tankens vätskenivå. Om detta
inte är möjligt, installera en backventil eller en avstängningsventil i
systemets in- och utlopp.
Handhavande
Innan första uppstart
Anslutning av kylsystemet
Försiktighet se till att enheten kan startas utan risk för
Använd hydraulslangar för att ansluta kylsystemet. Se till att
skada på person, egendom eller miljö.
kopplingar och slangar är dimensionerade efter hydraulsystemets
tryck, löde, temperatur och typ av olja. Kontrollera att:
Anslut hydraulslangarna till pumpenheten enligt Bild 4. • kylsystemets delar inte är skadade
A – Inlopp. • läkten roterar fritt (använd handkraft)
B – Utlopp för modell S-bypass, enpassage. • alla hydrauliska anslutningar är åtdragna
C - Utlopp för modell T-bypass, två-passage. • läkthusets insida är fri från föremål som kan slungas iväg och
D - Anslutning för termokontakt. orsaka skador på person eller egendom
Maximalt tillåten oljetemperatur är 100 °C. • ventiler eller liknande strypdon är öppna samt att ledningar eller
kopplingar inte är skadade.
Dimensioner på anslutningar beror på kylsystemets storlek.
Se Tekniska data för rekommenderade vätskekombinationer.
Maximalt tillåten vätsketemperatur i kylsystemet är 100 °C.
Innan start
Flödesschema, se Bild 5.
Försiktighet Se till att enheten kan startas utan risk för
För bästa möjliga pumpeffekt, placera kylsystemet under tankens
skada på person, egendom eller miljö.
vätskenivå (max. 5 meter) och så nära tanken som möjligt. Vid
montering ovanför tankens vätskenivå, skall höjdskillnaden Kontrollera att:
minimeras. • alla hydrauliska anslutningar är åtdragna
Inloppsledningens diameter bör inte vara mindre än pumpens • ventiler eller liknande strypdon är öppna samt att ledningar eller
anslutningsdiameter. En grövre diameter rekommenderas. kopplingar inte är skadade.
Undvik strömningshastigheter över 1 m/s i pumpens ingående
oljeledning. Maximalt tryck på pumpens sugsida är 0,5 bar.

Hydraulics Group
Förebyggande underhåll/Underhåll Air Oil Coolers, LOC
Vid start Rengöring

Kontrollera att: Varning Risk för personskada. Koppla bort drivkällan
• läktens rotationsriktning och luftlöde överensstämmer med för motorn innan rengöring.
indikering på läkthuset
• inga onormala ljud och vibrationer förekommer Varning Risk för allvarlig brännskada. Vid drift kan kyl-
• kylsystemet inte läcker. systemet bli mycket varmt. Vidrör ej kylsystemet förrän
det har svalnat.
Se till att inte överbelasta motorn vid kallstart eller på grund av
alltför hög viskositet. Kylsystem Vid yttre rengöring av kylsystemet med exempelvis
Viskositetsområde är 10 – 800 cSt med beaktande av pump, vatten, ska alla elanslutningar kopplas från. Beakta elmotorns
motorkapacitet, ilterdimension etc. kapslingsklass.
Kontakta Parker vid användning av oljor med hög viskositet
(t.ex. tjock smörjolja) eller vid kallstarter. Kylelement Kylelementets luftlameller rengörs enklast
För problemfri drift bör oljans renhetsklass enligt ISO 4406 vara med tryckluft. Vid behov, använd högtryckstvätt med
minst 17/15. avfettningsmedel. Vid högtrycksspolning måste strålen föras
parallellt med lamellerna. Se Bild 7.
Anm! Luft i inloppsledningen kan orsaka problem vid
igångsättning, fyll då ledningen med olja. Fläkthus Demontera kylelementet vid invändig rengöring av
Anm! Om kylsystemet är utrustat med en ilterenhet FX3, se läkthuset. Insidan av läkthuset rengörs enklast med tryckluft.
avsnitt för Filterenhet FX3. Vid behov, använd avfettningsmedel. Blås med tryckluft från
elmotorsidan genom läktgallret.
Under drift
Pump Parker ansvarar inte för ingrepp i pumpen vid t ex invän-
Varning Risk för allvarlig brännskada. Vid drift kan kyl- dig rengöring. Om pumpen har körts med smutsig olja rengörs
systemet bli mycket varmt. Vidrör ej kylsystemet förrän
den genom att köras med ren olja.
den har svalnat.
Anm! Använd hörselskydd vid vistelse under en längre tid i Filterenhet (tillval) Filterpatroner kan inte rengöras.
närheten av ett kylsystem i drift.
Varning LOC kylsystem får ej köras så att pumpens maximalt
tillåtna tryck överskrids, vilket kan inträffa om oljeledningen på Underhåll
pumpens utloppssida är stängd eller kraftigt strypt. (Se separat
Demontering Parker ansvarar inte för konsekvenser efter
broschyr för pumpen). Detta kan både skada pumpen och
orsaka personskador. egenhändigt, av kunden, utförda reparationer eller modiie-
Pumpen saknar tryckbegränsningsventil som standard. ringar.
Välj pump med tryckbegränsningsventil om systemet t.ex. Varning Risk för allvarlig brännskada. Vid drift kan kyl-
är utrustat med avstängningsventil samt om pumpen utsätts systemet bli mycket varmt. Vidrör ej kylsystemet förrän
för kallstarter. Som tillval inns internt eller externt dränerad
det har svalnat.
bypassventil färdigmonterad i pumpen.
Varning Risk för personskada. Koppla bort drivkällan
Förebyggande underhåll för motorn vid underhåll.
De viktigaste underhållsåtgärderna är de förebyggande Viktigt Använda patroner får ej kastas i vanlig sophantering
åtgärderna som brukaren ska utföra med jämna intervaller. utan skall lämnas in på därför avsedda depåer/stationer.
Kontrollera att: Demontering av kylelement
• inga onormala ljud och vibrationer förekommer
1. Stäng av systemet.
• kylsystemet är ordentligt fastsatt
• kylsystemet är rent, smuts försämrar kyleffekten 2. Koppla bort drivkällan för motorn.
• kylsystemet är fritt från skador, byt ut skadade komponenter 3. Se till att systemet är trycklöst.
• kylsystemet inte läcker 4. Stäng oljeanslutningarna.
• varningsdekaler är i gott skick, ersätt skadade eller saknade 5. Koppla bort hydraulslangarna.
dekaler omedelbart. 6. Skruva loss skruvarna med brickor som fäster kylelementet i
läkthuset. Se Bild 8.
Årligen: Kontrollera den elektriska installationen. Detta får en-
7. Lyft bort kylelementet.
dast utföras av behörig elektriker.
Pumpen är under normala driftsförhållanden underhållsfri. Montering av kylelement
Drift under extrema förhållanden kräver inspektion och underhåll 1. Lyft kylelementet på plats.
eller utbyte av pump och/eller koppling. Se separat broschyr för 2. Skruva fast kylelementet i läkthuset. Se Bild 8.
pumpen. 3. Anslut hydraulslangarna till kyl elementet. Se Bild 4.
4. Koppla till drivkällan för motorn.
5. Utför åtgärder enligt Innan start och Vid start.

Hydraulics Group
Underhåll Air Oil Coolers, LOC
Demontering av pump och koppling Montering av elmotor och fläkt

1. Stäng av systemet. Anm! Vissa modeller har fast nav, se Bild 10, andra modeller
2. Koppla bort drivkällan för motorn. har löst nav, se Bild 11 A och Bild 11 B.
3. Se till att systemet är trycklöst.
1. Skruva fast motorn på motorkonsolen.
4. Stäng oljeanslutningarna.
2. Skruva fast motorn i motorfästet. Se Bild 12.
5. Koppla bort hydraulslangarna från kylelementet.
3. Passa in spåret i navet mot krysskilen på motorn. Använd
6. Skruva ur skruvarna och gummistålbrickorna som håller
etanol i navet som smörjning och tryck fast läkten med nav
pumpen till elmotorn.
på motoraxeln. Knacka eventuellt försiktigt med t.ex. en
7. Tag bort pumpen och kopplingens kuggkrans.
gummiklubba. Applicera Loctite på skruven och skruva fast
Pumpen och kopplingsdelarna kan nu bytas ut.
läkten med navet i motoraxeln. Se Bild 10.
8. Lossa stoppskruven i axelkopplingsdelen.
4. Kontrollera att läkten sitter fast på motoraxeln och att den
Ta bort axelkopplingsdelen från elmotoraxeln.
inte glappar.
5. Lyft motorfästet med läkt, läktgaller, motor och motorkonsol
Montering av pump och koppling
på plats för montering i läkthuset.
1. Installera axelkopplingsdelen på elmotoraxeln. 6. Justera in läktgallret och motorn och skruva fast motorfästet
Installera stoppskruven. i läkt huset. Se Bild 9. Skruva fast motorkonsolen.
2. Installera pumpen och kopplingens kuggkrans. 7. Kontrollera att läkten är centrerad och roterar fritt (använd
3. Skruva i skruvarna och gummistålbrickorna som håller handkraft). Vid behov justera placeringen av läktgallret och
pumpen till elmotorn. motorn.
4. Anslut hydraulslangarna till kylelementet. Se Bild 4. 8. Se till att alla skruvar är åtdragna.
5. Koppla till drivkällan för motorn. 9. Koppla motorn till drivkällan.
6. Utför åtgärder enligt Innan start och Vid start. 10.Utför åtgärder enligt Innan start och Vid start.
Demontering av elmotor och fläkt Filterenhet FX3
Varning Risk för allvarlig brännskada. Vid drift kan Med vår ilterenhet typ FX3 iltreras oljan i en separat ilterkrets,
kylsystemet bli mycket varmt. Vidrör ej kylsystemet ett bra komplement till systemets eget ilter. Filterenhet FX3
förrän det har svalnat. inns som tillval.
Varning Risk för personskada. Koppla bort drivkällan Innan start
för motorn vid underhåll.
1. Avlufta ilterenheten genom att öppna luftpluggen vid ilteren-
Fläkten är balanserad tillsammans med navet vid leverans. hetens topp ca. två varv.
Anm! Vissa modeller har fast nav, se Bild 10, andra modeller 2. Fyll ilterenheten gradvis tills all luft kommit ut och stäng
har löst nav, se Bild 11 A och Bild 11 B. sedan luft pluggen.
1. Stäng av systemet. 3. Sätt systemet under fullt tryck och kontrollera om det inte
2. Demontera pumpen enligt Demontering av pump och läcker. Om så är fallet, se Periodiskt underhåll.
koppling.
Försiktighet Om ilterenheten inte avluftas ordentligt,
3. Säkra motorn.
stiger innehållet av löst luft i oljan, vilket förkortar dess
4. Skruva loss skruvarna med brickor som fäster motorfästet i
livslängd och kan även orsaka andra problem i hydraul-
läkthuset. Se Bild 9.
systemet.
5. Skruva loss skruvarna med brickor som håller
motorkonsolen till fötterna. Dra motorn bakåt. Periodiskt underhåll
6. Skruva loss skruven med bricka som fäster läkten med nav
Filterenheten fordrar normalt ingen speciell service utom
i motoraxeln. Se Bild 10. Dra försiktigt loss läkten med nav
periodisk kontroll av tryckfallsindikatorn. Schemalägg byte av
från motoraxeln. Använd avdragare vid behov.
ilterpatron var sjätte månad eller oftare och ha alltid ett rikligt
7. Skruva loss skruvarna med brickor som håller motorn till
förråd av patroner i reserv.
motor fästet. Se Bild 12.
8. Skruva loss skruvarna med brickor som håller motorn till Varning Om trycket i ilterenheten inte sänkts innan
motorkonsolen. ilterpatronen lossas, kan det medföra skador på per-
9. Lyft bort motorn. son, egendom och miljö.
Vid ytterligare demontering av läkt, märk upp alla delarna för
att säkerställa korrekt återmontering, framförallt med avseende
på balans och rotationsriktning. Se Bild 13.

Hydraulics Group
Underhåll Air Oil Coolers, LOC
Vid underhåll ska eventuell smuts på ilterenhetens utvändiga Indikator typ U

ytor avlägsnas. Underhåll ska göras med lämpliga verktyg. Den elektriska tryckfallsindikatorn U är försedd med en 2-polig
Vid externt läckage ska O-ringen vid läckaget bytas ut. Om AMP kontakt.
läckaget fortsätter, kontrollera om repor eller sprickor inns på
tätningsytan. Byt ut defekta delar. Byte av filterpatron
Ett smutsigt system kan snabbt sätta igen en ny ilterpatron. 1. Stäng av systemet och eventuell avstängningsventil.
Det kan krävas ett eller två patronbyten för att stabilisera patro- 2. Se till att systemet är trycklöst
nens livslängd. Om livslängden är kort eller tryckfallet är högt, 3. Öppna luftpluggen på ilterenhetens lock ca. två varv.
kan ilterenheten vara underdimensionerad, kontakta Parker. 4. Skruva bort locket motsols, sett ovanifrån.
Tryckfallsindikatorer 5. Lyft ur ilterpatronen. Släng både ilterpatron och packning.
Filterpatronen kan inte rengöras. Försök att rengöra ilterpa-
Tryckfallsindikatorer kontrollerar ilterpatronens kondition tronen kan bryta ner iltermediet och leda till att förorenad
genom att mäta differentialtryckfallet mellan iltrets in- olja läcker genom ilterpatronen. Använda patroner får ej
och utlopp. Tryckfallsindikatorn arbetar oberoende av kastas i vanlig sophantering, utan skall lämnas in på därför
överströmningsventilen och är avsedd att indikera före det avsedda depåer/stationer. 6. Sätt i en ny ilterpatron. Kon-
att ventilen öppnar. Detta innebär att det inns tid att byta trollera att den har en O-ring i botten.
ilterpatron innan överströmningsventilen öppnar och släpper 7. Sätt i en ny O-ring i ilterenhetens lock och skruva på locket.
igenom oiltrerad olja samt att ilterpatronens livslängd utnyttjas 8. Starta pumpmotorn med luftpluggen öppen cirka två varv.
maximalt. 9. Drag åt avluftningsskruven när enbart olja lyter ut. Vid upp-
Om indikeringen ignoreras och nedsmutsningen fortsätter, start kan tryckfallsindikatorn lösa ut på grund av hög viskosi-
öppnas överströmningsventilen i ilterenheten när tryckfallet tet. Återställ indikatorn. Kör inte systemet utan ilterpatron.
över ilterpatronen uppnår 3,5 bar. Systemet fungerar därefter
enbart som kylsystem utan iltrering. Efter patronbyte återställ tryckfallsindikatorn genom att trycka
in den röda knappen. Den elektriska indikatorn återställs auto-
Indikator typ D
matiskt. När systemet nått normal arbetstemperatur, kontrol-
Om den visuella tryckfallsindikatorn typ D är monterad och lera att den elektriska indikatorn inte har utlösts och/eller den
utlöser (den röda knappen skjuts ut 5 mm) under kallstart, visuella varningsknappen har förblivit intryckt. Om den visuella
återställs den genom att trycka på knappen när normal indikatorn skjuts ut på grund av kallstartsförhållande, återställ
arbetstemperatur uppnåtts. Om indikatorn utlöses efter den enligt beskrivning under Tryckfallsindikatorer.
återställning, byt ilterpatron. Parker garanterar inte ilterpatronens livslängd som vi inte råder
Indikator typ P över utan som beror på förhållandena hos det system i vilket
ilterenheten har installerats.
Den visuella indikatorn typ P har termoskydd, dvs om tempera-
turen understiger 0 °C sker ingen indikering förrän temperaturen Anm! Enheten är försedd med patronutdragningsmekanism
överstiger +29 °C. Denna indikator har manuell återställning. som underlättar patronbyte. Då locket tas av låser likarna på
patronens ändkåpa fast i locket varvid patronen automatiskt
Indikator typ M dras av från hylsan.
Den elektriska tryckfallsindikatorn M har automatisk återställ- Viktigt Försök inte att rengöra eller återanvända ilterpatronen.
ning och anslutning enligt DIN 43650, ISO4400 (Hirschmann)
och är fuktsäker enligt IP65. För effektiv övervakning av ilterpa- Filterpatronen ska bytas vid behov eller vid angivna intervaller,
tronens livslängd, använd både positiv indikering (grön lampa) maximalt sex månader.
och negativ indikering (röd lampa) för smutsig patron.
Om den elektriska tryckfallsindikatorn typ M används och
utlöser (dvs den röda lampan tänds) under kallstart, fortsätt
driften tills den röda lampan slocknar när systemet värmts upp
till normal arbetstemperatur. Denna funktion kan användas
som ”uppvärmningsindikering” i driftprocedurerna. Om den
röda lampan förblir tänd eller tänds när systemet är varmt, byt
ilterpatron.
Indikator typ M
Den elektriska tryckfallsindikatorn M har automatisk återställ-
ning och anslutning enligt DIN 43650, ISO4400 (Hirschmann)
och är fuktsäker enligt IP65. För effektiv övervakning av ilterpa-
tronens livslängd, använd både positiv indikering (grön lampa)
och negativ indikering (röd lampa) för smutsig patron.
Om den elektriska tryckfallsindikatorn typ M används och
utlöser (dvs den röda lampan tänds) under kallstart, fortsätt
driften tills den röda lampan slocknar när systemet värmts upp
till normal arbetstemperatur. Denna funktion kan användas
som ”uppvärmningsindikering” i driftprocedurerna. Om den
röda lampan förblir tänd eller tänds när systemet är varmt, byt
ilterpatron.

Hydraulics Group
Teknisk data Air Oil Coolers, LOC
Tekniska data
Kylsystem
Maximalt arbetstryck: 10 bar
Värmeöverföringstolerans: ±6%
Maximalt tillåten oljetemperatur: 100 °C
Kompatibilitet
Mineralolja
Syntetiska oljor
Vegetabiliska oljor
Vid drift med andra vätskor eller vid extrema driftsförhållanden,
kontakta Parker.
Material
Pumphus/Kylelement Aluminium
Filterenhet (tillval) Aluminium
Fläkthus Stål
Fläktblad/nav Glasiberförstärkt polypropylen/aluminium
Fläktgaller Stål
Ytbehandling Elektrostatisk pulverlackering
Elmotor
3-fas asynkronmotor enligt IEC 60034-1
Rekommenderad omgivnings temperatur -20 °C - +40 °C
Isolationsklass F
Temperaturstegring B
Kapslingsklass IP 55
För märkström, se separat manual för elmotorn.

Hydraulics Group
Försäkran om överrensstämmelse Air Oil Coolers, LOC
EC Dec
claration off conformitty
Manufacturer: Parker Hanniffin Manufacturing Swed

den AB
Acccumulator and
a Cooler Division
Strrömsätraväg
gen 16
SE
E-127 35 Skkärholmen
Sw
weden
Phone: +46 8 636 07 00
ail: infoolaerr.se@parke
Ma er.com
ww
ww.parker.co
om
Productt: Parker LOC Air

A oil coolerr with AC motor and cirrculation pump
Person authorised to compile the techniccal file: Rika

ard Eriksson
n, Parker Ha
annifin Man
nufacturing
n AB
Sweden
Parker Hannifin
H Maanufacturingg Sweden ABA declares s, according
g to Annex VVIII of the Machinery
M
Directivve 2006/42/E EC, under sole
s responsibility that the productt above to w
which this declaration
relates fulfils
f all the
e relevant provisions
p off the Machinery Directiive.
The pro
oduct is in conformity with
w the requ
uirements in
n the followiing standards and directives.
- Safety of machinery
S m – Basic conccepts, generral principle es for design
n, SS-EN IS SO 12100-
1/A1:2009 and
a SS-EN ISO 12100 0-2/A1:20099.
- S
Safety of machinery
m – Safety requ uirements foor fluid powwer systems and their components
c s
– Hydrauliccs, SS-EN IS
SO 4413:20 010.
- S
Safety of machinery
m – Safety dista ances to pre
event hazard zones be eing reache ed by upper
a lower liimbs, SS-EN ISO 1385
and 57:2008.
- Pumps and d pump unitss for liquidss – Common n safety req quirements, SS-EN 809 9+
A
A1:2009/AC C:2010.
- Electric motors used on
o the produ uct comply with
w the Low w Voltage DDirective (LV
VD)
2
2006/95/EC C and the Electromagnetic Compa atibility Direcctive (EMC) 2004/108//EC.
The abo
ove is valid for a complete producct delivered by Parker Hannifin
H Ma
anufacturing
g Sweden
AB and a complete
e product is
CE-marrked by Parrker Hannifin
n Manufacturing Swed
den AB.
If the prroduct is not delivered complete by Parker Ha

annifin Man
nufacturing S
Sweden AB
B the producct
is also not
n CE-marrked by Parkker Hannifin
n Manufactu
uring Sweden AB and must not be
e put into
service until the pro
oduct has been
b declared in conformity with th
he requirem
ments of the
e relevant
es and stan
directive ndards.
Sätra, January
J 15 2013 ___
__________
__________
_______
Rika
ard Eriksso
on
Tecchnical Man
nager
Parrker Hannifin Manufactturing Swed
den AB
PARKER Accumulator
A & Cooler Division Europe - Sätra
a · Box 8064 · 141
1 08 Kungenss Kurva © 2012 Copyrig
ght

Hydraulics Group
Introduction/Safety instructions/Description Air Oil Coolers, LOC
Introduction Installation
Danger Electrical shock hazard. All electrical connec-
The purpose of this manual is to serve as a reference guide for in-
tions must be made by a qualiied electrician!
stallation, maintenance and operation of the LOC cooling system.
Keep the manual at hand. A lost manual should be replaced as Operation, handling and maintenance
soon as possible. Caution Risk of bodily injury. Disconnect the motor
For optimum performance and in order to prevent incorrect use, power supply prior to maintenance.
please read this manual carefully and observe all safety precau-
tions prior to putting the cooling system into service. Caution Risk of bodily injury. Before disconnecting the
Installation and maintenance work should only be carried out by hydraulic connections, make sure the system is depres-
qualiied personnel. surized.
Parker reserve the right to make technical alterations without prior
Caution Risk of severe burns. As the cooling system
notice.
could become extremely hot during operation, make
Use sure the system is cool before touching.
The LOC cooling system is designed to cool oils and, as an op-
Precaution Risk of bodily injury. If the cooling system is
tion, to clean oils in hydraulic systems for industrial applications.
provided with a thermo contact, the fan will start when
Warranty and claims the preset temperature has been reached. Keep away
In the event of malfunction, consult your local Parker ofice. Parker from rotating parts.
shall not be held responsible for any consequences due to modii-
Precaution This indicates a toxic hazard. To prevent
cation and/ or alterations made by the customer.
bodily injury and damage to property or environment,
used oil should be collected according to speciic
Safety instructions industrial waste regulations of each country.
The installation contractor as well as the user should be aware Important Static electricity. Fans generate static electricity.
of, understand and observe all safety precautions in this manual, Do not put sensitive devices (electronics etc.) in the immediate vici-
including any information mentioned on labels attached to the nity of the cooling system. Antistatic fans are available on request.
product. Note! Use hearing protection when standing close to an opera-
Definition of Safety Warning Levels…. ting cooling system for long periods of time.
…concerning personal safety Warning label
All precautions concerning personal safety are classiied as per The warning label speciied below is attached to the LOC
below, depending on how severe the consequences of an inci- cooling system at delivery.
dent could be. Caution! High temperature surfaces! Use hearing protection!
Rotating fan!
Danger This alerts you to an action or procedure that, if (P/N 500029 – 70 x 30 mm or
performed im-properly, will produce bodily harm or death. P/N 5000291 – 120 x 50 mm). See Figure 1.
Caution This alerts you to an action or procedure that, if
performed improperly, is likely to produce bodily harm or
death. Description
Precaution This alerts you to an action or procedure that, The LOC cooling system consists of an air oil cooler, a DC motor
if performed improperly, is likely to cause an accident with and a gerotor type of low pressure pump from our QPM series.
physical harm. In addition, the cooling system can be provided with a ilter for
cleaning of the oil. LOC cooling system is avail able with cooling
…..concerning other safety issues
capacity 2.7 - 44.8 kW and nominal oil low 20 - 80 l/min.
Notiications concerning other safety issues (property, process or
environmental) and maintenance work are classiied as follows: Cooling system identification plate
Important This alerts you to an action or procedure that, if per- The type plate of the cooling system is located on the fan housing.
formed improperly, is likely to result in damages to the product, See Figure 2.
process or environment. The type plate contains the following information:
….concerning additional informationn A – Part number
Additional information is marked as follows. B – Designation
C – Serial number
Note! This alerts you to important information related to the text D – Date of delivery
in a paragraph. (year and week, e.g. 1018, i.e. year 2010 and week 18)
Overall instructions Replace a damaged or missing type plate as soon as possible.
Lifting Filter unit identification plate
Caution Risk of bodily injury. To prevent physical harm
when lifting the unit, ensure correct lifting technique is used. The type plate on the ilter unit contains information about:
Make sure that all lifting devices are free from damage and • P/N of the ilter element
approved for the weight of the cooling system. • Designation of ilter element (04” HP).

Hydraulics Group
Installation/Handling Air Oil Coolers, LOC
Installation Caution Be careful when connecting the equipment.

Improperly made connections, damaged cables, etc.
Lifting could cause parts to become current carrying or result in
incorrect direction of rotation of the electric motor, fan and
Caution Risk of bodily injury. To prevent bodily injury when
pump. See Figure 6.
lifting the unit, ensure correct lifting technique is used.
Make sure that all lifting devices are working properly and Important Do not exceed the maximum rated current for the
approved for the weight of the cooling system. electric motor, see electric motor rating plate.
The LOC cooling system as from size 033 can accommodate Note! An electric motor overload protection is recommended.
lifting eyes. Lifting eyes are available from Parker on request.
Mounting In extremely humid environments, especially when the operation is
intermittent, water condensation could build up. Some motors are
Precaution Risk of bodily injury. Make sure that all parts of itted with plugged holes, which can be used to drain condense
the cooling system are irmly secured. water. Depending on the placement of the electric motor, proper
plugs should be removed.
An upright installation of the cooling system standing on its feet is re-
LOC cooling system can be provided with a thermo contact for
commended. To prevent bodily injury, make sure the cooling system
temperature control. The fan will start automatically when the pre-
is securely ixed.
set temperature has been reached. Use a relay if the current load
A free space corresponding to a minimum of half the height of the
exceeds the maximum load for the thermo contact.
matrix should be available in front of and behind the cooling system
to allow for good airlow, i.e. optimal cooling capacity as well as low Note! The thermo contact may not be used for direct control of the
acoustic pressure level. See Figure 3. electric motor.
In cases where a ilter unit is provided, a space corresponding to at
least the size of the ilter element should be available above the ilter
unit to allow for replacement of the ilter element. See Figure 3.
The acoustic pressure could reach 57-86 dB(A) LpA at 1 m distance Handling
in normal operating conditions. Inappropriate location of the cooling Prior to initial start-up
system or operation in extreme conditions could generate increased
acoustic pressure and reduce cooling capacity. Consult your local Precaution Make sure the cooling system is securely ixed
Parker ofice. and correctly connected.
In order to avoid that the tank empties when replacing the ilter ele- We recommend the following prior to initial start-up:
ment, make sure that the cooling system oil level is above that of the 1. Run the cooling system with the same oil as used in the hydraulic
tank. If this is not possible, install a control valve or shut-off valve in system.
the system inlet and outlet. 2. Filter the oil before passing through the cooling system.
Connection of the cooling system See Technical specification for oil compatibility.
Connect the cooling system using lexible hydraulic hoses to the Prior to start up
hydraulic system. Make sure that all connections and hoses are Precaution Make sure that the unit can be put into service
sized according to the system pressure, low, temperature and without causing bodily injury or damage to property or
type of oil. Connect the hydraulic hoses as illustrated in Figure 4 environment.
A – Inlet. Make sure that:
B – Outlet for S by-pass, single-pass. • the fan rotates freely (use hand force)
C - Outlet for T by-pass, two-pass. • all oil linlets and outlets are tight
D - Connection for thermo contact • the inside of the fan housing is free from objects that could be
The sizes of connections are cooling system dependent. thrown around and cause bodily injury or damage to property
• valves and similar throttling devices are open and that conduits
Maximum permitted oil temperature is 100°C. and couplings are not damaged.
Flow chart, see Figure 5. • valves and similar throttling devices are open and that conduits
and couplings are not damaged.
To achieve the very best pump capacity, place the cooling system
below tank oil level (max. 5 meter) and as close to the tank as At start-up
possible. When installed above tank oil level, minimize the difference
in height. The size of the inlet line should not be inferior to the pump Make sure that:
connection size. A larger size is recommended. • the direction of rotation of the fan and the airlow corresponds to
Avoid low rates in excess of 1 m/s in the pump inlet line. indications on the fan housing,
Maximum pressure on the pump suction side is 0.5 bar. • the cooling system is free from abnormal noise and vibrations,
• the cooling system is free from leaks.
Electrical connection
Make sure not to overload the electric motor due to cold start
Danger Electrical shock hazard. All electrical connections conditions or operation with high oil viscosity. Viscosity range is
must be made by a qualiied electrician! 10 – 800 cSt considering the pump, motor power, ilter element
Prior to connecting the motor to the electrical supply system, make size etc.
sure the speciication on the electric motor rating plate corresponds
to the mains supply voltage and frequency. The electric motor
should be installed according to general rules and electrical safety
regulations and must be installed by a qualiied electrician.

Hydraulics Group
Preventive maintenance/Maintenance Air Oil Coolers, LOC
Consult your local Parker ofice when using high viscosity oils Cooling system When cleaning the exterior of the cooling
(e.g. thick lubricating oils) or when operating in cold start mode. system, for instance using water, disconnect all power supplies.
For optimal operation, a cleanliness rating of 17/15 according Be aware of the electric motor protection standard.
to ISO 4406 ISO is required.
Cooler matrix The air ins of the cooler matrix can be cleaned by
Note! Air in the inlet line could cause problem at start-up, ill blowing through with compressed air. If necessary, a highpressure
the line with oil. washing system and degreasing agent can be used. When using
a high-pressure washing system point the jet parallel to the air ins.
During operation See Figure 7.
Caution Risk of severe burns. The cooling system Fan housing Remove the cooler matrix when cleaning the inside
could become extremely hot during operation, make of the fan housing. To clean the inside of the fan housing, use
sure that the cooling system is cool before touching. compressed air. If necessary a degreasing agent can be used.
Note! Use hearing protection when standing in the immediate Blow with compressed air from the electric motor side through the
vicinity of an operating cooling system for long periods of time. fan guard.
Caution LOC cooling system must not be run in such Pump Parker will not be held responsible for any interference in
a way that the pump maximum pressure is exceeded, the pump such as internal cleaning. If the pump has been run with
which could occur if the pump outlet is closed or se- contaminated oil, clean it by running it with clean oil.
verely throttled. (See pamphlet for the QPM pump.) This Filter unit (option) Filter elements cannot be cleaned.
could damage the pump and cause personal injuries.
The pump has no pressure relief valve as standard. Install a
pressure relief valve if the system is equipped with e.g. a shut-
off valve and/or if the pump is operating in cold start condi- Maintenance
tions. A pump itted with internally or externally drained by-pass Dismounting Parker will not be held responsible for any con-
valve is available as option. sequences after repairs, modiications or alterations made by
the customer.
Preventive maintenance Caution Risk of severe burns. As the cooling system
could become extremely hot during operation, make
Preventive maintenance work must be carried out at regular sure that the cooling system is cool before touching.
intervals. Make sure that:
Caution Risk of bodily injury. Disconnect the motor
• the cooling system is free from abnormal noise or vibrations power supply prior to maintenance.
• the cooling system is securely ixed
• the cooling system is clean - debris will reduce the cooling Note! Used ilter elements should be collected according to
capacity speciic industrial waste regulations of each country.
• the cooling system is free from damage, and that damaged Dismounting the cooler matrix
components are replaced
• the cooling system is free from leaks 1. Turn off the system.
• warning labels are in good condition, replace any damaged/ 2. Disconnect the electric motor power supply.
missing label immediately. 3. Make sure that the system is de-pressurized.
4. Disconnect the oil inlets and outlets.
Annually: Check the electrical installation. This may only be 5. Disconnect the hydraulic hoses from the cooler matrix.
made by a qualiied electrician. 6. Unscrew the screws with washers ixing the cooler matrix to
In normal operating conditions the pump is maintenance free. the fan housing. See Figure 8.
In extreme operating conditions the pump requires inspection, 7. Remove the cooler matrix.
service or replacement of the pump and/or couplings.
See separate pump manual. Mounting of the cooler matrix
Cleaning 1. Locate the cooler matrix.
2. Secure the cooler matrix to the fan housing by screws.
Caution Risk of bodily injury. Prior to cleaning, See Figure 8.
disconnect all motor power supplies. 3. Connect the hydraulic hoses to the cooler matrix.
Caution Risk of severe burns. As the cooling system See Figure 4.
could become extremely hot during operation, make 4. Connect the electric motor power supply
sure the system is cool before touching. 5. Proceed to Prior to start-up and At start-up.

Hydraulics Group
Maintenance Air Oil Coolers, LOC
Dismounting the pump and coupling Mounting of the electric motor and fan
1. Turn off the system. Note! There are models with ixed hub Figure 10 and models with
2. Disconnect the power supply. detachable hub Figure 11 A and Figure 11 B.
3. Make sure that the system is de-pressurized.
4. Disconnect the oil inlets and outlets. 1. Fit the motor to the motor bracket.
5. Disconnect the hydraulic hoses from the cooler matrix. 2. Fit the motor to the motor attachment by screws.
6. Remove the screws and rubber steel washers ixing the pump See Figure 12.
to the electric motor. 3. Fit the hub groove to the motor spline. Lube the hub with
7. Remove the pump and the gear ring of the coupling. ethanol and secure the fan with hub to the cranks haft. If
The pump and the coupling parts can now be replaced. required, knock carefully with e.g. a rubber mal let. Use Loctite
8. Loosen the stop screw of the shaft coupling part. on the screw and secure the fan with hub on the crankshaft by
Remove the shaft coupling part from the crankshaft. screws. See Figure 10.
4. Make sure that the fan is itted to the crankshaft without too
Mounting of the pump and coupling much play.
5. Place the motor attachment with fan, fan guard, motor and
1. Fit the shaft coupling part to the crankshaft. motor support in the fan housing.
Tighten the stop screw. 6. Adjust the fan guard and motor and ix the motor attachment
2. Install the pump and gear ring of the coupling. onto the fan housing by screws. See Figure 9.
3. Install the screws and rubber steel washer ixing the pump to Secure the motor support by screws.
the electric motor. 7. Make sure the fan is centred/aligned and rotates freely
4. Connect the hydraulic hoses. See Figure 4. (use hand force). If necessary, adjust the location of the fan
5. Connect the electric motor power supply. guard and motor.
6. Proceed to Prior to start-up and At start-up. 8. Make sure all screws are tightened.
Dismounting the electric motor and fan 9. Connect the electric motor power supply.
10.Proceed to Prior to start-up and At start-up.
Caution Risk of severe burns. As the cooling system
could become extremely hot during operation, make sure Oil filter unit FX3
the system is cool before touching. Fitted with an ilter unit type FX3 the oil will be cleaned in a sepa-
Precaution Risk of bodily harm. Prior to maintenance, rate system. This is an excellent complement to the system oil
disconnect the electric motor power supply. The fan is cleaning system. Filter unit FX3 is available as option.
balanced together with the hub prior to delivery. Prior to start-up
The fan is balanced together with the hub at delivery. 1. Bleed ilter by opening the vent plug at the top of ilter approx-
Note! There are models with ixed hub Figure 10 and models with imately two turns.
detachable hub Figure 11 A and Figure 11 B. 2. Fill ilter until all air bleeds through the plug, then tighten plug.
3. Pressurize system fully and check for leaks; if leaks occur refer
1. Turn off the system. to Routine maintenance.
2. Dismount the pump according to Dismounting the pump and
coupling. Precaution Failure to bleed the ilter unit adequately will
3. Secure the motor. increase the dissolved air content of the system oil, which
4. Unscrew the screws with washers ixing the motor attachment will shorten oil life and may cause other problems in the
to the fan housing. See Figure 9. system.
5. Unscrew the screws with washers ixing the motor support to Routine maintenance
the feet. Pull the motor backwards.
6. Unscrew the screw with washer ixing the fan/hub to the The ilter unit FX3 does not normally require special attention
crankshaft. See Figure 10. Remove with care the fan/hub from except for periodic monitoring of the pressure drop indicator.
the crankshaft. Use a pulley if required. Schedule replacement of ilter element every six months or sooner,
7. Unscrew the screws with washers ixing the motor to the motor and have ample supply of spare elements available.
attachment. See Figure 12.
8. Unscrew the screws with washers ixing the motor to the motor Caution Failure to depressurize the ilter unit before servi-
bracket. cing element may result in personnel injury or damage to
9. Remove the motor. property, or environment.
If further dismounting of the fan is required, label all parts to ensure

correct assembly, irst of all with regard to balance and direction of
rotation. See Figure 13.

Hydraulics Group
Maintenance Air Oil Coolers, LOC
During servicing the external surfaces of the ilter assembly must Filter element replacement
be cleaned to remove any dust deposits. Servicing must be
conducted using suitable tools that do not present a hazard. If 1. Turn off the system and shut-off valve if any.
external leakage is noted, replace O-ring at leak. If leakage per- 2. Make sure the system is depressurized.
sists, check sealing surfaces for scratches or cracks; replace any 3. Open the vent plug on the ilter unit cover approximately two
defective parts. turns.
A dirty system can quickly plug a new ilter element. It may require 4. Unscrew and remove cover counter clockwise when viewed
one or two initial element changes to stabilize element life. If ele- from above.
ment life is short or differential pressure is excessive, ilter may be 5. Remove the ilter element. Discard both the ilter element and
undersized; contact your local Parker ofice. its O-ring. The ilter element is not cleanable. Any attempt to
clean the element can cause degradation of the ilter medium
Pressure drop indicators and allow contaminated oil to pass through the ilter element.
Used ilter elements should be collected according to speciic
A pressure drop indicator operates by sensing the differential industrial waste regulations of each country.
pressure between port upstream and downstream of the ilter 6. Install a new ilter element. Make sure this is itted with an
element. The pressure drop indicator operates independent from O-ring in the bottom.
the bypass valve and is intended to react before the valve opens. 7. Install a new O-ring in the ilter unit cover and screw on the
This implies that there is time available to change ilter cartridge cover.
before the bypass valve opens and lets uniltered oil through, and 8. Start the pump motor with vent plug open approximately two
this also maximizes the utilization time of the ilter element. turns.
If the indis ignored and the contamination persists, the bypass 9. Tighten the vent plug when only oil bleeds through.
valve will open in the ilter unit when the pressure drop across the During start-up the pressure drop indicator could actuate
ilter element reaches 3,5 bar. The system will then operate as a because of high viscosity. Reset the indicator. Do not run the
cooling system without oil cleaning. system without a ilter element installed.
Indicator type D After element change ensure pressure drop indicator is reset by
pushing in the red button. The electrical indicator will reset auto-
If visual indicator D is itted and actuates ‘cold start’ (red button matically.
extends 5 mm), reset by depressing the button when the normal When system reaches normal operating temperature, check that
operating temperature is reached. If indicatoractuates after reset- the electrical indicator has not actuated and/or the visual warning
ting, replace ilter element. button has remained depressed. If visual indicator rises due to
Indicator type P a cold start condition, reset again as per section Pressure drop
indicator.
Visual indicator type P has thermal lockout , i.e. no signal when Parker do not warrant the service life of the ilter element as this
the temperature is below 0 °C; signal when temperature is above is beyond our control and depends upon the condition of the
+29 °C. This indicator has manual reset. system into which the ilter unit is installed.
Indicator type M Note! The FX3 ilter unit is equipped with an element extraction
The electrical pressure drop indicator M has an automatic reset mechanism to facilitate element removal. While removing the cap,
and connection according to DIN 43650, ISO4400 (Hirschmann) tabs on the element end cap lock into hooks in the cap and the
and is moisture-proof according to IP65. Use of both positive element is automatically pulled from the nipple.
indication (green light) and negative indication (red light for dirty Important Do not attempt to clean or re-use the ilter element.
element) is recommended to effectively monitor ilter element life.
Filter elements should be replaced upon indication or at speciied
If an electrical pressure drop indicator type M is used and actuates intervals, six months maximum.
(e.g. red light comes on) during cold tart, continue operating until
the signal (red light) goes out as system warms to normal opera-
ting temperature. This feature can be used as ‘warm up’ indication
in operating procedures. If the warning signal (red light) remains or
appears when system is warm, replace the ilter element.
Indicator type U
The electrical pressure drop indicator type U is equipped with a
2-pole AMP contact.

Hydraulics Group
Technical specification Air Oil Coolers, LOC
Technical specification
Cooling system
Maximum working pressure 10 bar
Heat transfer tolerance: ±6%
Maximum permitted oil temperature 100 °C
Compatibility
Mineral oil
Synthetic oils
Vegetable oils
For use with other oils or operation in extreme conditions,
contact your local Parker office.
Material
Pump housing/Cooler matrix Aluminium
Filter unit (option) Aluminium
Fan housing Steel
Fan blades/hub Glass iber reinforced polypropylene/aluminium
Fan guard Steel
Surface treatment Electrostatic powder coating
Electric motor
3-phase asyncronuous motor according to IEC 60034-1
Recommended surrounding temperature -20 °C - +40 °C
Insulation standard F
Rise in temperature B
Protection standard IP 55
Regarding nominal voltage, see separate eletric motor manual.

Hydraulics Group
Declaration of conformity Air Oil Coolers, LOC
EC Dec

den AB
Acccumulator and
a Cooler Division
Strrömsätraväg
gen 16
SE
Sw
weden
Phone: +46 8 636 07 00
Ma er.com
ww
ww.parker.co
om
Productt: A oil coolerr with AC motor and cirrculation pump

Parker LOC Air

ard Eriksson
n, Parker Ha
annifin Man
nufacturing
n AB
Sweden
Parker Hannifin
M
s which this declaration
responsibility that the productt above to w
relates fulfils
f all the
The pro
w the requ n the followiing standards and directives.
uirements in
1/A1:2009 and
a SS-EN ISO 12100 0-2/A1:20099.
- S
Safety of machinery
c s
SO 4413:20 010.
- S
Safety of machinery
and 57:2008.
A
A1:2009/AC C:2010.
VD)
2
The abo
H Ma
anufacturing
g Sweden
AB and a complete
e product is
den AB.

annifin Man
nufacturing S
Sweden AB
B the producct
is also not
n Manufactu
e put into
oduct has been
he requirem
ments of the
e relevant
es and stan
directive ndards.
Sätra, January
J 15 2013 ___
__________
__________
_______
Rika
ard Eriksso
on
Tecchnical Man
nager
den AB
PARKER Accumulator
a · Box 8064 · 141
ght

Hydraulics Group
Einleitung/Sicherheitsvorschriften Air Oil Coolers, LOC
Einleitung Übergeordnete Vorschriften

Anheben
Diese Anleitung bezieht sich auf die LOC Baureihe von
Kühlsysteme. Sie soll als Hilfsmittel bei Installation, Einsatz und Warnung Quetschgefahr. Damit beim Anheben Verletz -
Wartung des Kühlsystems dienen. ungen verhindert werden, ist das richtige Hebeverfahren
anzuwenden. Sicherstellen, dass die verwendeten Hebvor-
Diese Anleitung ist so zu verwahren, dass sie jederzeit verfügbar richtungen und -geräte keine Fehler aufweisen und für das
ist. Eine beschädigte oder fehlende Anleitung ist unverzüglich Gewicht des Kühlsystems ausgelegt sind.
zu ersetzen.
Installation
Anweisungen und Warntexte sind vor Inbetriebnahme des
Kühlsystems sorgfältig zu lesen und entsprechend zu beachten. Gefahr Elektroschock. Alle elektrischen Anschlüsse dürfen
Damit wird sichergestellt, dass das Kühlsystem optimal nur von einem entsprechend ausgebildeten Elektriker aus-
genutzt und eine fehlerhafte Benutzung ausgeschlossen wird. geführt werden!
Installations- und Wartungsarbeiten dürfen nur von geschultem Betrieb, Bedienung und Wartung
Personal durchgeführt werden. Parker behält sich das Recht
vor, ohne vorherige Ankündigung, technische Änderungen Warnung Verletzungsgefahr. Vor Wartungsarbeiten ist die
vorzunehmen. Stromversorgung des Motors vom Netz zu trennen.
Einsatzbereiche Warnung Verletzungsgefahr. Vor dem Lösen von
Das LOC Kühlsystem ist für die Kühlung und evtl. Filterung von Hydraulikanschlüssen sicherstellen, dass die Anlage
Ölen in hydraulischen Systemen für industrielle Anlagen vorge- drucklos ist.
sehen. Warnung Gefahr schwerer Verbrennungen. Im Betrieb
Garantie und Reklamationen kann das Kühlsystem sehr heiß werden. Daher darf es
Im Störungsfall wenden Sie sich bitte an Parker. Parker haftet nicht erst berührt werden, wenn es sich abgekühlt hat.
für Folgeschäden, die durch eigenmächtige Reparaturen und/oder Vorsicht Quetschgefahr. Wenn das Kühlsystem mit
Modiikationen durch den Kunden entstehen. einem Thermokontakt ausgestattet ist, läuft das Lüfterrad
bei Erreichen der Einschalttemperatur automatisch an.
Sicherheitsabstand zu sich drehenden Teilen einhalten.
Sicherheitsvorschriften Vorsicht Vergiftungsgefahr. Verbrauchtes Öl ist gemäß
Installateure und Anwender müssen Warnungen und Hinwei- den Vorschriften des jeweiligen Landes zur Entsorgung
se auf Schildern, Aufklebern, sowie die Anweisungen in diesem von Industrieabfällen zu entsorgen, damit Verletzungen
Handbuch lesen und beachten. bzw. Schäden an Material oder Umwelt verhindert
werden.
Warnstufen und Hinweistexte
Wichtig! Statische Elektrizität! Das Lüfterrad kann durch
...zur persönlicher Sicherheit Luftreibung statische Ladung erzeugen. Bringen Sie keine
Hinweistexte zur Personensicherheit sind in die drei nachstehend empindlichen Geräte (Elektronik usw.) in die unmittelbare Nähe
beschriebenen Stufen unterteilt, die sich an den möglichen des Kühlsystems. Antistatische Lüfterräder können separat bestellt
ernsthaften Folgen eines Unfalls orientieren. werden.
Gefahr weist darauf hin, dass ein Unfall sich ereignen Hinweis: Bei längerem Aufenthalt in der Nähe des in Betrieb
wird, wenn diese Vorschriften nicht beachtet werden. Ein beindlichen Kühlsystems ist Gehörschutz zu tragen.
solcher Unfall führt zu ernsthaften Verletzungen oder sogar
zu Todesfällen. Warnaufkleber
Ein Warnaufkleber mit folgenden Angaben ist bei Lieferung am
Warnung weist darauf hin, dass ein Unfall sich ereignen
Kühlsystem angebracht.
kann, wenn diese Vorschriften nicht beachtet werden. Ein
solcher Unfall kann zu ernsthaften Verletzungen oder sogar Warnung Heiße Oberlächen! Gehörschutz tragen!
zu Todesfällen führen. Rotierendes Lüfterrad!
(Art.-Nr. 500029 – 70 x 30 mm oder
Vorsicht weist darauf hin, dass ein Unfall sich ereignen
Art.-Nr. 5000291 – 120 x 50 mm). Siehe Abb. 1.
kann, wenn diese Vorschriften nicht beachtet werden. Ein
solcher Unfall kann zu Verletzungen führen.
...und sonstigen Sicherheit
Hinweistexte zur sonstigen Sicherheit (Gegenstände, Prozesse
oder Umfeld) und Bedienung sind wie folgt unterteilt.
Wichtig weist darauf hin, dass ein Unfall sich ereignen kann,
wenn diese Vorschriften nicht beachtet werden. Ein solcher
Unfall kann zu Beschädigungen an Gegenständen, Prozessen
und Umfeld führen.
…zu Zusatzinformationen
Die Zusatzangaben sind wie folgt gekennzeichnet:
Hinweis! Weist auf wichtige Informationen hin, die mit dem Text
in einem Abschnitt in Zusammenhang stehen.

Hydraulics Group
Beschreibung/Installation Air Oil Coolers, LOC
Beschreibung Anschluss des Kühlsystems
Das LOC Kühlsystem besteht im Wesentlichen aus einen Öl- Der Anschluss des Kühlsystems erfolgt mittels
/Luftkühler, ein Drehstrommotor und einer Niederdruckpumpe der Hydraulikschläuchen. Sicherstellen, dass Anschlüsse und
Baureihe QPM. Darüber hinaus kann das Kühlsystem mit einem Schläuche auf Druck, Durchsatz, Temperatur und Öltyp der
Filter für die Reinigung des Öls ausgerüstet werden. Das LOC Anlage ausgelegt sind.
Kühlsystem ist mit einer Kühlleistung von 2,7–44,8 kW und einer Hydraulikschläuche wie in Abb. 4 an das Kühlelement anschlie-
Fördermenge von 20–80 l/min lieferbar. ßen:
Typenschild des Kühlsystems A – Eintritt
B – Austritt für S-Bypass, Einzeldurchlauf
Das Typenschild des Kühlsystems beindet sich am Lüftergehäuse.
C – Austritt für T-Bypass, Doppeldurchlauf
Siehe Abb. 2.
D – Anschluss für Thermokontakt
Es enthält folgende Angaben:
A - Artikelnummer Die Größe der Anschlüsse hängt vom Kühlsystem ab.
B - Artikelbezeichnung Die maximal zulässige Temperatur des Öls im Kühlelement be-
C - Seriennummer trägt 100 °C.
D – Lieferdatum Durchsatzdiagramm, siehe Abb. 5.
(Jahr und Kalenderwoche, Zur Erzielung der optimalen Pumpenleistung stellen Sie das Kühl-
z. B. 1018, also Jahr 2010 und KW 18) system unterhalb des Tankfüllstands (max. 5 Meter) mit der An-
saugseite so nah wie möglich am Tank auf. Bei Montage über
Ein beschädigtes oder fehlendes Typenschild ist unverzüglich Tankfüllstand halten Sie den Höhenunterschied zwischen Füll-
zu ersetzen. stand und Kühlsystem so gering wie möglich. Der Durchmesser
der Ansaugleitung darf nicht kleiner als der Durchmesser des
Typenschild am Filter
Pumpenanschlusses sein. Es wird ein größerer Durchmesser
Das Typenschild des Filters enthält folgende Angaben: empfohlen.
• Artikelnummer des Filterelements Vermeiden Sie Durchlussmengen in der Ansaugleitung von mehr
• Artikelbezeichnung des Filterelementes (04“ HP). als 1 m/s. Der maximale Druck an der Ansaugseite der Pumpe
beträgt 0,5 bar.
Elektrischer Anschluss
Installation
Gefahr Elektroschock. Alle elektrische Anschlüsse dürfen
Anheben
nur von einem entsprechend ausgebildeten Elektriker aus-
Warnung Quetschgefahr. Damit beim Anheben Verletz-- geführt werden!
ungen verhindert werden, ist das richtige Hebever-
Vor dem Anschluss des Motors an das Stromnetz ist sicherzu-
fahren anzuwenden. Sicherstellen, dass die verwendeten
stellen, dass die Angaben auf dem Typenschild des Motors der
Hebvorrichtungen und -geräte ordnungsgemäß
Spannung und Frequenz des Netzes entsprechen.
funktionieren und für das Gewicht des Kühlsystems
ausgelegt sind. Der Motor ist gemäß den allgemeingültigen Vorschriften und Elek-
Alle Kühlsysteme ab Größe 033 sind für Hebeösen vorbereitet. trosicherheitsbestimmungen von einem ausgebildeten Elektriker
Hebeösen sind als Zubehör von Parker zu bestellen. anzuschließen.
Montage Vorsicht Beim Anschluss des Gerätes ist sehr vorsichtig
zu arbeiten. Falsche Anschlüsse, beschädigte Kabel etc.
Vorsicht Verletzungsgefahr. Sicherstellen, dass das können zur Folge haben, dass Komponenten unter Strom
Kühlsystem immer ordnungsgemäß befestigt ist. gesetzt werden und Motor, Lüfterrad und Pumpe sich in
Eine stehende Aufstellung auf den Füßen des Kühlsystems ist die falsche Richtung drehen. Siehe Abb. 6.
zu bevorzugen. Um Verletzungsgefahr zu vermeiden, überprüfen Wichtig Der zulässige Nennstrom des Motors darf nicht über-
Sie ob das Kühlsystem ordnungsgemäß befestigt ist. Vor und schritten werden. Siehe Angaben auf dem Typenschild.
hinter dem Kühlsystem muss ein Mindestabstand von der halben
Höhe des Kühlelements (A) vorhanden sein, damit eine gute Hinweis! Parker empiehlt den Einsatz eines Überlastungsschutzes
Luftversorgung und damit eine optimale Kühlleistung und eine für den Elektromotor.
geringe Geräuschemission gewährleistet ist. Siehe Abb. 3. In sehr feuchter Umgebung und insbesondere bei nicht konti-
Wenn das System mit einem Filter ausgerüstet ist, muss über nuierlichem Betrieb kann sich im Motor Kondenswasser bilden.
dem Filterdeckel einen Freiraum von mindestens der Größe des Einige Motoren sind mit verschlossenen Ablauföffnungen für Kon-
Filterelementes vorhanden sein, damit das Filterelement problem- denswasser versehen. Abhängig von der Lage des Motors sind
los getauscht werden kann. Siehe Abb. 3. dazu die entsprechenden Verschlüsse zu entfernen.
Der Schaldruckpegel kann unter normalen Betriebsbedingungen
57-86 dB(A) LpA (Abstand von 1 m) erreichen. Bei unsachgemä- Das LOC Kühlsystem kann mit einem Thermokontakt für die
ßer Aufstellung des Kühlsystems oder Betrieb unter ungünstigen Temperaturregelung versehen werden. Das Lüfterrad läuft dann
Bedingungen kann der Schaldruckpegel steigen und die Kühllei- bei Erreichen der Einschalttemperatur automatisch an. Liegt die
stung sinken. Stromlast über dem für den Thermokontakt zulässigen Wert,
Wenden Sie sich mit entsprechenden Fragen bitte an Parker. sollte ein Relais verwendet werden.
Um eine Entleerung des Behälters beim Elementwechsel zu
Wichtig Mit dem Thermokontakt darf der Elektromotor nicht di-
verhindern, muss der Füllstand des Kühlsystems über dem des
rekt gesteuert werden.
Behälters liegen. Falls dies nicht möglich ist, installieren Sie am
Ein- und Austritt des Systems ein Rückschlag- oder Absperrventil.

Hydraulics Group
Bedienung/Vorbeugende Wartung Air Oil Coolers, LOC
Bedienung Warnung Das Kühlsystem darf unter keinen Umständen

so betrieben werden, dass der maximale Pumpendruck
Vor dem ersten Start überschritten wird. Dies kann eintreten, wenn das
System auf der Druckseite abgeschaltet oder sehr stark
Vorsicht Verletzungsgefahr! Sicherstellen, dass das
gedrosselt wird. (Siehe Produktbroschüre der QPM
Kühlsystem ordnungsgemäß befestigt ist und richtig
Niederdruckpumpe.) Dies kann Schäden an der Pumpe und
angeschlossen ist.
Verletzungen zur Folge haben.
Parker empiehlt folgende Vorgehensweise: Die Pumpe wird serienmäßig ohne Druckbegrenzungsventil
1. Das Kühlsystem mit demselben Öl wie im Hydrauliksystem geliefert. Installieren Sie ein Druckbegrenzungsventil, wenn das
durchspülen. System mit einem Absperrventil ausgerüstet ist oder die Pumpe
2. Das Öl vor dem Durchlauf durch das Kühlsystem iltern. unter Kaltstartbedingungen arbeitet. Eine Pumpe mit intern oder
Unter Technische Daten inden Sie zulässige Öltypen. extern abgeleitetem Bybass-Ventil ist wahlweise erhältlich.
Hinweis: Luft in der Ansaugleitung kann bei Inbetriebnahme zu

Problemen führen. In diesem Fall muss die Ansaugleitung mit Öl Vorbeugende Wartung
gefüllt werden.
Die wichtigsten Wartungsmaßnahmen dienen der Vorbeugung
Hinweis! Wenn das Kühlsystem mit einer Filtereinheit FX3 ausge- und sind vom Anwender in regelmäßigen Abständen
stattet ist, siehe Abschnitt Filtereinheit FX3. durchzuführen.
Vor dem Start Stellen Sie sicher, dass:
• keine ungewöhnlichen Geräusche oder Vibrationen erzeugt
Vorsicht Die Inbetriebnahme des Kühlsystem muss werden
mögliich sein, ohne dass Verletzungen oder Schäden an • das Kühlsystem sicher befestigt ist
Material oder Umweit drohen. • das Kühlsystem sauber ist – Verunreinigungen senken die
Stellen Sie sicher, dass: Kühlleistung
• alle Teile des Kühlsystems unbeschädigt sind • das Kühlsystem unbeschädigt ist; defekte Teile sind
• sich das Lüfterrad ungehindert drehen kann auszutauschen
(mit der Hand drehen) • keine Leckage vorliegen
• alle hydraulischen Anschlüsse fest angezogen sind • Warnschilder in gutem Zustand sind; beschädigte oder
• die Innenseite des Lüftergehäuses freivon Gegenständen ist, die fehlende Warnschilder sind unverzüglich zu ersetzen.
weggeschleudert werden und Personen verletzen oder Dinge Jährlich durchzuführende Maßnahmen: elektrische Anschlüsse
beschädigen können überprüfen. Dies darf nur von einem entsprechend ausgebildeten
• die Ventile und ähnlichen Bauteile bei der Inbetriebnahme geöffnet Elektriker durchgeführt werden! Die Pumpe ist unter normalen
sind, sowie Leitungen und Kopplungen unbeschädigt sind. Betriebsbedingungen wartungsfrei. Bei Betrieb unter
erschwerten Bedingungen sind Inspektion und Wartung bzw.
Beim Start Austausch der Pumpe und/oder der Kupplungen erforderlich.
Stellen Sie sicher, dass: Siehe dazu das separate Handbuch zur Pumpe.
• die Drehrichtung des Lüfterrads und der Luftdurchsatz den Reinigung
Angaben am Lüftergehäuse entsprechen Warnung Verletzungsgefahr. Vor der Reinigung ist der
• keine ungewöhnlichen Geräusche oder Vibrationen erzeugt Motor vom Netz zu trennen.
werden
• keine Leckage vorliegen. Warnung Gefahr schwerer Verbrennungen. Im Betrieb
kann das Kühlsystem sehr heiß werden. Daher darf es
Sicherstellen, dass der Elektromotor unter Kaltstartbedingungen erst berührt werden, wenn es sich abgekühlt hat.
oder bei Einsatz von Öl mit hoher Viskosität nicht überlastet wird.
Die zulässige Viskosität liegt zwischen 10–800 cSt unter Kühlsystem Bei Reinigungsarbeiten am Geräteäußeren (z. B. mit
Berücksichtigung von Pumpe, Motorleistung, Filtergröße usw. Wasser) trennen Sie das Kühlsystem von der Stromversorgung.
Bei Einsatz von Öl mit hoher Viskosität (z. B. dicklüssiger Dabei die Schutzart des Motors beachten.
Schmieröle) oder Kaltstartbedingungen halten Sie Rücksprache Kühlelement Die Luftlamellen können mit Druckluft gereinigt
mit Parker. werden. Dazu kann ggf. eine Hochdruckwaschanlage und ein
Für den optimalen Betrieb ist eine Reinheitsklasse von 17/15 Entfettungsmittel verwendet werden.
gemäß DIN ISO 4406 erforderlich. Beim Einsatz einer Hochdruckwaschanlage muss der Strahl
vorsichtig parallel zu den Luftlamellen geführt werden. Siehe
Hinweis: Luft in der Ansaugleitung kann bei Inbetriebnahme zu Abb. 7.
Problemen führen. In diesem Fall muss die Ansaugleitung mit Öl
gefüllt werden. Lüftergehäuse Das Kühlelement zur Innenreinigung des
Lüftergehäuses abnehmen. Das Innere des Lüftergehäuses wird
Während des Betriebs nur mit Druckluft gereinigt. Bei Bedarf kann ein Entfettungsmittel
eingesetzt werden. Die Druckluft von der Elektromotorseite
Warnung Gefahr schwerer Verbrennungen. Im Betrieb
durch das Schutzgitter blasen.
kann das Kühlsystem sehr heiß werden. Daher darf es erst
berührt werden, wenn es sich abgekühlt hat. Pumpe Parker haftet nicht für Folgeschäden, die durch
eigenmächtige Arbeiten an der Pumpe, z. B. Reinigung des
Hinweis! Bei längerem Aufenthalt in der Nähe des laufenden Pumpeninneren entstehen. Falls die Pumpe mit verunreinigtem
Kühlsystems ist Gehörschutz zu tragen. Öl betrieben wurde, reinigen Sie sie anschließend durch Betrieb
mit sauberem Öl.
Filtereinheit (optional) Filterelemente können nicht gereinigt
werden.

Hydraulics Group
Wartung Air Oil Coolers, LOC
Wartung Warnung Verletzungsgefahr. Vor Wartungsarbeiten den

Motorantrieb abschalten.
Demontage Parker haftet nicht für Folgeschäden, die durch
eigenmächtige Reparaturen und/oder Modiikationen durch den Das Lüfterrad wurde vor der Auslieferung zusammen mit der
Kunden entstehen. Nabe ausgewuchtet.
Warnung Gefahr schwerer Verbrennungen. Im Betrieb Hinweis! Einige Modelle haben eine starre Nabe siehe Abb. 10.
kann das Kühlsystem sehr heiß werden. Daher darf es Bei anderen Modellen ist die Nabe lose Abb. 11 A und Abb. 11 B.
erst berührt werden, wenn es sich abgekühlt hat. 1. Die Anlage abschalten.
Warnung Verletzungsgefahr. Vor Wartungsarbeiten ist 2. Die Pumpe mit den unter Demontage von Pumpe und Kupp-
die Stromversorgung des Motors vom Netz zu trennen. lung genannten Schritten demontieren.
3. Den Motor abstützen.
Wichtig Gebrauchte Filterelemente müssen unter Einhaltung der 4. Die Schrauben und Unterlegscheiben, mit denen die Motor-
Richtlinien für die Entsorgung von Industrieabfällen des jeweiligen halterung am Lüftergehäuse befestigt ist, entfernen.
Landes entsorgt werden. Siehe Abb. 9.
5. Die Schrauben samt Unterlegscheiben lösen, mit denen die
Demontage des Kühlelementes
Motorkonsole am Fuß befestigt ist. Den Motor nach hinten
1. Die Anlage abschalten. ziehen.
2. Den Motor von der Stromversorgung trennen. 6. Die Schraube samt Unterlegscheibe lösen, mit denen das
3. Sicherstellen, dass das System drucklos ist. Lüfterrad mit Nabe an der Motorwelle befestigt ist.
4. Die Öleintritt und -austritt verschließen. Siehe Abb. 10. Das Lüfterrad mit Nabe vorsichtig von der
5. Die Hydraulikschläuche lösen. Motorwelle abziehen ggf. einen Abzieher verwenden.
6. Die Schrauben und Unterlegscheiben, mit denen das Kühlele- 7. Die Schrauben samt Unterlegscheiben lösen, mit denen der
ment am Lüftergehäuse befestigt ist, entfernen. Motor an der Motorhalterung befestigt ist. Siehe Abb. 12.
Siehe Abb. 8. 8. Die Schrauben samt Unterlegscheiben entfernen, mit denen
7. Das Kühlelement abnehmen. der Motor an der Motorkonsole befestigt ist.
9. Den Motor abnehmen.
Montage des Kühlelementes
Wenn ein weiteres Zerlegen des Lüfterrads erforderlich ist, sind
1. Das Kühlelement im Lüftergehäuse setzen. alle Teile zur Gewährleistung des richtigen Zusammenbaus zu
2. Das Kühlelement am Lüftergehäuse anschrauben. kennzeichnen, insbesondere hinsichtlich Auswuchtung und
Siehe Abb. 8. Drehrichtung. Siehe Abb. 13.
3. Die Hydraulikschläuche am Kühlelement anschließen.
Siehe Abb. 4. Montage von Elektromotor und Lüfterrad
4. Die Stromversorgung des Motors anschließen.
Hinweis! Einige Modelle haben eine starre Nabe siehe Abb. 10.
5. Die unter Vor dem Start und Beim Start genannten Schritte
Bei anderen Modellen ist die Nabe lose Abb. 11 A und Abb. 11 B.
ausführen.
1. Den Motor an der Motorkonsole anschrauben.
Demontage der Pumpe und der Kupplung
2. Den Motor an der Motorhalterung anschrauben.
1. Die Anlage abschalten. Siehe Abb. 12.
2. Die Stromversorgung abschalten. 3. Bei Montage des Lüfterrades auf der Motorwelle ist die in der
3. Sicherstellen, dass das System drucklos ist. Lüfterradnabe beindliche Nut an der Passfeder der Motor-
4. Die Öleintritt und -austritt verschließen. welle auszurichten und auf diese aufzusetzen. Dabei ist als
5. Die Hydraulikschläuche lösen. Schmiermittel Äthanol zu verwenden. Ggf. ist die Lüfterradna-
6. Die Schrauben und Gummi-/Stahlunterlegscheiben entfernen, be mit einem Gummihammer vorsichtig auf die Motorwelle zu
mit denen die Pumpe am E-Motor befestigt ist. klopfen. Loctite auf die Schraube auftragen und das Lüfterrad
7. Die Pumpe und den Zahnkranz der Kupplung abnehmen. mit der Nabe an der Motorwelle festschrauben.
Die Pumpe und Kupplungsteile können jetzt ausgetauscht Siehe Abb. 10.
werden. 4. Überprüfen, ob das Lüfterrad fest auf der Motorwelle sitzt und
8. Die Anschlagschraube des Wellenkupplungsteils lösen. nicht zu viel Spiel hat.
Das Wellenkupplungsteil von der Motorwelle entfernen. 5. Die Motorhalterung mit Lüfterrad, Schutzgitter, Motor und
Motorkonsole zur Montage in das Lüftergehäuse setzen.
Montage von Pumpe und Kupplung 6. Schutzgitter und Motor ausrichten und die Motorhalterung am
1. Das Wellenkupplungsteil an der Motorwelle anbringen. Lüftergehäuse anschrauben. Siehe Abb. 9.
Die Anschlagschraube festziehen. Die Motorkonsole festschrauben.
2. Die Pumpe und den Zahnkranz der Kupplung anbringen. 7. Überprüfen, ob das Lüfterrad zentriert/ausgerichtet ist und
3. Die Schrauben und Gummi-/Stahlunterlegscheiben anbring- sich frei dreht (mit der Hand drehen). Bei Bedarf die Anbring-
en, mit denen die Pumpe am E-Motor befestigt ist. ung von Schutzgitter und Motor ändern.
4. Die Hydraulikschläuche anschließen. Siehe Abb. 4. 8. Sicherstellen, dass alle Schrauben festgezogen sind.
5. Die Stromversorgung des Motors anschließen. 9. Die Stromversorgung des Motors anschließen.
6. Die unter Vor dem Start und Beim Start genannten Schritte 10.Die unter Vor dem Start und Beim Start genannten Schritte
ausführen. ausführen.
Demontage von Elektromotor und Lüfterrad Filtereinheit FX3
Warnung Gefahr schwerer Verbrennungen. Im Betrieb Bei Ausstattung mit einer Filtereinheit des Typs FX3 wird das Öl
kann das Kühlsystem sehr heiß werden. Daher darf es in einem separaten System gereinigt. Dies ist eine hervorragende
erst berührt werden, wenn es sich abgekühlt hat. Ergänzung zum Ölreinigungssystem der Anlage. Die Filtereinheit
FX3 ist als Zubehör erhältlich.

Hydraulics Group
Wartung Air Oil Coolers, LOC
Vor dem Start Anzeige des Typs M

1. Filter durch Öffnen der Schraube an der Oberseite des Filters Die elektrische Anzeige M verfügt über eine automatische
um circa zwei Umdrehungen entlüften. Rückstellung und einen Hirschmann-Stecker nach DIN 43650,
2. Filter befüllen, bis die gesamte Luft entwichen ist. ISO4400. Sie ist nach Schutzklasse IP65 feuchtigkeitsfest.
Dann Ventil schließen. Zur Überwachung des Filterelements empiehlt es sich, zwei
3. Das System voll mit Druck beaufschlagen und auf Leckagen Anzeigeleuchten vorzusehen: die positive Anzeige zur Unver-
prüfen. Bei Undichtigkeiten siehe Regelmäßige Wartung. sehrtheit des Filters (grüne Lampe) und die negative Anzeige
(d. h. rote Lampe bei verschmutztem Element). Dies trägt zur
Vorsicht Wird die Filtereinheit nicht ordnungsgemäß wirksamen Steuerung der Filterstandzeit bei. Falls die elektrische
entlüftet, steigt der Gehalt an gelöster Luft im Öl. Das Anzeige des Typs M unter Kaltstartbedingungen anspricht (d. h.
verkürzt die Standzeit des Öls und kann im Hydrauliksys- die rote Lampe leuchtet auf), betreiben Sie das System weiter,
tem weitere Probleme verursachen. bis das Signal (die rote Lampe) bei Erreichen der normalen
Regelmäßige Wartung Betriebstemperatur erlischt. Diese Funktion kann während des
Betriebs zum Anzeigen der ”Aufwärmphase” verwendet werden.
Mit Ausnahme der regelmäßigen Kontrolle der Differenzdruck- Falls das Signal (rote Leuchte) weiterhin anliegt oder bei normaler
anzeigen erfordern Filtereinheiten des Typs FX3 keine spezielle Betriebstemperatur auftritt, ersetzen Sie das Filterelement.
Wartung. Die Filterelemente sind nach Ansprechen der Anzeige, Anzeige des Typs U
spätestens jedoch nach sechs Monaten zu wechseln. Es sollten
immer genügend Ersatzilter vorrätig sein. Die elektrische Differenzdruckanzeige Typ U ist mit einem 2-poli-
gen AMP-Kontakt versehen.
Warnung Wird die Filtereinheit vor Wartung des Ele- Austausch des Filterelements
ments nicht drucklos gemacht, drohen Verletzungen und
Schäden an Material oder Umwelt. 1. Anlage und ggf. Rückschlagventil abschalten.
2. Das System druckentlasten.
Während des Elementwechsels müssen alle Außenlächen des 3. Entlüftungsschraube am Filtergehäuse mit circa zwei Umdre-
Filters gereinigt werden, um Staubablagerungen zu entfernen. hungen öffnen.
Der Wechsel muss mit geeignetem Werkzeug durchgeführt 4. Den Deckel gegen den Uhrzeigersinn abdrehen (bei Drauf-
werden. sicht).
Bei äusserer Leckage sind an den entsprechenden Stellen die 5. Das Filterelement entfernen. Das Filterelement und den O-
O-Ringe zu ersetzen. Wird die Leckage dadurch nicht behoben, Ring entsorgen. Das Filterelement kann nicht gereinigt und
Dichtlächen auf Kratzer und Risse untersuchen. Defekte Teile wiederverwendet werden. Versuche, das Filterelement zu
ersetzen. reinigen, können die Funktion des Filtermedium verschlech-
Durch Schmutz im System kann sich ein neues Filterelement tern und dazu führen, dass verunreinigtes Öl durch das
schnell zusetzen. Um die Standzeit der Elemente zu stabilisie- Filterelement strömt. Gebrauchte Filterelemente müssen unter
ren, müssen die ersten und/oder zweiten Elemente in kürzeren Einhaltung der Richtlinien für die Entsorgung von Industrieab-
Abständen ausgetauscht werden. fällen des jeweiligen Landes entsorgt werden.
Falls die Standzeit der Elemente zu kurz oder der Differenz-druck 6. Neues Filterelement einbauen. Sicherstellen, dass es mit
zu hoch ist, müssen evtl. größere Filter installiert werden. einem O-Ring im Unterteil versehen ist.
Wenden Sie sich dazu an Parker. 7. Neuen O-Ring im Deckel des Filters einsetzen und Deckel
festschrauben.
Differenzdruckanzeigen 8. Den Pumpenmotor bei circa zwei Umdrehungen geöffneter
Differenzdruckanzeigen messen den Druckunterschied zwischen Entlüftungsschraube starten.
Ein- und Ausgang des Filterelements. Sie operieren unabhängig 9. Wenn nur Öl austritt, die Entlüftungsschraube schließen.
vom Bypass-Ventil und sollen vor Öffnen des Ventils ansprechen. Während des Starts kann aufgrund hoher Viskosität u. U. die
Das heißt, dass vor dem Öffnen des Bypass-Ventils und Durch- Differenzdruckanzeige an. Die Anzeige zurücksetzen. Das
lass ungeilterten Öls Zeit bleibt, das Filterelement zu wechseln. System nicht ohne eingesetztes Filterelement betreiben.
Dies maximiert auch die Standzeit des Filterelements. Nach dem Elementwechsel sicherstellen, dass die Differen-
Wenn die Filterelemente nicht rechtzeitig ausgewechselt werden, zdruckanzeige zurückgesetzt wird (roten Knopf drücken). Die
schaltet der Filter auf Bypassbetrieb um als der Druckabfall über elektrische Anzeige wird automatisch zurückgesetzt.
das Filterelement 3,5 bar erreicht. Das System fungiert dann nur Nach Erreichen der normalen Betriebstemperatur prüfen, ob
noch als Kühlsystem ohne Ölreinigung. die elektrische Anzeige erloschen ist und/oder der optische
Anzeige des Typs D Anzeigenknopf eingedrückt bleibt. Falls die optische Anzeige
aufgrund von Kaltstartbedingungen angesprochen hat, diese wie
Falls eine optische Anzeige D eingebaut ist und während des in Abschnitt Differenzdruckanzeige beschrieben zurücksetzen.
Kaltstarts anspricht (roter Knopf springt 5 mm heraus), drücken Parker garantiert nicht die Standzeit der Filterelemente, da sich
Sie den Knopf nach Erreichen der normalen Betriebstemperatur diese dem Einluss von Parker entzieht und von den Betriebs-
wieder ein. Spricht die Anzeige nach der Rückstellung wieder an, dingungen des Systems abhängt, in dem die Elemente installiert
wechseln Sie das Filterelement. sind.
Anzeige des Typs P Hinweis! Die FX3 Filtereinheit ist zur Erleichterung des Element-
wechsels mit einer Elementwechselvorrichtung ausgerüstet.
Die optische Anzeige des Typs P besitzt eine Kaltstartunter- Beim Entfernen des Deckels greifen die Haken am Elementdeck-
drückung sowie eine manuelle Rückstellung. Kein Signal unter el in die Haken im Deckel ein und das Element wird automatisch
0 °C, Signal über 29 °C. vom Nippel abgezogen.
Wichtig Niemals das Element reinigen oder wiederverwenden.
Die Filterelemente müssen bei Ansprechen der Anzeige bzw. in
regelmäßigen Intervallen, jedoch spätestens nach sechs Mona-
ten ausgewechselt werden.

Hydraulics Group
Technische Daten Air Oil Coolers, LOC
Technische Daten
Kühlsystem
Maximaler Betriebsdruck 10 bar
Kühlleistungstoleranz ±6%
Maximal zulässige Öltemperatur 100 °C
Zulässige Öltypen
Mineralöl
Synthetiköle
Planzenöle
Hinsichtlich eines Betriebs mit anderen Ölen oder unter erschwerten
Bedingungen wenden Sie sich an Parker.
Material
Pumpengehäuse/Kühlelement Aluminium
Filtereinheit (optional) Aluminium
Lüftergehäuse Stahl
Lüfterrad/Nabe Glasfaserverstärktes Polypropylen/Aluminium
Schutzgitter Stahl
Oberläche Im Magnetpulververfahren aufgebrachte Pulver-Schicht
E-Motor
3-phasig, asynchron gemäß IEC 60034-1
Empfohlene Umgebungstemperatur -20 °C - +40 °C
Isolationsklasse F
Temperaturklasse B
Schutzklasse IP 55
Hinsichtlich der Nennspannung siehe gesondertes Handbuch zum E-
Motor.

Hydraulics Group
Konformitätserklärung Air Oil Coolers, LOC
EC Dec

den AB
Acccumulator and
a Cooler Division
Strrömsätraväg
gen 16
SE
Sw
weden
Phone: +46 8 636 07 00
Ma er.com
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ww.parker.co
om
Productt: A oil coolerr with AC motor and cirrculation pump

Parker LOC Air

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PARKER Accumulator
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Hydraulics Group
Introduction/Consignes de sécurité Air Oil Coolers, LOC
Introduction Consignes générales

La présente notice d’utilisation concerne le système de Levage
refroidissement LOC. Elle est indispensable à l’installation, à Avertissement Risque de pincement/d’écrasement. Pour
l’utilisation et à l’entretien du système LOC. éviter les blessures corporelles lors des levages, l’utilisation
Conservez toujours cette notice à portée de main. Remplacez d’une méthode de levage correcte est impérative. Vériiez
immédiatement une notice perdue. que les dispositifs de levage utilisés sont en bon état et
Lire attentivement la notice et les textes d’avertissement avant homologués pour le poids du système de refroidissement.
d’utiliser le système de refroidissement. Cela vous permettra de
tirer un meilleur proit de votre appareil et d’en éviter une utilisation Installation
incorrecte. Danger Risque d’électrocution. La connexion électrique
Seul, un personnel qualiié est autorisé à installer, à manipuler et doit être exclusivement effectuée par un électricien agréé.
à entretenir le système. Parker se réserve le droit d’effectuer des
modiications techniques sans préavis. Fonctionnement, manipulation et entretien
Avertissement Risque de blessures corporelles.
Utilisation prévue
Déconnectez la source d’entraînement du moteur avant
Le système de refroidissement LOC est destiné au
toute intervention d’entretien.
refroidissement d’huiles hydraulique et, en option, au iltrage
des huiles hydrauliques dans les systèmes à applications Avertissement Risque de blessures corporelles.
industrielles. Assurez-vous que le système est purgé de toute pression
avant la déconnexion des raccords hydrauliques.
Garantie et réclamations
Dans le cas d’une éventuelle avarie, contactez Parker. La Avertissement Risque de brûlures graves. Pendant
responsabilité de Parker concernant le produit cesse dès lors que le fonctionnement, le système LOC peut devenir très
des réparations et/ou des modiications ont été effectuées sur chaud. Ne pas toucher avant qu’il n’ait refroidi.
celui-ci par l’utilisateur lui-même.
Prudence Risque de pincement. Le système LOC peut
être commandé via un thermocontact. Dans ce cas, le
ventilateur démarre automatiquement dès que la tempé-
Consignes de sécurité rature préréglée est atteinte. Soyez prudent lorsque vous
Les installateurs et les utilisateurs doivent connaître, comprendre séjournez près des composants en rotation.
et respecter les avertissements concernant la sécurité indiqués Prudence Risque d’intoxication. Traitez l’huile usée se-
dans cette notice d’utilisation et les informations mentionnées lon la législation sur les déchets industriels en vigueur
sur les autocollants apposés sur le produit. dans chaque pays ain de prévenir tout risque de dom
Niveaux d’avertissement et des textes de mise en garde mages aux personnes, aux biens ou à l’environnement.
...relatifs à la sécurité personnelle Important Électricité statique. Les ventilateurs génèrent de
Les textes de mise en garde relatifs à la sécurité personnelle l’électricité statique. Évitez de placer des équipements sensibles
sont, en fonction de la gravité des suites possibles d’un acci- (appareils électroniques etc.) à proximité immédiate du système.
dent, classés selon les catégories présentées ci-dessous. Des ventilateurs antistatiques sont disponibles sur demande.
Danger indique qu’un accident va se produire en cas de Remarque Pour tout séjour prolongé à proximité d’un système
nonrespect de la consigne. Cet accident entraînera de de refroidissement en fonctionnement, portez toujours un casque
graves blessures corporelles voire même mortelles. antibruit.
Avertissement indique qu’un accident peut se produire Autocollant d’avertissement
en cas de nonrespect de la consigne. Cet accident peut L’autocollant d’avertissement ci-dessous cidessous est apposé
entraîner de graves blessures corporelles voir même sur le système de refroidissement à la livraison.
mortelles.
Avertissement Surfaces très chaudes. Portez un casque antibruit.
Prudence indique qu’un accident peut se produire en cas Hélice en rotation
de nonrespect de la consigne. Cet accident peut entraîner (n° de réf. 500029 - 70 x 30 mm ou
des blessures corporelles. n° de réf. 5000291 - 120 x 50 mm). Voir la Figure 1.
...relatifs aux autres aspects de la sécurité
Les textes de mise en garde relatifs aux autres aspects de la
sécurité (biens, procédé ou environnement) et à l’entretien du
système de refroidissement, sont classés comme suit:
Important indique qu’un accident peut se produire en cas de
nonrespect des consignes. Cet accident peut entraîner des dom-
mages au produit,, au procédé ou à l’environnement .
...relatifs aux informations complémentaires
Les informations complémentaires sont indiquées comme suit :
Remarque! Indique une information complémentaire
susceptible de faciliter la compréhension ou l’exécution d’une
certaine opération.

Hydraulics Group
Description/Installation Air Oil Coolers, LOC
Description Raccordement du système de refroidissement
Le système de refroidissement LOC se compose d’un échangeur Utilisez des lexibles hydrauliques pour raccorder le système LOC
air/huile, d’un moteur triphasé et d’une pompe basse pression au système hydraulique. Assurez-vous que tous les raccords
de la série QPM. Le système de refroidissement peut également et lexibles sont dimensionnés suivant la pression, le débit, la
être équipé d’un iltre pour nettoyage de l’huile. température et le type d’huile du système.
Le système de refroidissement LOC offre une capacité de refroi- Raccordez les lexibles hydrauliques selon la Figure 4.
dissement de 2,7 à 44,8 kW ainsi qu’une plage de débit d’huile A – Entrée.
standard de 20 à 80 l/min. B – Sortie pour modèle Bypass type S, 1 passe.
C – Sortie pour Bypass type T, 2 passes
Plaque signalétique du système de refroidissement
D – Connexion pour le thermocontact
La plaque signalétique du système de refroidissement est placée
Les dimensions des connexions dépendent de la taille du système
sur le caisson ventilateur. Voir la Figure 2.
LOC.
La plaque signalétique contient les informations suivantes: La température maximale autorisée de l’huile eset de 100 °C.
A – Le numéro de référence du produit Schéma de principe, voir la Figure 5.
B – La désignation du produit Pour une capacité optimale de le pompe, placez le système LOC
C – Le numéro de série du produit endessous du niveau de l’huile du réservoir (maxi 5 m) et le plus
D – La date de livraison (année et semaine, par exemple près possible du réservoir. En cas d’une installation au-dessus du
1018, c’est-à-dire l’année 2010 et la semaine 18) niveau de l’huile du réservoir, minimisez la différence de hauteur.
Le diamètre du lexible d’entrée ne doit pas être inférieur à celui
Remplacez immédiatement une plaque endommagée ou du raccordement à la pompe. Un diamètre supérieur est recom-
manquante. mandé. Évitez un débit supérieur à 1 m/s dans le lexible d’entrée
Plaque signalétique du filtre de la pompe. La pression maximale du côté aspiration de la pompe
est de 0,5 bar.
La plaque signalétique du iltre contient les informations
suivantes: Connexion électrique
• Le numéro de référence de l’élément iltrant Danger Risque d’électrocution. Toute connexion électrique
• La désignation de l’élément iltrant (04” HP). doit être effectuée par un électricien agréé.
Avant la connexion du moteur au réseau électrique, contrôlez que
Installation les données sur la plaque signalétique du moteur correspondent à
Levage la tension et à la fréquence du réseau.
L’installation du moteur doit être effectuée conformément à la
Avertissement Risque de pincement/d’écrasement. Pour réglementation et aux prescriptions de sécurité électriques en
éviter les blessures corporelles lors des levages, l’utilisation vigueur et exclusivement par un électricien agréé.
d’une méthode de levage correcte est impérative. Vériiez
que les dispositifs de levage utilisés sont en bon état Avertissement Effectuez la connexion avec un maximum
et homologués pour le poids du système LOC. Tous les de soins. Une connexion incorrecte, des câbles défectueux
systèmes LOC à partir de la taille 033 sont preparés pour etc. peuvent résulter en des éléments conducteurs de
être équipés d’anneaux de levage. Les anneaux de levage courant et un sens de rotation incorrect du moteur, du
sont disponibles sur demande auprès de Parker. ventilateur et de la pompe. Voir la Figure 6.
Montage Important Ne surchargez pas le moteur électrique (courant trop
élevé). Consultez la plaque signalétique sur le moteur.
Prudence Risque de blessures corporelles. Assurez-vous
que tous les éléments du système de refroidissement sont Remarque Nous recommandons une protection contre les sur-
correctement ixés. charges pour le moteur.
Nous vous recommandons d’installer le système debout sur ses Dans un environnement extrêmement humide, surtout en
pieds. Pour éviter toute blessure corporelle, assurez-vous que le sys- fonctionnement intermittent, de la condensation peut se former.
tème de refroidissement est bien ixé. Certains moteurs sont munis de trous obturés lesquels peuvent
Laissez un espace libre correspondant à au moins la moitié de la être utilisés pour purger cette condensation. En fonction de
hauteur du radiateur devant et derrière le système LOC pour assurer l’emplacement du moteur électrique, retirez les bouchons
une capacité de refroidissement optimale grâce à une bonne circu- appropriés.
lation d’air et pour réduire la pression acoustique. Voir la Figure 3. La température du système LOC peut être commandé via un
Si le ème est équipé d’un iltre, laisser une espace correspondant thermocontact. Le ventilateur démarre automatiquement dès
au moins à la taille de l’élément iltrant audessus du iltre ain de per- que la température préréglée est atteinte. Utilisez un relais si le
mettre le remplacement de l’élément iltrant. Voir la Figure 3. thermocontact est soumis à une charge supérieure à sa charge
La pression acoustique peut atteindre 57-86 dB(A) LpA à une dis- maximale.
tance de 1 m dans des conditions de fonctionnement normales.
Important N’utilisez jamais le thermocontact pour un contrôle
L’installation d’un système de refroidissement dans un endroit inap-
direct du moteur électrique.
proprié ou un fonctionnement dans des conditions de fonctionne-
ment extrêmes risque d’entraîner une pression acoustique élevée et
même réduire la capacité de refroidissement. Contactez Parker.
Pour éviter que le réservoir ne se vide pendant le remplacement
de l’élément iltrant, le niveau d’huile du système LOC doit être
au-dessus du niveau du luide du réservoir. Si cela n’est pas
possible, installez un clapet de commande ou un clapet d’arrêt
côté entrée et sortie du système.

Hydraulics Group
Consignes d’emploi/Entretien préventi Air Oil Coolers, LOC
Consignes d’emploi Avertissement Le système LOC ne doit pas être utilisé

dans des conditions qui pourraient engendrer des niveaux
Avant la mise en service initiale de pressions supérieurs aux pressions admissibles dans
Prudence Contrôler que le système LOC est bien ixé et la pompe. Ceci peut se produire si le circuit sur le côté sor-
correctement connecté. tie de la pompe est fermé ou étranglé. (Consultez la bro-
chure de la pompe série QPM.) Ceci pourrait causer des
Avant la mise en service initiale, nous recommandons: dommages sur la pompe et des blessures corporelles.
1. d’effectuer un cycle de fonctionnement du système LOC La pompe n’est pas équipée en série d’un limiteur de
en utilisant la même huile que celle utilisée dans le système pression. Utilisez un limiteur de pression si le système est
hydraulique. équipé de clapets d’arrêt et/ou si la pompe est démar-
2. de iltrer l’huile avant son passage dans le système. rée à froid. Une pompe équipée d’une soupape by-pass
Pour la compatibilité des huiles, reportez-vous au purgée interne ou externe est proposée en option.
Caractéristiques techniques.
Remarque De l’air dans le lexible d’entrée peut causer des
problèmes au démarrage. Dans ce cas, remplissez le lexible Entretien préventif
d’entrée avec de l’huile. Les opérations d’entretien préventif doivent être effectuées à
Remarque Dans le cas où le système est equipé d’un iltre FX3, intervalles réguliers.
effectuez les procédures Filtre à huile. FX3. Vériiez que :
Avant le démarrage • il n’y a pas de bruits anrmaux ni de vibrations dans le système
LOC,
Prudence Assurez-vous que le système peut être mis en • le système est correctement ixé,
service sans risquer de causer de blessures aux personnesni • le système est propre – des débris réduiront sa capacité de
de dommages aux biens ou à l’environnement. refroidissement,
Contrôler que : • le système est intact: remplacez tout composant défectueux,
• les composannts du système sont en bon état, • il n’y a pas de fuites dans le système,
• le ventilateur tourne librement (procédez à la main), • les autocollants d’avertissement sont en bon état : remplacez
• les raccords hydrauliques sont bien serrés, immédiatement tout autocollant endommagé/manquant.
• l’intérieur du caisson de ventilateur est exempt d’objets pouvant Tous les ans : Vériiez l’installation électrique. Ce contrôle ne doit
être projetés et entraîner des blessures corporelles ou dommages être effectué que par un électricien qualiié.
matériels, Dans des conditions normales de fonctionnement, la pompe
• les vannes ou les mécanismes de régulation similaires sont n’exige aucune entretien. Dans des conditions extrêmes de
ouverts et que les conduits et raccords sont en bon état. fonctionnement, la pompe doit être contrôlée et entretenue. Dans
Lors du démarrage certains cas, la pompe et/ou ses raccords doivent être remplacés.
Consultez le manuel séparé concernant la pompe.
Contrôler que :
• le sens de rotation et le débit du ventilateur correspondent aux Nettoyage
indications de l’autocollant sur le caisson ventilateur, Avertissement Risque de blessures corporelles. Avant de
• il n’y a pas de bruits anormaux ni de vibrations dans le système, commencer le nettoyage, déconnectez toutes les sources
• il n’y a pas de fuites dans le système.s. d’entraînement du moteur.
Veillez à ce que le moteur électrique ne soit pas surchargé Avertissement Risque de brûlures graves. Pendant le
en raison d’un démarrage à froid ou par une huile avec une fonctionnement, le système LOC peut devenir très chaud.
viscosité élevée. Ne pas toucher avant qu’il n’ait refroidi.
La plage de viscosité s’étend de 10 à 800 cSt, considérant
la pompe, la puissance du moteur, la dimension de l’élément Système de refroidissement Pour le nettoyage de l’extérieur
iltrant. du système LOC, avec de l’eau par exemple, déconnectez toutes
Consultez Parker lorsque vous utilisez des huiles avec une les sources d’entraînement. Observez la norme de protection du
viscosité élevée (des huiles lubriiantes épaisses par exemple) moteur électrique.
ou en cas de démarrages à froid. Radiateur Le nettoyage des ailettes s’effectue le plus simplement
Pour une fonctionnement optimal, le degré de pureté de l’huile, à l’air comprimé. Au besoin, utilisez un équipement haute pression
selon la norme ISO 4406, ne devrait pas être inférieur à 17/15. et un agent dégraissant. Lors d’un lavage haute pression, dirigez
Remarque De l’air dans le lexible d’entrée peut causer des le jet parallèlement aux lamelles. Voir la Figure 7.
problèmes au démarrage. Dans ce cas, remplissez le lexible Caisson de ventilateur Pour le nettoyage de l’intérieur du
avec de l’huile. caisson ventilateur, démontez le radiateur. Utilisez de l’air
Pendant le fonctionnement comprimé. Au besoin, utilisez un agent dégraissant. Dirigez le
Avertissement Risque de brûlures graves. Pendant le jet d’air comprimé à travers la grille et par le côté du moteur
fonctionnement, le système LOC peut devenir très chaud. électrique.
Ne pas toucher avant qu’il n’ait refroidi.
Remarque Pour tout séjour prolongé à proximité d’un système
de refroidissement en fonctionnement, portez un casque antibruit.

Hydraulics Group
Entretien Air Oil Coolers, LOC
Pompe Parker ne peut être tenu responsable des Montage de la pompe et du raccord
dysfonctionnements engendrés à la suite d’un nettoyage
de l’intérieur de la pompe. Si vous avez utilisé une huile 1. Posez la partie de raccord de l’arbre du moteur .
contaminée, nettoyez la pompe en la faisant fonctionner avec Serrez la vis d’arrêt.
une huile propre. 2. Posez la pompe et la couronne du raccord.
3. Posez les vis et les joints à lèvres qui ixent la pompe au
Filtre (option) moteur électrique.
4. Connectez les lexibles hydrauliques. Voir la Figure 4.
Les éléments iltrants ne peuvent pas être nettoyés. 5. Connectez la source d’entraînement du moteur.
6. Effectuez les procédures Avant le démarrage et Au
Entretien démarrage.
Démontage du moteur électrique et du ventilateur
Démontage La responsabilité de Parker concernant le produit
cesse dès lors que des réparations et/ou des modiications ont Avertissement Risque de brûlures graves. Pendant le
été effectuées sur celui-ci par l’utilisateur lui-même. fonctionnement, le système peut devenir très chaud. Ne
pas toucher avant qu’il n’ait refroidi.
Avertissement Risque de brûlures graves. Pendant
le fonctionnement, le système LOC peut devenir très Avertissement Risque de blessures corporelles.
chaud. Ne pas toucher avant qu’il n’ait refroidi. Déconnectez la source d’entraînement du moteur avant
Avertissement Risque de blessures corporelles.
Déconnectez la source d’entraînement du moteur avant À la livraison, le ventilateur est équilibré avec le moyeu.
Remarque Certains modèles sont équipés d’un moyeu ixe
Important Les éléments iltrants usagés doivent être traités Figure 10 et d’autres ont un moyeu non ixe Figure 11 A et
selon la législation sur les déchets industriels en vigueur dans Figure 11 B.
chaque pays.
1. Arrêtez le système.
Démontage du radiateur 2. Démontez la pompe selon la procédure Démontage de la
pompe et du racc
1. Arrêtez le système. 3. Fixez le moteur.
2. Déconnectez la source d’entraînement du moteur. 4. Dévissez les vis avec rondelles qui ixent le support du
3. Assurez-vous que le système est purgé de toute pression. moteur au caisson ventilateur. Voir la Figure 9.
4. Déconnectez les entrées et les sorties d’huile. 5. Dévissez les vis avec les rondelles qui ixent la chaise du
5. Déconnectez les lexibles hydrauliques du radiateur. moteur aux pieds. Tirez le moteur en arrière.
6. Dévissez les vis avec rondelles qui ixent le radiateur au 6. Dévissez la vis avec la rondelle qui ixe l’hélice/moyeu à
caisson ventilateur. Voir la Figure 8. l’arbre du moteur. Voir la Figure 10.
7. Déposez le radiateur. Déposez avec soin l’hélice/moyeu de l’arbre du moteur.
Montage du radiateur Utilisez une extracteur si besoin.
7. Dévissez les vis avec les rondelles qui ixent le moteur à son
1. Mettez le radiateur en place. support. Voir la Figure 12.
2. Fixez le radiateur au caisson ventilateur avec les vis. 8. Dévissez les vis avec rondelles qui ixent le moteur à la
Voir la Figure 8. chaise.
3. Connectez les lexibles hydrauliques au radiateur. 9. Déposez le moteur.
Voir la Figure 4.
4. Connectez la source d’entraînement du moteur. Si le ventilateur doit être démonté, marquez toutes les pièces
5. Effectuez les procédures Avant le démarrage et Au pour assurer un remontage correct, surtout du point de vue de
démarrage. l’équilibre et du sens de rotation. Voir la Figure 13.
Démontage de la pompe et du raccord Montage du moteur électrique et du ventilateur
1. Arrêtez le système. Remarque Certains modèles sont équipés d’un moyeu ixe
2. Déconnectez la source d’entraînement. Figure 10 et d’autres ont un moyeu non ixe Figure 11 A et
3. Assurez-vous que le système est purgé de toute pression. Figure 11 B.
4. Déconnectez les entrées et les sorties d’huile. 1. Fixez le moteur à sa chaise à l’aide des vis.
5. Déconnectez les lexibles hydrauliques. 2. Fixez le moteur à sa chaise avec les vis. Voir la Figure 12.
6. Retirez les vis et les joints à lèvres qui ixent la pompe au 3. Adaptez la rainure dans le moyeu par rapport à la clavette
moteur électrique. longitudinale sur moteur. Lubriiez l’intérieur du moyeu avec
7. Déposez la pompe et la couronne du raccord. de l’alcool éthylique et ixez l’hélice avec le moyeu sur l’arbre
La pompe et les parties du raccord peuvent maintenant être du moteur en poussant. Si nécessaire, frappez légèrement
remplacées. avec un maillet en caoutchouc par exemple. Appliquez du
8. Desserrez la vis d’arrêt de la partie de raccord de l’arbre. produit Loctite sur la vis et ixez l’hélice avec le moyeu à
Retirez la partie de raccord de l’arbre du moteur. l’arbre du moteur. Voir la Figure 10.
4. Assurez-vous que le ventilateur est bien ixé à l’arbre du
moteur et qu’il ne presente pas de jeu.
5. Installez le support du moteur avec le ventilateur, la grille, le
moteur et sa chaise dans le caisson ventilateur.

Hydraulics Group
6. Ajustez la grille et le moteur puis ixez le support du moteur Indicateurs de colmatage

au caisson ventilateur avec des vis. Voir la Figure 9. Fixez la
chaise du moteur avec des vis. Un indicateur de colmatage permet de veriier l’êtat d’un
7. Contrôlez que le ventilateur est bien centré/aligné et élement iltrant en controllant la pression différentielle entre
tourne librement (procédez à la main). Ajustez si besoin le l’éntrée et la sortie du iltre. L’indicateur de colmatage
positionnement de la grille et du moteur. fonctionne indépendamment de la soupape by-pass et il
8. Assurez-vous que toutes les vis sont bien serrées. réagit avant l’ouverture de la soupape. Cela signiie qu’il y a
9. Connectez la source d’entraînement du moteur. du temps pour le remplacement de l’élément iltrant avant
10.Effectuez les procédures Avant le démarrage et Au que la soupape by-pass ne s’ouvre et ne laisse couler l’huile
démarrage. noniltrée. Cela permet d’optimiser le temps d’utilisation de
l’élément iltrant.
Filtre à huile FX3 Dans le cas où l’indication est ignorée et la contamination
persiste, la soupape by-pass s’ouvrira dès que la pression à
Grâce au iltre de type FX3, l’huile est épurée dans un système travers l’élément iltrant descend à 3,5 bars. Le système
séparé. C’est un complément parfait au circuit de nettoyage de fonctionnera comme un système de refroidissement sans
l’huile du système. Le iltre FX3 est disponible en option. nettoyage de l’huile.
Avant le démarrage Indicateur type D
1. Purgez le iltre en dévissant deux tours le bouchon d’évent Si un indicateur optique type D est installé et se déclenche
situé sur la partie supérieure du iltre. lors d’un démarrage à froid (le témoin rouge sort de 5 mm),
2. Remplissz le iltre jusqu’à ce que la totalité de l’air ait été réarmez-le en appuyant dessus lorsque la température normale
purgée, puis revissez l’évent. de service est atteinte. Si l’indicateur se déclenche à nouveau,
3. Faites monter le système sous pression et vériiez qu’il n’y remplacez l’élément iltrant.
a pas de fuites. En cas de fuites, reportez-vous à Entretien
régulier. Indicateur type P
Prudence Une mauvaise purge du iltre augmentera la L’indicateur optique type P possède un verrouillage thermique,
quantité d’air dissous dans l’huile du système, ce qui c’est-à-dire pas de signal en dessous de 0 °C et apparition
réduira la durée de vie de l’huile et pourra engendrer d’un signal au-dessus de +29 °C. Cet indicateur possède un
d’autres problèmes dans le système. réarmement manuel.
Entretien régulier Indicateur type M
Le iltre FX3 n’exige normalement pas d’attention particulière L’indicateur électrique type M possède un réarmement
si ce n’est le contrôle régulier de l’indicateur de colmatage. automatique et une connexion Hirschmann selon la norme
Programmez le remplacement de l’élément iltrant au moins DIN 43650, ISO4400. L’indicateur est protégé contre l’humidité
tous les six mois et veillez à disposer d’un stock d’éléments de suivant la norme IP65. Pour contrôler eficacement la durée de
rechange sufisant. vie de l’élément iltrant, il est recommandé d’utiliser à la fois
une indication positive (témoin vert) et une indication négative
Avertissement Le fait de ne pas dépressuriser le (témoin rouge pour élément sale).
iltre avant l’entretien de l’élément peut entraîner Si l’indicateur électrique type M se déclenche (le témoin rouge
des dommages aux personnes, aux biens ou à s’allume, par exemple) lors d’un démarrage à froid, poursuivez
l’environnement. jusqu’à ce que le signal (témoin rouge) s’éteigne lorsque le
Lors de l’entretien, nettoyez les surfaces externes du iltre ain système atteint la température normale de service. Cette
d’éliminer les dépôts de poussière. Toute maintenance doit être fonction peut être utilisée comme une indication de “montée
effectuée à l’aide d’outils appropriés. en température”. Si le signal reste allumé (témoin rouge) ou
En cas de fuite externe, remplacez le joint torique à apparaît lorsque le système a atteint sa température de service,
l’emplacement de la fuite. Si la fuite persiste, contrôlez que remplacez l’élément iltrant.
les surfaces d’étanchéité ne comportent pas de rayures ni de Indicateur type U
issures et remplacez toute pièce défectueuse.
Un système sale peut entraîner un colmatage rapide de L’indicateur électrique type U est doté d’un contact type AMP
l’élément iltrant neuf. Un ou plusieurs éléments iltrants à deux pôles.
peuvent être nécessaires avant d’obtenir une durée de vie
stabilisée. Si la durée de vie de l’élément iltrant est trop courte
ou si la pression différentielle est excessive, il est possible que
le iltre soit trop petit. Contactez Parker.

Hydraulics Group
Remplacement de l’élément filtrant

1. Arrêtez le système et éventuellement le clapet d’arrêt.
2. Assurez-vous que le système est purgé de toute pression.
3. Dévissez de deux tours le bouchon d’évent qui se trouve sur
la partie supérieure du iltre.
4. Dévissez le couvercle dans le sens inverse des aiguilles
d’une montre (vue du dessus) et retirez-le.
5. Retirez l’élément iltrant. Jetez l’élément iltrant et son joint
torique. L’élément iltrant ne peut pas être nettoyé. Toute
tentaative de nettoyage de l’élément iltrant peut entraîner
une dégradation de l’agent iltrant et permettre à l’huile
polluée de traverser l’élément iltrant. Les éléments iltrants
usagés doivent être traités selon la législation sur les déchets
industriels en vigueur dans chaque pays.
6. Installez un élément iltrant neuf. Assurez-vous que le fond
du iltre est doté d’un joint torique.
7. Installez un joint torique neuf dans le iltre et revissez le
couvercle en place.
8. Démarrez le moteur de la pompe avec le bouchon d’évent
ouvert de deux tours.
9. Serrez le bouchon de vidange lorsque l’huile sort du iltre.
Au démarrage, il est possible que l’indicateur se déclenche
à cause d’une viscosité trop élevée. Réenclenchez-le. Ne
faites pas fonctionner le système sans qu’un élément iltrant
ne soit installé.
Suite au remplacement de l’élément, vériiez que l’indicateur
de colmatage est armé en appuyant sur le témoin rouge. Les
indicateurs électriques se réarment automatiquement.
Lorsque le système atteint la température normale de service,
vériiez que l’indicateur électrique n’est pas déclenché et/
ou que le témoin de l’indicateur optique n’est pas sorti.
Si l’indicateur optique se déclenche de nouveau lors d’un
démarrage à froid, réarmez-le comme indiqué dans le chapitre
Indicateur de colmatage.
Parker ne garantit pas la durée de vie de l’élément iltrant car
cela échappe à son contrôle et dépend de l’état du système
dans lequel le iltre est installé.
Remarque Le iltre FX3 est équipé du mécanisme d’extraction
de l’élément ain d’en faciliter la dépose. Lors du retrait du
couvercle, les pattes de la coupelle supérieure de l’élément
s’emboîtent dans les crochets du couvercle et l’élément est
automatiquement extrait du manchon.
Important N’essayez pas de nettoyer ni de réutiliser l’élément
iltrant. Les éléments iltrants doivent être remplacés sur
indication ou à des intervalles déinis de six mois maximum.

Hydraulics Group
Caractéristiques techniques Air Oil Coolers, LOC
Caractéristiques techniques
Système de refroidissement
Pression de service maxi 10 bar
Tolérance de transfert de chaleur ±6%
Température maximale de l’huile 100 °C
Compatibilité
Huile minérale
Huiles synthétiques
Huiles végétales
Consultez Parker en cas d’utilisation d’autres huiles ou d’une utilisation
dans des conditions extrêmes.
Matériaux
Corps de pompe/radiateur Aluminium
Filtre (option) Aluminium
Caisson de ventilateur Acier
Hélice/moyeu Polypropylène renforcé ibre de verre/aluminium
Grille du ventilateur Acier
Revêtement Décapage électronique et revêtement de poudre
Moteur électrique
Moteur triphasé asynchrone selon IEC 60034-1
Température ambiante recommandée -20 °C - +40 °C
Isolement F
Élévation de température B
Norme de protection IP 55
Pour de plus amples informations sur le courant nominal,
consultez la brochure du moteur.

Hydraulics Group
Déclaration de conformité Air Oil Coolers, LOC
EC Dec

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Acccumulator and
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Hydraulics Group
Introducción/Instrucciónes de seguridad Air Oil Coolers, LOC
Introducción Consignas generales

El presente manual de uso concierne a los sistemas de Elevación/Transporte
refrigeración serie LOC. Es indispensable para la instalación, uso Advertencia Riesgo de caída. Para evitar daños corporales
y mantenimiento de los mismos. en la elevación, es básico utilizar un método de elevación
Conserve siempre este manual a mano y no dude en pedir uno a correcto. Controlar que el dispositivo de elevación y las
su distribuidor en caso de pérdida. herramientas de uso estén en buen estado y homologados
Lea detenidamente este manual y los textos de advertencia del para la elevación del peso del sistema LOC.
mismo antes de utilizar el sistema LOC. Esto le permitirá sacar
el máximo provecho al sistema y evitará un uso incorrecto del Instalación
mismo. Peligro Riesgo de electrocución. La conexión eléctrica
El sistema LOC será instalado, manipulado y utilizado solamente debe ser efectuada exclusivamente por personal eléctrico
por personal cualiicado para ello. cualiicado!.
Parker se reserva el derecho de realizar modiicaciones técnicas
sin previo aviso. Funcionamiento, manipulación y mantenimiento
Uso previsto Advertencia Riesgo de heridas corporales. Desconectar
El sistema de refrigeración LOC está destinado al enfriamiento de la fuente eléctrica el motor antes de cualquier
de luidos hidráulicos pertenecientes a sistemas de aplicación manipulación.
industrial. Advertencia Riesgo de heridas corporales. Asegurarse
Garantía y reclamaciónes que el sistema esté despresurizado antes de la desco-
En caso de avería, contacte con Parker. La responsabilidad de nexión de los rácords.
Parker concerniente al producto cesa en el momento en que el Advertencia Riesgo de quemaduras graves. Indica
usuario realice por si mismo las reparaciones o modiicaciones en peligro por alta temperatura supericial. Durante el
el sistema LOC. funcionamiento el sistema LOC puede estar muy
caliente. No tocar el sistema hasta que se haya enfriado.
Instrucciónes de seguridad Precaución Riesgo de atrapamiento. El sistema LOC
Los instaladores e usuarios deben conocer, comprender y puede funcionar por la acción de un termocontacto. En
respetar las advertencias e informaciones incluídas en este estos casos el ventilador se pone en funcionamiento
manual de uso e indicadas en las etiquetas ijadas en el equipo. automáticamente en cuanto se ha alcanzado la
temperatura de consigna. Prudencia con los elementos
Definición de niveles de seguridad de rotación.
...relativos a la seguridad del personal Precaución Riesgo de intoxicación. Desechar el acei-
Los textos de advertencia y peligro relativos a la seguridad del te usado en un contenedor adecuado y previsto para
personal, están en función de la gravedad de los posibles acci- tal efecto con el in de prevenir cualquier riesgo para las
dentes. Se clasiican en tres niveles: personas o el medio ambiente.
Peligro Alerta que una acción o procedimiento realizado Importante Electricidad estática. Los ventiladores generan
incorrectamente provocará graves heridas corporales o, electricidad estática. Evitar colocar cerca del sistema de refri-
incluso, la muerte. geración equipos especialmente sensibles (electrónicos, etc.).
Ventiladores antiestáticos están disponibles bajo pedido.
Advertencia alerta que una acción o procedimiento
realizado incorrectamente puede provocar graves heridas Nota! Para un trabajo prolongado cerca de un sistema LOC en
corporales o, incluso, la muerte. funcionamiento, se deben utilizar protectores auditivos.
Precaución alerta que una acción o procedimiento Etiqueta de advertencia
realizado incorrectamente puede provocar un accidente
con heridas corporales. La etiqueta especiicada abajo está colocada sobre el sistema
LOC en la entrega. Remplácela de inmediato en el caso de pér-
...relativos a otros aspectos de seguridad dida y/o rotura.
Las indicaciones de seguridad concernientes a otros aspectos
de seguridad (propiedad, proceso, medio ambiente) y a la mani- Peligro! Alta temperatura en supericie! Usar protectores auditi-
pulación del producto están clasiicadas como sigue: vos. Ventilador en rotación!
(Referencia 500029-70x30 mm o bienerencia 5000291-
Importante alerta que una acción o procedimiento realizado inco- 120x50 mm). Ver fig 1.
rrectamente puede provocar daños en el equipo, al proceso o al
medio ambiente.
...relativos a las infórmaciones complementarias
Las informaciones complementarias están indicadas como sigue.
Nota! Este tipo de alertas indica informaciones complementarias
susceptibles de facilitar la comprensión o ejecución de una
operación.

Hydraulics Group
Descripción/Instalación Air Oil Coolers, LOC
Descripción Conexión del sistema LOC
El sistema de refrigeración LOC se compone principalmente de Utilizar lexibles hidráulicos para las conexiones de entrada
un intercambiador aire/aceite, un motor de corriente alterna y y salida del radiador. Asegurarse de que los rácords y
una bomba de baja presión tipo engrenaje de la serie QPM. los lexibles estén dimensionados y sean adecuados a la
Además, el sistema de refrigeración puede equiparse con un presión, el caudal, la temperatura y el aceite del sistema.
iltro para la limpieza del aceite. El sistema de refrigeración LOC Conectar los lexibles hidráulicos al radiador como sigue.
está disponbile con una capacidad de refrigeración de 2,7 – Ver fig 4.
44,8 kW, y un caudal de aceite nominal de 20 – 80 l/min. A – Entrada
B – Salida modelo estándar o salida modelo by-pass tipo S,
Placa del fabricante Sistema de refrigeración
1 paso
La placa del fabricante del sistema LOC está colocada sobre la C – Salida modelo by-pass tipo T, 2 pasos
caja del ventilador. Ver fig 2. D – Conexión para termocontactoTemperatura máxima perme-
tida del aceite es de 100 °C.
La placa del fabricante contiene la siguiente información:
Las dimensiones de las conexiones dependen del tamaño del
A – Referencia del producto radiador.
B – Descripción del producto La temperatura máxima permitida del radiador es de 100 ºC.
C – Número de serie Diagrama de lujo. Ver fig 5.
D – Fecha de entrega
(año y semana, p.e. 1018, es decir año 2010 semana 18). Para mejorar la capacidad de la bomba, coloque el sistema de
refrigeración bajo el nivel de aceite del depósito (máx. 5 metros)
Remplace de inmediato una placa perdida o rota. y tan cerca del depósito como sea posible. En caso de una ins-
Placa del fabricante Filtro talación por encima del nivel de aceite del depósito, minimizar la
diferencia de altura.
La placa del fabriante del iltro contiene la siguiente información: El diámetro de la tubería de la entrada no debe ser inferior al
• Referencia del elemento iltrante diámetro de la conexion de la bomba. Se recomienda un diá-
• Descripción del elemento iltrante. (04” HP). metro mayor.
Evitar caudales superiores de 1 m/seg. en la tubería de entrada
de la bomba. Presión máxima lado aspiración de la bomba es
Instalación de 0,5 bar.
Elevación/Transporte Conexionado eléctrico
Advertencia Riesgo de caída. Para evitar daños corporales Peligro Riesgo de electrocución. La conexión eléctrica
en la elevación, es básico utilizar un método de elevación debe ser realizada por personal eléctrico cualiicado.
correcto. Controlar que el dispositivo de elevación y las Antes de la conexión del motor a la fuente eléctrica, controlar
herramientas de uso estén en buen estado y homologados que los datos de la placa del motor correspondan a la tensión y
para la elevación del peso del sistema LOC. a la frecuencia de la fuente.
Todos los sistemas de refrigeración apartir del modelo LOC 033 La instalación del motor debe ser efectuada conforme a la
están preparados para llevar cáncamos de elevación. os cánmos de normativa vigente sobre seguridad eléctrica y exclusivamente
elevación están disponibles bajo pedido como accesorios de Parker. por personal cualiicado.
Montaje Precaución Efectuar la conexión con cuidado. Una
conexión incorrecta, cables defectuosos, etc. pueden
Precaución Riesgo de heridas corporales. Asegurarse de acortar la vida útil de los componentes o provocar un
que todas las piezas del sistema de refrigeración estén co- sentido incorrecto de giro del motor eléctrico, del ventila-
rrectamente colocadas. dor y de la bomba. Ver fig 6.
Parker recomienda un montaje vértical sobre las patas del
sistema. Para evitar daños corporales, asegurarse de que el Importante No sobrecargar el motor eléctrico. Ver la placa técnica
sistema esté bien ijado. del motor eléctrico.
Para garantizar un circulación de aire óptima y con esto una Nota! Parker recomienda el uso de una protección de sobrecarga
capacidad de refrigeración máxima y un bajo nivel de presión para motor eléctrico.
acústica, déjar un espacio libre correspondiente a, al menos, la
mitad de la altura del radiador en la parte frontal y posterior del En ambientes muy húmedos, en especial cuando la operación es
sistema LOC. Ver fig 3. intermitente, es posible que se genere una acumulación de agua
En el caso en que el sistema LOC esté equipado con un iltro, de condensación. Ciertos motores vienen equipados con oriicios
el espacio correspondiente a, como mínimo, el tamaño del taponados para poder ser usados como drenajes de agua de
elemento de iltro debe estar disponible sobre el iltro a in de condensación. Dependiendo de la ubicación del motor, deberá
permitir la sustitución del elemento. Ver fig 3. extraer estos tapones.
El nivel de presión acústica puede alcanzar los 57-86 dB(A) El sistema LOC puede estar equipado con un termocontacto
LpA a una distancia de 1 metro en condiciones operativas para el control de la temperatura. El ventilador se pone en marcha
normales. Un emplazamiento inadecuado, o su funcionamiento automáticamente cuando se alcanza la temperatura de consigna.
en condiciones extremas, puede provocar un nivel de presión Utilize un relé si la corriente excede la corriente máxima permitida
acústica elevado y reducir la capacidad de refrigeración. en el termocontacto.
Para evitar el vaciado del depósito al sustituir el elemento, Importante El termocontacto no puede ser utilizado para control
asegúrese de que el nivel de aceite del sistema LOC es superior directo del motor eléctrico.
al nivel del depósito. Si esto no fuera posible, instale una válvula
de control o de cierre en la entrada y la salida del sistema.

Hydraulics Group
Modo de empleo/ Mantenimiento preventivo Air Oil Coolers, LOC
Modo de empleo Advertencia El sistema LOC no puede ser utilizarse en

aquellas condiciones en que podrían originarse presio-
Antes de la puesta en marcha inicial nes superiores a la máxima presión de la bomba. Esto
puede ocurrir si la salida de la bomba está cerrada o
Precaución Controlar que el sistema de refrigeración esté
severamente obstruida. (Ver el catálogo Bombas de baja
correctamente ijado y conectado eléctricamente. Parker
presión serie QPM.) Esto podría causar daños persona-
recomienda efectuar los siguientes pasos preparativos
les y daños a la bomba.
antes de la puesta en marcha inicial:
La versión estándar de la bomba no equipa válvula limitadora
1. Realizar un ciclo de funcionamiento utilizando el mismo luido del
de presión. Instale una válvula limitadora de presión si el sistema
sistema hidráulico.
dispone, por ejemplo, de una válvula de cierre, o si la bomba
2. El luido debe ser iltrado antes de su paso por el sistema LOC.
está funcionando bajo condiciónes de arranque en frío. Opcio-
Para conocer la compatibilidad de los luídos recomendados, ver nalmente está disponible una bomba equipada con una válvula
las Características técnicas. by-pass con drenaje interno o externo.
Nota! El aire presente en la tubería de entrada puede causar
problemas en el arranque inicial. En este caso llenar la ubería
con aceite.
Mantenimiento preventivo
El mantenimiento preventivo es efectivo si se realiza a intervalos
Nota! En el caso de que el sistema LOC esté equipado de un iltro
regulares.
FX3, efectuar los procesos de Conjunto de iltro FX3.
Controlar que:
Antes de la puesta en marcha • no existan ruidos anormales o vibraciones,
Precaución Asegúrese de que el sistema puede ponserse • el sistema LOC esté correctamente ijado,
en marcha sin causar daño a personas, cosas o al medio • el radiador está limpio, las impurezas ó suciedad reducen la
ambient. capacidad de refrigeración,
• el sistema LOC no esté dañado. Remplazar cualquier pieza
Controlar que: dañada.
• todas las piezas del sistema estén en buen estado, • el sistema LOC no tenga fugas,
• el ventilador gira libremente (comprobarlo con la mano), • las etiquetas de alerta y seguridad estén en buen estado,
• las conexiones de entrada y salida de aceite estén herméticas, remplazar de inmediato las etiquetas dañadas o perdidas.
• el interior de la caja del ventilador esté exenta de objetos que
puedan ser proyectados y provocar daños corporales o Anualmente: Controlar la instalación eléctrica. Esta intervención
materiales, debe ser efectuada exclusivamente por personal eléctrico
• las válvulas y dispositivos de regulación similares estén abiertos, y cualiicado.
que las tuberías y acoplamientos no estén dañados. Bajo condiciones operativas normales, la bomba no requiere
En el momento de la puesta en marcha mantenimiento. Bajo condiciones operativas extremas, la
bomba requiere tareas de inspección, servicio o sustitución
Controlar que: de la propia bomba o de los acoplamientos. Ver el catálogo
• el sentido de rotación y el caudal del ventilador correspondan Bombas baja presión serie QPM.
a las indicaciones de la caja del ventilador,
• no existen ruidos anormales o vibraciones, Limpieza
• el sistema LOC no tenga fugas ni escapes. Advertencia Riesgo de heridas corporales. Desconectar
Asegurarse de no sobrecargar el motor eléctrico debido a con- siempre el motor de la fuente de alimentación antes de
diciónes de arranque en frío o su operación con un alto nivel de proceder a la limpieza.
viscosidad del aceite. Advertencia Riesgo de quemaduras graves. Durante el
Rango de viscosidad es de 10 – 800 cSt teniendo en cuenta la funcionamiento el sistema LOC puede estar muy caliente.
bomba, la potencia del motor, el tamaño del elemento iltrante etc. No tocar el sistema hasta que haya podido enfriarse.
Consulte Parker acerca del uso de aceites de alta viscosidad Sistema de refrigeración Para la limpieza externa del sistema LOC,
(p.ej. aceites lubricantes pesados) o sobre cuándo operar en por ejemplo con agua, desmontar todas las conexiones eléctri-
modo de arranque en frío. cas. Observar las normativas de protección del motor eléctrico.
Para lograr el funcionamiento óptimo, se require un código de
limpieza de 17/15, conforme a la norma ISO 4406. Radiador La limpieza de las aletas del radiador se realiza sim-
plemente con aire comprimido. Si es necesario, utilizar un equipo
Nota! El aire presente en la tubería de entrada puede causar de alta presión y un desengrasante. Para el lavado a alta presión,
problemas en el arranque inicial. En este caso llenar la tubería realizarlo en posición paralela a las aletas. Ver fig 7.
con aceite.
Caja del ventilador Para la limpieza del interior de la caja del
Durante el funcionamiento ventilador desmontar el radiador. Utilizar aire comprimido. Si es
Advertencia Riesgo de quemaduras graves. Durante necesario puede usarse un desengrasante. Dirigir el aire com-
el funcionamiento el sistema LOC puede estar muy primido a través de la rejilla del ventilador partiendo del motor
caliente. No tocar el sistema hasta que haya podido eléctrico.
enfriarse.
Nota! Para un trabajo prolongado cerca de un sistema LOC en
funcionamiento, se deben utilizar cascos o tapones anti-ruido.

Hydraulics Group
Mantenimiento Air Oil Coolers, LOC
Bomba Parker no se responsabilizará de un mal funcionamien- Montaje de la bomba y del acoplamiento

to consecuencia de una limpieza interior de la bomba. En el
caso de que la bomba haya trabajado con un aceite sucio lim- 1. Montar la pieza del acoplamiento en el eje del motor eléctrico.
piarla haciendola trabajar con el mismo luido limpio. Instalar el tornillo de cierre.
2. Instalar la bomba y la corona dentada del acoplamiento.
Filtro (opción) El elemento iltrante no puede limpiarse. 3. Fijar los tornillos y las arandelas de acero/goma que ijan la
bomba al motor eléctrico.
4. Conectarlos lexibles hidráulicos. Ver fig 4.
Mantenimiento 5. Conectar la fuente de alimentación del motor eléctrico.
6. Efectuar los procesos de Antes de la puesta en marcha y En el
Desmontaje momento de la puesta en marcha.
Parker no será considerada responsable de posibles consecuen- Desmontaje del motor eléctrico y del ventilador
cias ocurridas tras las reparaciones, modiicaciones o alteraciones
realizadas por el cliente. Advertencia Riesgo de quemaduras graves. Durante el
funcionamiento el sistema LOC puede estar muy caliente.
Advertencia Riesgo de quemaduras graves. Durante el No tocar el sistema hasta que haya podido enfriarse.
funcionamiento el sistema LOC puede estar muy caliente.
No tocar el sistema hasta que haya podido enfriarse. Advertencia Riesgo de heridas corporales. Desconectar
siempre el motor de la fuente de alimentación antes de
Advertencia Riesgo de heridas corporales. Desconectar proceder a la limpieza.
siempre el motor de la fuente de alimentación antes de
proceder a su mantenimiento. A la entrega del equipo el ventilador está alineado con el asiento.
Importante Los elementos del iltro usados deben recogerse Nota! Algunos asientos de los ventiladores son ijos, ver fig 10, y en
conforme a los normativas de residuos industriales vigentes en otros modelos el asiento es desmontable, ver fig 11 A y fig 11 B.
cada país. 1. Parar el sistema.
Desmontaje del radiador 2. Desconectar la fuente de alimentación eléctrica del motor.
3. Asegurar el motor eléctrico.
1. Parar el sistema. 4. Desatornillar los tornillos con arandelas que ijan el soporte de
2. Desconectar la fuente de alimentación eléctrica del motor. motor a la caja del ventilador. Ver fig 9.
3. Asegurarse de que el sistema esté despresurizado. 5. Destornillar los tornillos con arandelas que ijan la consola del
4. Desconectar la entrada y salida de aceite del radiador. motor a las patas del sistema. Tirar del motor hacia atrás.
5. Desconectar los lexibles hidráulicos del radiador. 6. Desatornillar el tornillo con arandela que ija el ventilador con
6. Desatornillar los tornillos con arandelas que ijan el radiador a la asiento al eje del motor. Ver fig 10.
caja del ventilador. Ver fig 8. Retirar prudentemente el ventilador con asiento del eje del
7. Extraer el radiador. motor. Utilizar un extractor si es necesario.
Montaje del radiador 7. Desatornillar los tornillos con arandelas que ijan el motor al
soporte motor. Ver fig 12.
1. Colocar el radiador en su posición. 8. Desatornillar el motor de la consola.
2. Fijar el radiador a la caja del ventilador con los tornillos con 9. Quitar el motor.
arandelas. Ver fig 8.
3. Conectar los lexibles hidráulicos al radiador. Si el ventilador debe ser desmontado, marcar odas las piezas
Ver fig 4. para asegurar un correcto montaje, sobre todo respecto al equili-
4. Conectar el motor a la fuente de alimentación eléctrica. brio y sentido de rotación. Ver fig 13.
5. Efectuar los procesos de Antes de la puesta en marcha y En el Montaje del motor eléctrico y del ventilador
momento de la puesta en marcha.
Nota! Algunos asientos de los ventiladores son ijos, ver fig 10, y en
Desmontaje de la bomba y del acoplamiento otros modelos el asiento es desmontable, ver fig 11 A y fig 11 B
1. Parar el sistema. 1. Fijar el motor a su consola con los tornillos.
2. Desconectar la fuente de alimentación eléctrica del motor. 2. Fijar el motor a la consola con los tornillos. Ver fig 12.
3. Asegurarse de que el sistema esté despresurizado. 3. Adaptar la ranura del asiento a la chaveta longitudinal del motor.
4. Desconectar la entrada y salida de aceite del radiador. Utilizar alcohol etílico para lubricar el interior del asiento y ijar
5. Desconectar los lexibles hidráulicos de aceite del radiador. el asiento del ventilador sobre el eje del motor presionando.
6. Desatornillar los tornillos con arandelas de acero/goma que Si se cree necesario aplicar lgunos golpecitos con una maza
ijan la bomba al motor eléctrico. de caucho. Aplicar Loctite sobre el tornillo y ijar el asiento del
7. Retirar la bomba y la corona dentada del acoplamiento. ventilador sobre el eje del motor. Ver fig 10.
Ahora ya puede sustituir las piezas de la bomba y las piezas del 4. Controlar que el ventilador esté bien ijado sobre el eje del motor
acoplamiento. y que no tenga ningún juego.
8. Desatornillar el tornillo de cierre de la pieza del acoplamiento. 5. Instalar en su sitio el soporte del motor con su ventilador, la rejilla
Extraer la pieza del acoplamiento del eje motor eléctrico. de protección, motor y consola del motor para montaje en la caja
del ventilador.
6. Ajustar la rejilla de protección y el motor y ijar el soporte del
motor a la caja del ventilador con tornillos. Ver fig 9. Fijar la
consola del motor a las patas del sistema con tornillos.

Hydraulics Group
7. Controlar que el ventilador esté bien centrado y gire bien (con la Dispositivo de presión diferencial tipo D
mano). Ajustar si se cree necesario la posición de la rejilla y del
motor. Si se dispone de indicador visual y este actúa durante el arranque
8. Asegurarse de que los tornillos estén bien apretados. en frío (el botón rojo sobresale 5 mm), reajustar pulsando el
9. Conectar la fuente de alimentación al motor. botón al alcanzarse la temperatura normal de funcionamiento. Si
10. Efectuar los procesos de Antes de la puesta en marcha y En después del reajuste, el indicador volviese a activarse, reemplazar
el momento de la puesta en marcha. el elemento.
Conjunto de filtro FX3 Dispositivo de presión diferencial tipo P
Equipado con un sistema de iltro de tipo FX3, el aceite se limpiará El indicador opcional ‘P’ se activa por temperatura y se reajusta
en un sistema aparte. El iltro FX3 es un excelente complemento de forma manual. Sin señal por debajo de 0 °C, con señal por
del iltro propio sistema. El iltro FX3 está disponible como opción. encima de 29 °C.
Antes de la puesta en marcha Dispositivo de presióndiferencial tipo M
1. Purgar el iltro abriendo el tapón de venteo en la parte superior El indicador eléctrico tipo M se reajusta de manera automática.
del iltro con aproximadamente dos vueltas. Su conexión está en conformidad con DIN 43650, ISO 4400
2. Llenar el iltro hasta que todo el aire salga por el tapón; apretar (Hirschmann) y está protegido frente la humedad conforme a
el tapón. IP65. Se recomienda utilizar el indicador positivo (luz verde) y el
3. Presurizar el sistema y comprobar que no hay fugas; en caso indicador negativo (luz roja para elemento sucio) para controlar de
de detectar fugas véase el apartado Mantenimeinto rutinario. forma eicaz la vida útil del elemento iltrante.
Si actúa el interruptor eléctrico (por ejemplo, se enciende la luz
Precaución Si no se realiza el purgado correcto de la roja) durante el arranque en frío, continuar con el servicio hasta
carcasa del iltro, aumentará el contenido de aire disuelto que la señal (luz roja) se apague cuando el equipo se caliente
en el luido del sistema, lo que acortará la vida del mismo y hasta alcanzar una temperatura de servicio normal. Esta función
podrá provocar otros problemas en el sistema. se puede utilizar como un indicador de ‘calentamiento’ durante
el servicio. Si la señal de aviso (luz roja) permanence encendida o
Mantenimiento rutinario se enciende cuando el sistema está caliente, se deberá sustituir el
Los iltros FX3 normalmente no requieren un mantenimiento elemento iltrante.
especial, salvo la revisión periódica del dispositivo de presión Dispositivo de presión diferencial tipo U
diferencial. La sustitución del elemento de iltro se deberá realizar
cada seis meses o antes y se deberá tener disponible un surtido El indicador de tipo U está equipado con un contacto AMP de 2
amplio de elementos de repuesto. polos.
Advertencia Si no se libera la presión del iltro antes de Sustitución del elemento
llevar a cabo el manteniminento del elemento, se puede
provocar lesiones personales, daños en el equipo y al 1. Desconectar el sistema y la válvula de cierre, si procede.
medio ambiente. 2. Asegurarse de que el sistema esté despresurizado.
3. Abrir el tapón de venteo en la parte superior del iltro aprox. con
Al realizar el mantenimiento se deberán limpiar las supericies 2 vueltas.
externas del conjunto de iltro para eliminar cualquier resto de 4. Desenroscar y quitar la cubierta del tubo girando en sentido
polvo. El mantenimiento se deberá realizar utilizando herramientas antihorario visto desde arriba.
adecuadas que no supongan un peligro. 5. Quitar el elemento iltrante. Desechar el elemento iltrante y su
junta tórica. El elemento iltrante no debe limpiarse. La limpieza
En caso de detectar fugas externas se deberá sustituir la junta del elemento iltrante puede provocar la degradación del medio
tórica en el punto de fuga. Si la fuga persiste, revisar si las iltrante y permitir el paso del luido contaminado a través
supericies de sellado están ralladas o rotas; sustituir cualquier del iltro. Los elementos iltrantes usados deben gestionarse
pieza defectuosa. conforme a las normativas de residuos industriales vigentes en
Un sistema sucio puede embozar rápidamente un elemento cada país.
iltrante nuevo. Puede ser necesario realizar uno o dos cambios 6. Montar un elemento nuevo. Asegurarse de que esté equipado
de elemento antes de estabilizarse la vida útil del mismo. Si la con una junta tórica en el fondo.
vida útil del elemento es muy corta o si la presión diferencial 7. Instalar una nueva junta tórica en la cubierta del iltro y atornillar
es excesiva, es posible que el iltro sea demasiado pequeño; la cubierta.
contacte con Parker. 8. Arranque el motor con el tapón de venteo abierto con
Dispositivos de presión diferencial aproximadamente dos vueltas.
9. Cerrar el tapón de venteo cuando solo salga aceite por el
Un dispositivo de presión diferencial actúa detectando la presión tapón.
diferencia existente entre la entrada y la salida del iltro. El
dispositivo de presión diferencial funciona independientemente 10.Reajustar el indicador. No hacer funcionar el sistema sin el
de la válvula bypass, y está diseñada para reaccionar antes de la elemento iltrante instalado.
apertura de la válvula. Esto signiica que existe tiempo suiciente
disponible para cambiar el cartucho del iltro antes de que la
válvula by-pass se abra permitiendo el paso de aceite no iltrado;
igualmente maximiza la vida útil del elemento.
Si la indicaión fuera ignorada y la contaminación persistiera, el iltro
pasará a funcionar en bypass cuando la caída de presión alcance
los 3,5 bar. El sistema operará entonces como un sistema de
refrigeración sin función de limpieza de aceite.

Hydraulics Group
Después de cambiar el elemento iltrante veriicar si se ha reajus-

tado el dispositivo de presión diferencial pulsando el botón rojo;
los dispositivos eléctricos se reajustan automáticamente.
Cuando el sistema alcanza la temperatura de servicio normal,
comprobar que el interruptor eléctrico no ha actuado y/o el botón
de aviso visual sigue bajado. Si el indicador visual v uelve a subir
debido a condiciones de arranque en frío, reajustar como se des-
cribe en el apartado Dispositivos de presión diferencial.
Parker no garantiza la vida útil del elemento iltrante, ya que ex-
cede al control del vendedor y depende de las condiciones del
sistema en el que se instale el iltro.
Nota! El iltro FX3 está equipado con un mecanismo de extrac-
ción para facilitar la retirada del elemento. Al retirar la cubierta, las
lengüetas en el extremo del elemento encajan en los enganches
de la cubierta y el elemento sale automáticamente del soporte.
Importante No intentar limpiar o reutilizar el elemento iltrante.
Los elementos iltrante se deberán substituir cuando se indique o
a intervalos especiicados de seis meses como máximo.
Los elementos del iltro usados deben recogerse conforme a los
normativas de residuos industriales vigentes en cada país.

Hydraulics Group
Características técnicas Air Oil Coolers, LOC
Características técnicas
Sistema de refrigeración
Máxima presión de régimen de trabajo 10 bar
Tolerancia de transferencia de calor ±6%
Máxima temperatura permitida del aceite 100 °C
Compatibilidad
Aceite mineral
Aceites sintéticos
Aceites vegetales
Para utilizar otros aceites, o para el funcionamiento bajo
condiciones extremas, contacte con su empresa
Material
Carcasa de la bomba/Radiador Aluminio
Conjunto iltro (opcional) Aluminio
Caja del ventilaor Acero
Helices/asiento ventilador Polipropileno reforzado con ibra de vidrio/aluminio
Rejilla de protección Acero
Revestimiento Pintado mediante polvo electrostático
Motor eléctrico
Motor asíncrono trifásico en conformidad con IEC 60034-1
Temperatura ambiente recomendada -20 °C - +40 °C
Estándar de aislamiento F
Aumento de temperatura B
Estándar de protección IP 55
Con respecto a la tensión nominal, consulte el manual
adjunto del motor eléctrico.

Hydraulics Group
Declaración de conformidad Air Oil Coolers, LOC
EC Dec

den AB
Acccumulator and
a Cooler Division
Strrömsätraväg
gen 16
SE
Sw
weden
Phone: +46 8 636 07 00
Ma er.com
ww
ww.parker.co
om


ard Eriksson
n, Parker Ha
annifin Man
nufacturing
n AB
Sweden
Parker Hannifin
M
s responsibility that the productt above to w
which this declaration
relates fulfils
f all the
The pro
w the requ
uirements in
n the followiing standards and directives.
1/A1:2009 and
a SS-EN ISO 12100 0-2/A1:20099.
- S
Safety of machinery
c s
SO 4413:20 010.
- S
Safety of machinery
and 57:2008.
A
A1:2009/AC C:2010.
VD)
2
The abo
H Ma
anufacturing
g Sweden
AB and a complete
e product is
den AB.

annifin Man
nufacturing S
Sweden AB
B the producct
is also not
n Manufactu
e put into
oduct has been
he requirem
ments of the
e relevant
es and stan
directive ndards.
Sätra, January
J 15 2013 ___
__________
__________
_______
Rika
ard Eriksso
on
Tecchnical Man
nager
den AB
PARKER Accumulator
a · Box 8064 · 141
ght

Hydraulics Group

Hydraulics Group
Parker Worldwide
Europe, Middle East, Africa HU – Hungary, Budaoers North America
Tel: +36 23 885 470
AE – United Arab Emirates, parker.hungary@parker.com CA – Canada, Milton, Ontario
Dubai Tel: +1 905 693 3000
Tel: +971 4 8127100 IE – Ireland, Dublin
Tel: +353 (0)1 466 6370 US – USA, Cleveland
parker.me@parker.com
parker.ireland@parker.com (industrial)
AT – Austria, Wiener Neustadt Tel: +1 216 896 3000
Tel: +43 (0)2622 23501-0 IT – Italy, Corsico (MI)
Tel: +39 02 45 19 21 US – USA, Elk Grove Village
parker.austria@parker.com
parker.italy@parker.com (mobile)
AT – Eastern Europe, Wiener Tel: +1 847 258 6200
Neustadt KZ – Kazakhstan, Almaty
Tel: +43 (0)2622 23501 900 Tel: +7 7273 561 000 Asia Pacific
parker.easteurope@parker.com parker.easteurope@parker.com
AU – Australia, Castle Hill
AZ – Azerbaijan, Baku NL – The Netherlands, Oldenzaal Tel: +61 (0)2-9634 7777
Tel: +994 50 22 33 458 Tel: +31 (0)541 585 000
parker.azerbaijan@parker.com parker.nl@parker.com CN – China, Shanghai
Tel: +86 21 2899 5000
BE/LU – Belgium, Nivelles NO – Norway, Asker
Tel: +32 (0)67 280 900 Tel: +47 66 75 34 00 HK – Hong Kong
parker.belgium@parker.com parker.norway@parker.com Tel: +852 2428 8008
BG – Bulgaria, Soia PL – Poland, Warsaw IN – India, Mumbai
Tel: +359 2 980 1344 Tel: +48 (0)22 573 24 00 Tel: +91 22 6513 7081-85
parker.bulgaria@parker.com parker.poland@parker.com JP – Japan, Fujisawa
BY – Belarus, Minsk PT – Portugal, Leca da Palmeira Tel: +81 (0)4 6635 3050
Tel: +375 17 209 9399 Tel: +351 22 999 7360 KR – South Korea, Seoul
parker.belarus@parker.com parker.portugal@parker.com Tel: +82 2 559 0400
CH – Switzerland, Etoy RO – Romania, Bucharest MY – Malaysia, Shah Alam
Tel: +41 (0)21 821 87 00 Tel: +40 21 252 1382 Tel: +60 3 7849 0800
parker.switzerland@parker.com parker.romania@parker.com
NZ – New Zealand, Mt Wellington
CZ – Czech Republic, Klecany RU – Russia, Moscow Tel: +64 9 574 1744
Tel: +420 284 083 111 Tel: +7 495 645-2156
parker.czechrepublic@parker.com parker.russia@parker.com SG – Singapore
Tel: +65 6887 6300
DE – Germany, Kaarst SE – Sweden, Spånga
Tel: +49 (0)2131 4016 0 Tel: +46 (0)8 59 79 50 00 TH – Thailand, Bangkok
parker.germany@parker.com parker.sweden@parker.com Tel: +662 717 8140
DK – Denmark, Ballerup SK – Slovakia, Banská Bystrica TW – Taiwan, New Taipei City
Tel: +45 43 56 04 00 Tel: +421 484 162 252 Tel: +886 2 2298 8987
parker.denmark@parker.com parker.slovakia@parker.com
ES – Spain, Madrid SL – Slovenia, Novo Mesto South America
Tel: +34 902 330 001 Tel: +386 7 337 6650
AR – Argentina, Buenos Aires
parker.spain@parker.com parker.slovenia@parker.com
Tel: +54 3327 44 4129
FI – Finland, Vantaa TR – Turkey, Istanbul
BR – Brazil, Cachoeirinha RS
Tel: +358 (0)20 753 2500 Tel: +90 216 4997081
Tel: +55 51 3470 9144
parker.inland@parker.com parker.turkey@parker.com
CL – Chile, Santiago
FR – France, Contamine s/Arve UA – Ukraine, Kiev
Tel: +56 2 623 1216
Tel: +33 (0)4 50 25 80 25 Tel +380 44 494 2731
parker.france@parker.com parker.ukraine@parker.com MX – Mexico, Apodaca
Tel: +52 81 8156 6000
Ed. 2013-01-30
GR – Greece, Athens UK – United Kingdom, Warwick

Tel: +30 210 933 6450 Tel: +44 (0)1926 317 878
parker.greece@parker.com parker.uk@parker.com
ZA – South Africa, Kempton Park
Tel: +27 (0)11 961 0700
parker.southafrica@parker.com
© 2013 Parker Hanniin Corporation. All rights reserved. Catalogue HY10-6003-UM/EU, 1M, 03/2013, VITT
EMEA Product Information Centre

Free phone: 00 800 27 27 5374
(from AT, BE, CH, CZ, DE, DK, EE, ES, FI, FR, IE, IL,
IS, IT, LU, MT, NL, NO, PL, PT, RU, SE, SK, UK, ZA)
US Product Information Centre
Toll-free number: 1-800-27 27 537
www.parker.com Your local authorized Parker distributor
9.7 MANUALE TRASMETTITORE DI TEMPERATURA
IOM_14479_2 (09.16) Pages 40/59

Manuale d'uso
Termoresistenze (RTD) e termocoppie (TC)

- IT
Esempi
IWIKAII
5 Part of your business
IT Manuale d'uso modelli RTD e TC Pagina 3 - 24
© 2012 WIKA Alexander Wiegand SE & Co. KG

Tutti i diritti riservati.
WIKA® è un marchio registrato in vari paesi.
Prima di iniziare ad utilizzare lo strumento, leggere il manuale d'uso!

Conservare per future consultazioni!
03/2016 IT based on 12/2015 EN
2 WIKA manuale d'uso RTD e TC

Contenuti
Contenuti
IT
1. Informazioni generali 4
2. Esecuzione e funzioni 4
3. Sicurezza 5
4. Trasporto, imballaggio e stoccaggio 10
5. Messa in servizio, funzionamento 11
6. Malfunzionamenti e guasti 18
7. Manutenzione e pulizia 20
8. Smontaggio, resi e smaltimento 21
9. Specifiche tecniche 23
10. Accessori 24
03/2016 IT based on 12/2015 EN
WIKA manuale d'uso RTD e TC 3

1. Informazioni generali / 2. Esecuzione e funzioni
1. Informazioni generali
■ Le sonde di temperatura descritte nel manuale d'uso sono stati fabbricate secondo lo
stato dell'arte della tecnica.
IT
■ Questo manuale d'uso contiene importanti informazioni sull'uso dello strumento.
Lavorare in sicurezza implica il rispetto delle istruzioni di sicurezza e di funzionamento.
■ Osservare le normative locali in tema di prevenzione incidenti e le regole di sicurezza

generali per il campo d'impiego dello strumento.
■ Il manuale d‘uso deve essere letto con attenzione e compreso dal personale qualificato
prima dell‘inizio di qualsiasi attività.
■ Soggetto a modifiche tecniche.
■ Ulteriori informazioni:
- Indirizzo Internet: www.wika.it
- Consulenze tecniche ed applicative: Tel.: +39 02 93861-1
Fax: +39 02 93861-74
info@wika.it
2. Esecuzione e funzioni
2.1 Descrizione
Queste termoresistenze e termocoppie sono usate per la misura della temperatura in
applicazioni industriali.
Questo documento descrive gli strumenti nella versione standard. Per le applicazioni in
aree pericolose sono richiesti strumenti speciali.
Per ulteriori informazioni sul funzionamento in aree pericolose, vedere le informazioni

addizionali del tipo di protezione antideflagrante corrispondente (documento separato).
Lo strumento è stato progettato e costruito esclusivamente per la sua destinazione d'uso e

può essere impiegato solo per questa.
03/2016 IT based on 12/2015 EN
Punto di misura non a massa

Le sonde di temperatura modello TRxx o modello TCxx sono composte da un tubo saldato,
un cavo protetto a isolamento minerale o fili della termocoppia ad isolamento ceramico
in cui è inserito il sensore di temperatura. Questo è immerso in una polvere ceramica, un
materiale di tenuta termoresistente, un composto in cemento o una pasta a convezione
termica.

2. Esecuzione e funzionamento / 3. Sicurezza
Termocoppie, non isolate (a massa)

Per applicazioni speciali, ad esempio la misura della temperatura superficiale, i sensori
sono a contatto diretto con il manicotto protettivo, oppure i punti di misura delle
termocoppie sono saldati sul fondo.
Punto di misura isolato (non a massa) Punto di misura non isolato (a massa) IT
Termocoppia Punto di misura Termocoppia Punto di misura
Guaina Guaina
Collegamento elettrico
Per quanto riguarda il collegamento elettrico, la sonda è dotata di una custodia e di un
connettore o di un filo nudo uscente. La custodia contiene il terminali di connessione o i
trasmettitori certificati. In opzione, nelle custodie possono essere integrati separatamente
display digitali certificati.
2.2 Scopo di fornitura

Controllare lo scopo di fornitura con il documento di consegna / trasporto.
3. Sicurezza
3.1 Legenda dei simboli
ATTENZIONE!
... indica una situazione di potenziale pericolo che, se non evitata, può
causare ferite gravi o morte.
CAUTELA!
causare ferite lievi o danni alle apparecchiature o all'ambiente.
03/2016 IT based on 12/2015 EN
ATTENZIONE!
causare ustioni causate da superfici o liquidi bollenti.

3. Sicurezza
Informazione
... fornisce suggerimenti utili e raccomandazioni per l'utilizzo efficiente e
senza problemi dello strumento.
IT
3.2 Destinazione d'uso
Le sonde di temperatura qui descritte sono adatte per misura della temperatura in
applicazioni industriali.
A seconda dell'esecuzione, queste sonde di temperatura possono essere montate

direttamente nel processo o nel pozzetto termometrico. Le esecuzioni dei pozzetti possono
essere scelte a piacere, tuttavia vanno tenuti in considerazione i dati di processo operativi
(temperatura, pressione, densità e portata).
Non sono consentite né riparazioni né alterazioni in quanto ciò annullerebbe la validità

della garanzia e della rispettiva certificazione. Il costruttore non è responsabile per le
modifiche costruttive dopo la fornitura degli strumenti.
Lo strumento è stato progettato e costruito esclusivamente per la sua destinazione d'uso e

può essere impiegato solo per questa.
Le specifiche tecniche riportate in questo manuale d'uso devono essere rispettate.
Il costruttore non è responsabile per reclami di qualsiasi natura in caso di utilizzo dello
strumento al di fuori della sua destinazione d'uso.
3.3 Responsabilità dell'operatore

L'operatore è responsabile della selezione della sonda o del pozzetto e della selezione
dei rispettivi materiali, al fine di garantire che il loro funzionamento nell'impianto o nella
macchina avvenga in maniera sicura. Nel preparare un preventivo, WIKA può solo dare
suggerimenti che sono basati sulla propria esperienza in applicazioni simili.
Le istruzioni di sicurezza all'interno di questo manuale d'uso, così come la sicurezza, la

prevenzione degli incidenti e le normative di tutela ambientale per l'area di applicazione
devono essere rispettati.
L'operatore è obbligato a mantenere sempre perfettamente leggibile l'etichetta dello

strumento.
03/2016 IT based on 12/2015 EN

3. Sicurezza
3.4 Qualificazione del personale
ATTENZIONE!
Rischio di lesioni in caso di personale non qualificato
L'uso improprio può condurre a lesioni gravi o danni alle apparecchiature. IT
▶ Le attività riportate in questo manuale d'uso possono essere effettuate
solo da elettricisti in possesso delle qualifiche riportate di seguito.
Personale qualificato per la parte elettrica

Per personale qualificato per le parti elettriche si intende personale che, sulla base dei
corsi di formazione tecnica, delle proprie conoscenze tecniche di strumentazione e
controllo e delle normative nazionali e sulla base della propria esperienza, è in grado di
portare a termine il lavoro sulle parti elettriche e riconoscere autonomamente potenziali
pericoli. Il personale qualificato per la parte elettrica deve essere formato in modo specifico
per l'ambiente di lavoro e conoscere i relativi regolamenti e standard nazionali. Il personale
qualificato per la parte elettrica deve rispondere ai regolamenti nazionali in termini di
prevenzione degli incidenti sul lavoro.
Personale operativo
Per personale formato dall'operatore si intende personale che, sulla base della propria
istruzione, conoscenza ed esperienza, sia in grado di svolgere il lavoro descritto e
riconoscere autonomamente potenziali pericoli.
Eventuali condizioni operative speciali richiedono inoltre conoscenze specifiche, es. fluidi
aggressivi.
03/2016 IT based on 12/2015 EN

3. Sicurezza
3.5 Etichettatura, simboli per la sicurezza
3.5.1 Etichetta prodotto per termoresistenze (esempio)


IT
 TR10-B 11012345
D-63911 Klingenberg IEC 60751
1 x Pt100 / B / 3 (F) -50 ... +250 °C
T32 4 ... 20 mA -50 ... +250 °C
HART ®
Made in Germany 2015
 
■ Etichetta prodotto per inserto di misura TR10-A

D-63911 Klingenberg
TR10-A
IEC 60751 11012345
1 x Pt100 / B / 3
-50 ... +250 °C
D = 6 mm 525 mm
(F)

 Modello
 Modello del trasmettitore (solo per esecuzioni con trasmettitore)
 Anno di produzione
 Sensore conforme agli standard
03/2016 IT based on 12/2015 EN
■ F = Termoresistenza a film sottile

■ FT = Termoresistenza a film sottile, punta sensibile
■ W = Termoresistenza con filo avvolto
 Simbolo sensore
■ quasi a massa = la sonda di temperatura va considerata a massa per via delle sue
distanze a basso isolamento tra il sensore a resistenza e la guaina.

3. Sicurezza
3.5.2 Etichetta prodotto per termocoppie (esempio)

 TC10-B 11012345
D-63911 Klingenberg IEC 60584 IT
1 x Type K / 1 / . 0 ... 1260 °C
T32 4 ... 20 mA -50 ... +250 °C
HART ®
 
■ Etichetta prodotto per inserto di misura TC10-A
D-63911 Klingenberg

TC10-A
IEC 60584 11012345
1 x Type K / 1 / .
0 ... 1260 °C
D = 2 mm 525 mm

 Modello
 Modello del trasmettitore (solo per esecuzioni con trasmettitore)
 Anno di produzione
 Sensore conforme agli standard
■ non collegato a massa
■ collegato a massa
 Simbolo sensore
03/2016 IT based on 12/2015 EN
■ ungrounded = saldato non collegato a massa
■ grounded = saldato alla guaina (a massa)

■ quasi a massa = la sonda di temperatura va considerata a massa per via delle sue
distanze a basso isolamento tra il sensore e la guaina.

3. Sicurezza / 4. Trasporto, imballaggio e stoccaggio
Simboli
Prima di montare e installare lo strumento, assicurarsi di avere letto

attentamente il manuale d'uso!
IT
Gli strumenti riportanti questo marchio sono in accordo con le relative
Direttive Europee.
4. Trasporto, imballo e stoccaggio

4.1 Trasporto
Verificare che lo strumento non abbia subito danni nel trasporto.
Danni evidenti devono essere segnalati tempestivamente.
CAUTELA!
Danni dovuti a trasporto improprio
Con un trasporto non corretto, lo strumento può subire danni gravi.
▶ Quando le merci imballate si scaricano al momento della consegna, così
come durante il trasporto interno, procedere con cautela e osservare i
simboli riportati sull'imballo.
▶ In caso di trasporti interni, osservare le istruzioni riportate nel capitolo 10
“Accessori”.
Se lo strumento viene spostato da un ambiente freddo a uno caldo, la formazione di

condensa può portare a un malfunzionamento dello strumento. Prima di mettere in
funzione lo strumento, attendere che la temperatura dello strumento e quella dell'ambiente
si equalizzino.
4.2 Imballaggio e stoccaggio

Rimuovere l'imballo solo appena prima dell'installazione.
Condizioni consentite per lo stoccaggio:

Temperatura di stoccaggio:
Sonde senza trasmettitore incorporato: -40 ... +80 °C
Sonde con trasmettitore incorporato: vedere il manuale d'uso del relativo
03/2016 IT based on 12/2015 EN
trasmettitore
Evitare l'esposizione ai seguenti fattori:

■ Esposizione diretta al sole o prossimità con oggetti molto caldi
■ Vibrazioni e shock meccanici (posare lo strumento in modo energico)
■ Fuliggine, vapori, polvere e gas corrosivi
■ Ambienti pericolosi, atmosfere infiammabili

4. Trasporto ... / 5. Messa in servizio, funzionamento
Conservare lo strumento nel suo imballo originale in un luogo rispondente alle condizioni
riportate sopra. Se l'imballo originale non è disponibile, imballare e conservare lo
strumento come indicato di seguito:
1. Riporre lo strumento nella scatola con materiale assorbente gli urti.
2. Se la conservazione deve essere effettuata per un lungo periodo (più di 30 giorni), IT
includere una bustina di gel antiumidità all'interno dell'imballo.
5. Messa in servizio, funzionamento

ATTENZIONE!
Danno allo strumento di misura con funzionamento oltre i limiti
superiori ed inferiori della temperatura operativa
Non è possibile rispettare la temperatura operativa; inoltre, considerando la
convezione e radiazione, è possibile danneggiare il termometro durante il
montaggio.
▶ I limiti superiori ed inferiori del campo di temperatura operativa specificato
non vanno oltrepassati.
5.1 Montaggio meccanico

5.1.1 Assemblaggi multipoint
Sono normalmente fornite di una custodia nella quale sono montati i trasmettitori o le
morsettiere.
I display digitali/trasmettitori sono fissati meccanicamente (es. sistema di guide nella
custodia o supporto nella testa di connessione).
5.1.2 Sonda a cavo

Queste non sono generalmente dotate di custodia. Tuttavia, possono essere connesse in
una custodia supplementare in cui sono montati i trasmettitori o le morsettiere.
5.1.3 Filettature cilindriche

Se la testa di connessione, il tubo di estensione, il pozzetto termometrico o l'attacco al
processo sono connessi con filettature cilindriche (es. G ½, M20 x 1,5 ...), esse vanno
fissate usando guarnizioni che evitino ai liquidi di penetrare nelle sonde.
Come standard, WIKA utilizza guarnizioni in rame per la connessione tra il tubo di
estensione e il pozzetto termometrico, e guarnizioni piatte in carta per la connessione tra la
03/2016 IT based on 12/2015 EN
testa di connessione e il tubo di estensione o il pozzetto termometrico.
Se il termometro e il pozzetto termometrico sono già connessi, le guarnizioni saranno già

montate (se ordinate). L'operatore dell'impianto deve controllare se le guarnizioni sono
adatte per le condizioni d'impiego e vanno sostituite, se necessario, con guarnizioni adatte
(vedere capitolo 10 “Accessori”).
Le guarnizioni vanno sostituite dopo lo smontaggio!

5.1.4 Filettature coniche

Con NPT o altre filettature coniche, bisogna controllare se è necessario saldarle
ulteriormente con nastro PTFE o canapa. Le filettature vanno lubrificate con un lubrificante
idoneo prima del montaggio.
IT
5.2 Montaggio elettrico
Utilizzo di un trasmettitore/display digitale (opzione):
Osservare i contenuti dei manuali d'uso per il trasmettitore/display digitale (vedere lo
scopo di fornitura).
Pressacavi
Requisiti per raggiungere la classe di protezione:
■ Usare solo pressacavi all'interno della coppia di serraggio indicata (diametro del cavo
adatto al pressacavo).
■ Non usare l'area di serraggio inferiore con tipi di cavo molto morbidi.
■ Usare solo cavi a sezione circolare (se necessario, a sezione leggermente ovale).
■ Non torcere il cavo.
■ È possibile l'apertura/chiusura ripetuta; tuttavia, solo se necessario in quanto potrebbe
avere un effetto dannoso sulla classe di protezione
■ Per i cavi con un comportamento “cold-flow” pronunciato, il collegamento a vite deve
essere completamente serrato.
03/2016 IT based on 12/2015 EN

5.3 Collegamento elettrico
CAUTELA!
Pericolo di cortocircuito
Danni ai cavi, fili e punti di collegamento possono comportare il IT
malfunzionamento dello strumento.
▶ Evitare di danneggiare i cavi e i fili. I cavi flessibili sottili con terminali
scoperti vanno dotati di giunzioni finali.
5.3.1 Termoresistenze
■ Con morsettiera
1 x Pt100, 2 fili 1 x Pt100, 3 fili 1 x Pt100, 4 fili
3160629.06
rosso bianco rosso
bianco rosso bianco rosso bianco rosso
rosso rosso
rosso rosso rosso
bianco bianco bianco

bianco
2 x Pt100, 2 fili 2 x Pt100, 3 fili 2 x Pt100, 4 fili
nero
nero giallo
nero giallo giallo
bianco rosso bianco bianco rosso

rosso
rosso rosso
rosso rosso rosso
bianco bianco bianco

bianco
nero nero
nero nero
03/2016 IT based on 12/2015 EN
nero
giallo giallo giallo
giallo

■ Con cavo o connettore
Senza connettore
rosso rosso
IT
3160629.06
1 x Pt100
2 fili bianco bianco
2 x Pt100
2 fili
nero
rosso giallo
1 x Pt100 rosso
3 fili rosso
bianco rosso
2 x Pt100 bianco
rosso 3 fili nero
1 x Pt100 rosso nero
4 fili
bianco giallo
bianco
Connettore Lemosa
Connettore (maschio) Connettore (femmina)
3366036.02
Vista frontale Vista frontale
1 x Pt100
2 fili
1 x Pt100
3 fili
1 x Pt100
4 fili
2 x Pt100
2 fili
03/2016 IT based on 12/2015 EN
2 x Pt100
3 fili

Connettore a vite (Binder, Amphenol)

Connettore (maschio) Connettore (femmina)
3366142.05
IT
Vista dei contatti Vista dei contatti
1 x Pt100 Binder
2 fili Serie 680
1 x Pt100 Binder
3 fili Serie 680
1 x Pt100 Binder
4 fili Serie 680
2 x Pt100 Binder
2 fili Serie 680
2 x Pt100 Binder
3 fili Serie 692
2 x Pt100 Amphenol
4 fili C16-3
03/2016 IT based on 12/2015 EN

5.3.2 Termocoppie
■ Con morsettiera
Termocoppia singola Termocoppia doppia
3166822.03
IT
La marcatura
colorata sul polo
positivo determina
la correlazione tra
polarità e terminale.
Codice colore dei conduttori

Tipo di sonda Standard Polo positivo Polo negativo
K IEC 60584 Verde Bianco
J IEC 60584 Nero Bianco
E IEC 60584 Viola Bianco
N IEC 60584 Rosa Bianco
■ Con cavo o connettore
Cavo Connettore Lemosa, Connettore binder,

maschio sul cavo maschio sul cavo
(connettore a vite)
3374900.01a
3171966.01
3374896.01
Per la marcatura
delle parti finali del
cavo, vedi tabella
Termocoppia
singola
Termocoppia
doppia
03/2016 IT based on 12/2015 EN
Connettore compensato I terminali positivo e negativo sono indicati.

Due connettori termici vengono usati con
termocoppie doppie.

5.4 Residuo della temperatura dal processo

Non è consentito un riflusso termico dal processo che supera la temperatura operativa
del trasmettitore (display digitale) o della custodia e va evitato installando un isolamento
termico adatto o un tubo di estensione sufficientemente lungo.
Aumento della distanza dai componenti di collegamento alle superfici calde

IT
La lunghezza d'estensione (N) è definita come la distanza tra il bordo inferiore della testa
di connessione o della custodia e la superficie termoradiante. La temperatura attesa
sul bordo inferiore della testa di connessione o della custodia deve essere al massimo
di 80 °C. Vanno considerate le condizioni per i trasmettitori o display incorporati, e se
necessario, va aumentata la lunghezza del tubo di estensione.
3160670.07
filettatura cilindrica filettatura conica
Per aiutare a selezionare la lunghezza minima dell'estensione, vanno determinati i seguenti

valori standard.
Massima temperatura del fluido Raccomandazione per la Raccomandazione per
dimensione N la dimensione X
100 °C - -
135 °C 20 mm 20 mm
03/2016 IT based on 12/2015 EN
200 °C 50 mm 50 mm
> 200 °C ≤ 0 °C 100 mm 100 mm
Per le sonde di temperatura dotate di un cavo di connessione, viene ristretta la temperatura

sull'interfaccia con il cavo di connessione. La massima è 150 °C. Per garantire che non
venga superata la temperatura ammessa, la dimensione X va selezionato di conseguenza.

5. Messa in servizio ... / 6. Malfunzionamenti e guasti
Aumento della distanza dai componenti di collegamento alle superfici calde

La lunghezza X è definita come la distanza tra il punto di transizione dal cavo alla
superficie che emette calore. La temperatura attesa sul punto di transizione deve essere
massimo di 120 °C.
▶ Se necessario, va aumentata la lunghezza X.
IT
11355647.01
Filettatura Filettatura(NPT)
6. Malfunzionamenti e guasti
CAUTELA!
Lesioni fisiche e danni alle cose e all'ambiente
Se il guasto non può essere eliminato mediante le misure elencate, lo
strumento deve essere messo fuori servizio immediatamente.
▶ Assicurarsi che non vi sia più alcun segnale e proteggerlo dalla
riattivazione accidentale.
▶ Contattare il costruttore.
▶ Se è necessario restituire lo strumento, seguire le istruzioni riportate nel
capitolo 8.2 “Resi”.
03/2016 IT based on 12/2015 EN
ATTENZIONE!
Lesioni fisiche e danni alle cose e all'ambiente causati da fluidi
pericolosi
A contatto con fluidi pericolosi (ad esempio ossigeno, acetilene, sostanze
infiammabili o tossiche), con fluidi nocivi (ad esempio corrosivi, tossici,
cancerogeni, radioattivi), e anche con impianti di refrigerazione e
compressori, vi è il rischio di lesioni fisiche e danni alle cose e dell'ambiente.

6. Malfunzionamenti e guasti
In caso di guasto, nello strumento possono essere presenti fluidi aggressivi

con temperature estreme, alta pressione o vuoto.
▶ Per questi fluidi, in aggiunta a tutte le normative standard esistenti, è
necessario seguire appropriati codici o regolamenti.
▶ Indossare l'equipaggiamento protettivo richiesto (a seconda
IT
dell'applicazione, la sonda stessa non è di per se pericolosa).
Per informazioni dettagliate, vedere il capitolo 1 “Informazioni generali” o il

retro del manuale d'uso.
Malfunzionamenti Cause Rimedi

e guasti
Nessun segnale/ Carico meccanico troppo elevato Sostituire la sonda o l'inserto di misura
rottura del cavo o sovratemperatura con un'esecuzione adatta
Valori misurati Deriva sensore causata da Sostituire la sonda o l'inserto di misura
erronei sovratemperatura con un'esecuzione adatta
Deriva sensore causata da Usare un pozzetto termometrico
aggressione chimica adatto.
Valori misurati Ingresso di umidità nel cavo o Sostituire la sonda o l'inserto di misura
erronei (troppo inserto di misura con un'esecuzione adatta
bassi)
Valori misurati Geometria di montaggio errata, L'area del sensore sensibile alla
erronei e tempi di per esempio profondità di temperatura deve essere interna al
risposta troppo montaggio troppo profonda o fluido e le misure superficiali non
lunghi dissipazione del calore troppo alta devono essere a massa
Depositi sul sensore o pozzetto Rimuovere i depositi
termometrico
Valori misurati Tensioni parassite (tensione Utilizzare cavi di compensazione
erronei (delle termica, tensione galvanica) o idonei
termocoppie) linea di equalizzazione errata
Visualizzazione dei Rottura del cavo nel cavo di Sostituire la sonda o l'inserto di
salti nel valore di connessione o contatto allentato misura con un'esecuzione adatta, per
misura causato da sovraccarico esempio dotata di un anti-tensione o di
meccanico una sezione trasversale del conduttore
più spessa
Corrosione Struttura chimica del fluido Analizzare il fluido quindi selezionare
03/2016 IT based on 12/2015 EN
diversa rispetto a quella attesa o un materiale più idoneo o sostituire

modificata o materiale pozzetto regolarmente il pozzetto termometrico
termometrico selezionato errato

7. Manutenzione e pulizia / 6. Malfunzionamenti e guasti
Malfunzionamenti Cause Rimedi

e guasti
Interferenza di Correnti parassite causate da Usare cavi di connessione schermati,
segnale campi elettrici o ritorni di terra aumentare la distanza da motori e
IT linee di alimentazione
Ritorni di terra Eliminare le differenza di potenziale
usando trasmettitori o separatori isolati
galvanicamente.
7. Manutenzione e pulizia
Per informazioni dettagliate, vedere il capitolo 1 “Informazioni generali” o il

retro del manuale d'uso.
7.1 Manutenzione
Le sonde di temperatura qui descritte sono esenti da manutenzione.
Le riparazioni devono essere effettuate solo dal costruttore.
7.2 Pulizia
CAUTELA!
Lesioni fisiche e danni alle cose e all'ambiente
Una pulizia non corretta può provocare lesioni fisiche e danni alle cose e
all'ambiente. I residui dei fluidi di processo negli strumenti smontati possono
causare rischi alle persone, all'ambiente ed alla strumentazione.
▶ Effettuare la pulizia come descritto di seguito.
▶ Prima della pulizia, scollegare adeguatamente lo strumento.

▶ Usare l'equipaggiamento protettivo richiesto (a seconda dell'applicazione: il termometro
stesso è di base non pericoloso).
▶ Pulire lo strumento con un panno umido.
Ciò si applica in particolare alle sonde con una custodia in plastica e sonde a cavo con
cavo di connessione isolato in plastica, per assicurare l'assenza di qualsiasi rischio di
03/2016 IT based on 12/2015 EN
cariche elettrostatiche.
Le connessioni elettriche non devono entrare in contatto con l'umidità!

7. Manutenzione e pulizia / 8. Smontaggio, resi e smaltimento
CAUTELA!
Danni allo strumento
Una pulizia non corretta può causare danni allo strumento!
▶ Non usare detergenti aggressivi.
▶ Per la pulizia non utilizzare oggetti appuntiti o duri.
IT
▶ Lavare o pulire lo strumento smontato, allo scopo di proteggere le persone e l'ambiente
dall'esposizione con i fluidi residui.
7.3 Taratura, ritaratura

Si consiglia di ritarare l'inserto di misura a intervalli regolari (termoresistenze: ca. 24 mesi,
termocoppie: ca. 12 mesi). Tale periodo può ridursi, a seconda dell'applicazione. La
taratura può essere svolta dal costruttore oppure sul posto da personale tecnico qualificato
dotato di strumenti di calibrazione.
8. Smontaggio, resi e smaltimento

8.1 Smontaggio
ATTENZIONE!
Lesioni fisiche e danni alle cose e all'ambiente a causa di fluidi residui
A contatto con fluidi pericolosi (ad esempio ossigeno, acetilene, sostanze
infiammabili o tossiche), con fluidi nocivi (ad esempio corrosivi, tossici,
cancerogeni, radioattivi), e anche con impianti di refrigerazione e
compressori, vi è il rischio di lesioni fisiche e danni alle cose e dell'ambiente.
▶ Prima dello stoccaggio, lavare o pulire lo strumento smontato (dopo l'uso),
allo scopo di proteggere le persone e l'ambiente dall'esposizione con i
fluidi residui.
▶ Usare l'equipaggiamento protettivo richiesto (a seconda dell'applicazione:
il termometro stesso è di base non pericoloso).
▶ Osservare le informazioni contenute nella scheda di sicurezza per il
corrispondente fluido.
Scollegare la sonda solo dopo aver tolto la pressione al sistema.
ATTENZIONE!
Rischio di ustioni
03/2016 IT based on 12/2015 EN
Durante lo smontaggio c'è il rischio di fuoriuscita di fluidi pericolosamente

caldi.
▶ Lasciare raffreddare sufficientemente lo strumento prima di smontarlo!

8. Smontaggio, resi e smaltimento
8.2 Resi
Osservare attentamente lo seguenti indicazioni per la spedizione dello strumento:

Tutti gli strumenti inviati a WIKA devono essere privi di qualsiasi tipo di sostanze pericolose
(acidi, basi, soluzioni, ecc.) e pertanto devono essere puliti prima di essere restituiti.
IT
ATTENZIONE!
Lesioni fisiche e danni alle cose e all'ambiente a causa di fluidi residui
I residui dei fluidi di processo negli strumenti smontati possono causare
rischi alle persone, all'ambiente ed alla strumentazione.
▶ In caso di sostanze pericolose, è inclusa la scheda di sicurezza del
materiale per il fluido corrispondente.
▶ Pulire lo strumento, vedere capitolo 7.2 “Pulizia”.
In caso di restituzione dello strumento, utilizzare l'imballo originale o utilizzare un

contenitore di trasporto adeguato.
Per evitare danni:

1. Riporre lo strumento nella scatola con materiale assorbente gli urti.
Posizionare materiale per assorbire gli urti su tutti i lati all'interno dell'imballo.
2. Se possibile, includere una bustina di gel anti-umidità all'interno dell'imballo.
3. Etichettare la spedizione come trasporto di uno strumento altamente sensibile.
Le informazioni sulle modalità di gestione resi sono disponibili nella sezione

“Servizi” del nostro sito web.
8.3 Smaltimento
Lo smaltimento inappropriato può provocare rischi per l'ambiente.
Lo smaltimento dei componenti dello strumento e dei materiali di imballaggio deve essere
effettuato in modo compatibile ed in accordo alle normative nazionali.
03/2016 IT based on 12/2015 EN

9. Specifiche tecniche
9. Specifiche tecniche
A causa dell'elevata varianza, le specifiche sono molto estese. Pertanto, facciamo

riferimento alle relative schede tecniche di WIKA e ai documenti d'ordine.
IT
■ Termoresistenze ■ Termocoppie
Modello Scheda tecnica Modello Scheda tecnica
TR10-A TE 60.01 TC10-A TE 65.01
TR10-B TE 60.02 TC10-B TE 65.02
TR10-C TE 60.03 TC10-C TE 65.03
TR10-D TE 60.04 TC10-D TE 65.04
TR10-F TE 60.06 TC10-F TE 65.06
TR10-H TE 60.08 TC10-H TE 65.08
TR10-J TE 60.10 TC10-K TE 65.11
TR10-K TE 60.11 TC10-L TE 65.12
TR10-L TE 60.12 TC40 TE 65.40
TR11-A TE 60.13 TC50 TE 65.50
TR11-C TE 60.14 TC53 -
TR11-H - TC55 TE 65.55
TR20 TE 60.20 TC80 TE 65.80
TR22-A TE 60.22 TC81 TE 65.81
TR22-B TE 60.23 TC95 TE 70.01
TR25 TE 60.25
TR40 TE 60.40
TR50 TE 60.50
TR51 TE 60.51
TR53 TE 60.53
TR55 TE 60.55
TR60 TE 60.60
TR81 TE 60.81
TR95 TE 70.01
03/2016 IT based on 12/2015 EN

10. Accessori
10. Accessori
Le guarnizioni possono essere ordinate a WIKA, indicando il numero d’ordine

IT
WIKA e/o la designazione (vedi tabella).
WIKA codice Descrizione Adatto per le

d'ordinazione filettature
11349981 secondo DIN 7603 forma C 14 x 18 x 2 -CuFA G ¼, M14 x 1,5
11349990 secondo DIN 7603 forma C 18 x 22 x 2 -CuFA M18 x 1,5, G ⅜
11350008 secondo DIN 7603 forma C 21 x 26 x 2 -CuFA G ½, M20 x 1,5
11350016 secondo DIN 7603 forma C 27 x 32 x 2,5 -CuFA G ¾, M27 x 2
11367416 secondo DIN 7603 forma C 20 x 24 x 2 -CuFA M20 x 1,5
1248278 secondo DIN 7603 D21,2 x D25,9 x 1,5 -Al G ½, M20 x 1,5
3153134 secondo DIN 7603 forma C D14,2 x D17,9 x 2 -StFA G ¼, M14 x 1,5
3361485 secondo DIN 7603 forma C D33,3 x D38,9 x 2,5 -StFA G1
Legenda:
CuFA = Rame, max. 45HBa; riempito con materiale sigillante privo di amianto
Al = Alluminio Al99; F11, da 32 a45 HBb
StFA = Ferro dolce, da 80 a 95 HBa; riempito con materiale sigillante privo di amianto
03/2016 IT based on 12/2015 EN

03/2016 IT based on 12/2015 EN
WIKA manuale d'uso RTD e TC

25
26
03/2016 IT based on 12/2015 EN
03/2016 IT based on 12/2015 EN

27
Filiali WIKA nel mondo, visitate il nostro sito www.wika.it.
03/2016 IT based on 12/2015 EN
WIKA Italia Srl & C. Sas

Via G. Marconi, 8
20020 Arese (Milano)/Italia
Tel. +39 02 93861-1
Fax +39 02 93861-74
info@wika.it
www.wika.it

9.8 MANUALE TRASMETTITORE DI LIVELLO
IOM_14479_2 (09.16) Pages 41/59

Sensore Continuo di Livello
CARATTERISTICHE GENERALI
& = 1 -
1
> > 1
"
)> = 1
1 > "
? - @"
% A#),&6&57$)
• Acciaio inox ─ AISI 316
• ! ! "
• # (LC)
• # $ (LCT)
• # % (LCTV)
• & ' ( $ (LCO)
• ) * "
• +
• , - . / 0 1# 2 3
• , 0
4 0
• 5 &+*
• 6
+, ! +, ! 7,
• 4 ) $,48 4 ! ) $,48 &
GALLEGGIANTI , -"
S29 S32 S52 S52 S100

∅. 9. ∅. 9. ∅ '6( ∅ 9*: ∅
Materiale $ - ! $&6& . *
Peso specifico 1 1 1 1* 1*
Risoluzione di misura / mm ! !
Pressione max – Bar .
Temperatura max – Classe L ; 0
$ R ; 0
USCITA ELETTRICA , -"

W1 S1 S1 P1 / P2 P1 / P2 O1
LC – LCT – LCTV LC LCT / LCTV LC LCT / LCTV LCO

Con dissipatore ! '<( LCT – LCTV – LCO = R
74
Sensore Continuo di Livello
ATTACCHI DI PROCESSO Tab.3
Tipo LC uscita P1–P2 = Montaggio dall’interno Tipo LC – LCT – LCTV – LCO = Montaggio dall’esterno
Tipo
10 15 25 32 40 50 FSHX DN65 DN125
Gallegg.
3/8” ½” 1” 1 1/4” 1 1/2” 2” Flangia Flangia Flangia
S29 G GCN GCN ●
S32 G GCN GCN ●
Tutti i tipi di galleggiante
S52S GCN ●
Tutti i tipi di filettatura
S52 GCN ●
S100 / ●
Filettature maschio Materiali disponibili DN = Materiali disponibili
G C N S S C
Gas cilindrico Gas conico conico AISI 316 AISI 316 Acciaio
UNI 228/1 UNI 7/1 NPT su richiesta
FLANGE Dimensioni in mm.
6 fori su A Attacco flangiato

∅60 mm A1 Attacco filettato
∅4,5 mm
FSHX DN = Flangie UNI – DIN – ANSI
CABLAGGIO ELETTRICO
USCITA INDICATORE
USCITA 4/20 mA USCITA 0/5 / 0/10 V
POTENZIOMETRICA USCITA 4/20 mA
R = 1K ÷ 15K Carico max. 500

In funzione della LM Alimentazione 18 ÷ 36 Vdc
LC LCT LCTV LCO
DIMENSIONI Quote in mm. Tab.4

Le quote L0 LM sono misurate a partire dalla battuta del raccordo (A1) o della flangia (A) di attacco.
Tolleranza sulle quote L0 LM + 3 mm.
S29 S32 S52 (S) S52 S100
A 15 15 25 35 50
A1 35 35 45 55
B 25 25 30 40 60
Tubo di calma −S −V
▬
su richiesta AISI 316 PVC
OPZIONE – Sensore di temperatura integrato

Solo per il tipo LC = su richiesta è possibile installare sul fondo dell’asta, all’interno dello strumento, un sensore di temperatura:
PT100 − PT1000 PTC NTC
EN 60751 − IEC 751 Resistenza a 25°C ≤ 500 E Resistenza a 25°C 2 5 10 50 100 KE
Classe B − A (a richiesta) Temperature 60°C ÷ 150°C Precisione ± 5% / ± 3% (a richiesta)
NOMENCLATURA
LC S52 10 1300 / 1400 S −S 50 G S W1 L 1,5 M
● Tipo: LC – LCT – LCTV / LCO
● Tab.1 Galleggiante
● Tab.1 Risoluzione di misura in mm.
● Tab.4 Lunghezza di misura LM / Lunghezza totale L0 in mm.
● Tab.3 Materiale dell’asta di misura
● Tab.4 Presenza e materiale tubo di calma (opzione)
● Tab.3 Dimensione attacco di processo
● Tab.3 Filettatura attacco di processo
● Tab.3 Materiale attacco di processo
● Tab.2 Uscita elettrica
● Tab.1 Classe di temperatura
● Tab.2 Lunghezza cavo (P1 P2) 1,5m / 3m, oltre a richiesta
Ci riserviamo il diritto di apportare modifiche e/o aggiornamenti senza preavviso B#177/1 04/2014
75
9.9 MANUALE TAPPO DI CARICO
IOM_14479_2 (09.16) Pages 42/59

Revisioni/Modifirations Rev.04 - Generai Revision l O.M. 3943 - 2110512009 - Z.A. l Questo documento e' di proprieta' della MP filtri S.p.A. - Senza autorizzazione scritta della stessa non potra' essere utilizzato per la
costruzione dell'oggetto rappresentato ne venire conunicato a terzi . La societa' proprietaria tutela i propri diritti a rigore di legge .
All proprietary rights reserved by MP filtri S.p.A.- This drawing shall not be reproduced, or in any way utilized, far the manufacture of the
component or unit herein illustrated and must not be released to other parties, without written consent. Any infringement will be legally pursued.
98 51
2
35
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9.10 SCHEDA TECNICA LIVELLO VISIO
IOM_14479_2 (09.16) Pages 43/59

VISUAL OIL LEVEL
S.r.l. DWG. 19.102.614/500/MFQ
REGGIO EMILIA 38.16
Technical features
Fluid viscosity range (cSt) 2.8 - 380

Fluid temperature range ( C) -55 +60
Mass
SCREW: INOX-A4-70
PIPE: Glass borosilicated
BLOCK AND PROTECTION: Stainless Steel AISI316
Seal material : MFQ
Dimension
25
370
500
550
500
50
40
25
M5
40
8
35
37
9.11 MANUALE POMPA
IOM_14479_2 (09.16) Pages 44/59

Bulletin HY30-3245-INST/UK
Installation and
start-up information
PV series
Design series ≥ 44, PVplus
Effective: October 05, 2011

Supersedes: September 07, 2011
Variable displacement
axial piston pump
Bulletin HY30-3245-INST/UK Axial Piston Pump
Installation Manual Series PV, series 44 and higher
Contents Page
1. Installation and start-up .............................................................................................................3

2. Displacement adjustment ...........................................................................................................6
3. Standard pressure compensator, code ...MMC ........................................................................6
4. Standard pressure compensator with D03 interface, code ...MM1 .........................................7
5. Standard pressure compensator for accessory mounting, code ...MMZ ...............................7
6. Remote pressure compensator, codes ...MRC, ...MR1 and ...MRZ .........................................8
7. Load sensing compensator, codes ...MFC, ...MF1 and ...MFZ .................................................8
8. Two spool load sensing compensator, codes ...MTP and ...MTK ...........................................9
9. Horse power compensator, codes ...*L*, ...*C* ........................................................................10
10. Compensator accessories .......................................................................................................11
10.1 Pressure relief pilot valve, code PVAC1P................................................................................11
10.2 Multiple pressure pilots PVAC1E..., PVAC2P..., PVAC2E... und PVAC2M... ...........................11
11. Trouble shooting guide .............................................................................................................12
Note: The compensator ordering code is represented by

the last three digits of the pump ordering code (digit 13 to 15).
Note
This document and other information from Parker Hannifin GmbH & Co KG, its subsidiaries, sales offices
and authorized distributors provide product or system options for further investigation by users having
technical expertise. Before you select or use any product or system it is important that you analyse all
aspects of your application and review the information concerning the product or system in the current
product catalogue. Due to the variety of operating conditions and applications for these products or sys-
tems, the user, through his own analysis and testing, is solely responsible for making the final selection
of the products and systems and assuring that all performance and safety requirements of the application
are met. The products are subject to change by Parker Hannifin GmbH at any time without notice.
2 Parker Hannifin
Pump and Motor Division
Chemnitz, Germany
1. Installation and start-up The suction pipe must have access to clean, cooled
For a safe and disruption free operation of any and filtered fluid, free of air bubbles. No turbulences
machine or system a careful installation and start or high flow velocities should occur at the tube inlet.
up according to the manufacturers instructions is Therefore position inlet as far as possible away from
mandatory. return line and drain line. Make sure that the fluid
Hydraulic systems can be designed for many totally circulation in the reservoir does keep return flow from
different functions and they require consequently suction pipe inlet. In case of positive head use shut
different start up procedures. The hydraulic pump off valve in the inlet, monitored with proximity switch
is in this respect only one, but nevertheless a very or equivalent to avoid start up of motor when valve
important component of the whole system. is closed. When installed into the reservoir use short
A general start up instruction therefore can give many suction pipe with pipe end cut under 45°.
helpful hints but it needs to be completed by specific
additions depending of the individual nature of the Pressure port
system or power unit. Select correct pressure rating for pipe, hose and con-
During installation and start up the following steps nectors. Take pressure peaks into account. Dimension
need to be carried out carefully: the piping according to the port size. Prevent excitation
of the system by using flexible port connections.
Visual inspection
Make sure that all components of the shipment are Drain port
complete, free of any damage, free of outside con- Always use highest possible drain port of the pump.
tamination and properly protected against ingression Drain port must be higher than pump centerline or
of contamination. install additional air bleed line. Never combine pump
drain line with other return lines and/or drain lines.
Cleanliness Pump shall not be able to run empty. Max. allowable
case pressure ≤0.5 bar (2 bar peak), also during
Contamination of any kind is the enemy of any hy-
compensation.
draulic component. It is still the number one cause
for component failure. Therefore maximum care and Use low pressure pipe/hose, as short as possible and
cleanliness are required during all handling and man- full cross section according to port dimension. Do not
aging of parts that come in contact with the hydraulic use elbows or sharp corners. When drain port is on the
fluid. All ports of the pumps and other components side of the pump drain line should have bridge higher
must be covered until pipes or hoses are mounted to than pump top (also when installed in reservoir). Drain
them. Perform assembly preferrably in a dry and dust pipe must end at least 200 mm below fluid level even
free room. Use only suitable tools. at lowest filling level. Never let drain flow go direct into
suction area of reservoir (temperature, air bubbles).
Max. length 2 m, otherwise use larger pipe diameter
Installation than port size.
Installation horizontal or vertical, avoid rigid connec- Note: During operation of PV pumps of all sizes under
tion from pump to reservoir cover or frame and to inlet the following conditions:
and outlet piping to prevent excitation of the whole
system due to pump vibrations. Q ~ Qmax
pinlet < 2 bar absolute
Poutlet < 25 bar
Suction port
(e. g. low pressure circulation) the drain flow can
Position to the side or to the bottom, max. fluid velocity
change direction. Fluid is taken from the case into the
approx. v = 1.0 m/sec, cut suction pipe inlet under 45°.
piston mainly through the decompression orifice and
Minimum distance from bottom 2 - 3 times diameter
across the slippers. There is a danger that the pump
and, even at lowest fluid level, approx. 200 mm below
case runs dry, the pump overheats and the bearings
fluid level. Inlet pressure, even during compensation,
lack of lubrication when the fluid is removed from the
never should drop below 0.8 bar (absolute).
pump case.
Absolute gas tight connection (risk of cavitation,
Therefore the drain pipe must be able to take fluid from
noise). Air bubbles due to vacuum in the inlet can
the reservoir. That means: The drain line must end
destroy pumps within a short time due to cavitation
below fluid level, and a check valve in the drain line
erosion. Suction pipe should be as short as possible.
is not permissible. If it has to be installed for whatever
Use only clean, low pressure pipe, avoid sharp elbows
reason the case needs to be flushed with a flow of
and any restriction of cross section.
10 - 15% of the nominal pump flow.
3 Parker Hannifin
Chemnitz, Germany
Port positions for PV (shown for clockwise rotation, for ccw rotation ports are mirrored)
L1 drain port interface for
compensator suction port (inlet)
adjustment screw
lock nut
alternative drain
port L3
case drain line

from drain port
bearing flushing port,

covered, below pump
gage port
pressure port (outlet)
alternative drain port L2
For side mounting (suction port facing down)

use alternative drain port 1 (cw rotation) or 2
(ccw rotation).
Flushing port bearing flushing

The PV pumps of design series 44+ are line to bearing main flushing line to
equipped with three drain ports*. In addition flushing port alternative drain port
pumps with seal option W and P, all pumps 1, 2
PV140 - PV360 and pumps with X-modification
X5830 (bearing flushing port) are equipped
with a flushing port for front bearing and shaft Alternative drain port
seal. The flushing flow can - depending on the Interface for Drain port
actual working conditions - be used to keep the compensator
pump case filled, to warm up the pump (during
cold temperature operation) or for better heat
dissipation e. g. for operation with HFC fluids
(water glycole) to keep the case fluid tem-
perature in the allowed range. Permanent dead
head operation ( >15 min) either for pumps of
frame size 3 and larger (PV063 and higher) or
at high input speeds above 1,800 rpm requires
flushing of the pump case.
Gage port
* PV016-092+PV270-PV360 DS45 Port L1 on
top ; L2,L3 at the side L4 at bottom (standard:
Flushing port,
PV270-360)
covered below Pressure port
pump (outlet)
* PV140-PV180-KS44 Ports L1/L2 at topside, Suction port
L3 at the bottom, L4 at the side (Standard) (inlet)
4 Parker Hannifin
Chemnitz, Germany
Flushing should be taken from the filter/cooling circuit Filling of the system
(e. g. pre-loaded return line). Recommended flushing Use only high quality mineral oil based fluids, like
flows see following table. HLP oils according to DIN 51524 part 2. For other
PV016 - PV028 4 - 6 l/min fluids (HFC, HFD, bio degradable or synthetic fluids)
PV032 - PV046, PV076 5 - 8 l/min please contact Parker and review the Hydraulic Fluids
PV063 - PV092 7 - 10 l/min Information in Catalogue 2500/UK.
PV140 - PV180 9 - 12 l/min Operation viscosity should be 16 to 100 mm²/s, op-
PV270 - PV360 13 - 17 l/min timum viscosity range is in the 20 to 40 mm²/s, max.
viscosity for short time up to 320 mm²/s.
(flushing flow for front bearing: 10 - 15% of the total
Because of the possibly uncompatible ingredients
flushing flow)
fluids should not be mixed (separation of fluid, reduc-
tion or loss of fluid properties).
Drive input
For direct drive use elastic coupling free of axial Pay highest attention on cleanliness!
and radial reaction forces. Please follow strictly the
Fill system only via a filtration device. Use filtration
instructions of the coupling supplier regarding axial
unit, when basic contamination of the refill fluid ex-
clearance, axial displacement and angular tolerances.
ceeds class 10 according NAS 1638 (contamination
Couplings never shall be mounted using a hammer.
level 21/19/16 according to ISO 4406). Hydraulic
Threads in the shaft end allow smooth mounting of
fluid supplied in barrels typically exceeds these con-
the coupling.
tamination levels.
The drive shaft should only carry true torque. Contact
Parker for allowable side loads or axial forces.
Filtration
PV pumps are normally for one direction of rotation Filtration is the most important factor to the opera-
only. Therefore check rotation of drive motor prior to tional life of the hydraulic system. Statistical analy-ses
installation. indicate, that contamination is by far the most impor-
tant reason for system or component failure.
Electrical interface Use return line, pressure and/or bypass filtration.
Check voltage, current, phase and connection proper- Bypass filtration usually is most efficient. For general
ties. Verify direction of motor rotation. purpose hydraulic systems with limited requirements
for operational life contamination level 19/15 accord-
Fluid reservoir ing to ISO 4406 should be desired; corresponding filter
The reservoir needs to meet all system requirements rating: x = 25 µm ( b25≥75 ) according to ISO 4572.
concerning design, size, location and porting. Beside Cleanliness level for systems with higher re-quire-
beeing reservoir for the hydraulic fluid, the tank also ments for operational life and functional safety should
supports heat dissipation, air removal, water removal be 18/16/13 according to ISO 4406; corresponding
and contamination sedimentation. Often the reservoir filter rating x = 10 µm ( b10≥75 ) according to ISO
also is the fundament for the motor pump unit. In this 4572.
case the separation of pump and remaining struc- Use filter with indicator or electrical signal when ca-
ture by elastic means is mandatory to avoid noise pacity limit is approached.
and vibration being induced into the frame work. The Suction filter should be avoided. Suction conditions
reservoir needs to be carefully sealed against ingres- will be affected. Filter can be blocked and cause
sion of contamination and water. A level indicator and cavitation and severe pump damage. When used, a
thermometer should be placed in an easily accessible vacuum sensor with shut off function is mandatory.
location.
Properly dimensioned breather rating ≤10 µm should
Fluid content (general rule): stationary systems 3 to be used. Observe min. and max. fluid level; consider
4 times pump nominal flow, 1 times or even smaller exchange volume with cylinders in the system.
in mobile systems.
Filling of pump case
Pump case must be filled via the drain port, to ensure
lubrication, sealing and smooth start up.
5 Parker Hannifin
Chemnitz, Germany
Start up
Minimum adjustable
Check if all ports are properly connected according
to the specification, all connectors are tightened and
change per turn

change per mm
(approx. cm³/U)
(approx. cm³/U)
(approx. cm³/U)
all adjustments are made.
Displacement
Displacement
displacement
Open suction valve (if installed)!
Switch system to free circulation or to lowest pressure.
Allow air bleeding for quick priming. Start pump in tip
mode operation until pump and all pipes are filled
and free from air bubbles. If pump does not build up Size
pressure, double check the installation.
PV016 1.5 1.5 9
Raise pressure setting only when all air is re-
moved. Let the pump work at reduced pressure for PV020 1.5 1.5 13
5 - 10 min, check if all pipes and connections are leak PV023 1.5 1.5 16
free and tight. PV028 1.5 1.5 20
Observe reservoir: fluid level, built up of foam, fluid PV032 2.2 2.2 17
temperature. When system is warmed up first func- PV040 2.2 2.2 25
tional tests can be performed. PV046 2.2 2.2 30
PV063 3.4 5.1 35
2. Displacement adjustment
PV076 2.2 2.2 40
All axial piston pumps of the PV series are equipped
with an adjustable displacement limiter. PV080 3.4 5.1 50
The servo piston stroke is limited at full displacement PV092 3.4 5.1 65
by a screw, guided in the end cover plug of the servo PV140 5.6 8.4 20
piston bore. The screw is protected against uninten- PV180 5.6 8.4 60
tional adjustment by a self-sealing lock nut (see figure PV270 6.8 10.2 120
on page 4). PV360 8.6 12.9 180
The factory setting of the displacement is according to
the nominal displacement of the pump. An adjustment
may only be made to a lower displacement (turning 3. Standard pressure compensator, code ...MMC
screw in). An adjustment to a higher than the nominal The adjustment of the compensating pressure is
displacement can destroy the pump. performed for the standard pressure compensator
Adjustment should only be made with the pump work- directly at the compensator.
ing at full displacement (not compensated) and at a To adjust the pressure, the lock nut (SW 13) is to be
low output. At full displacement the piston area of the loosened and the adjustment spindle is to be turned
servo piston is under case pressure. Opening the (screw driver).
self-sealing nut will only cause a negligible leakage
Turning clockwise will increase the compensating
under these conditions.
pressure, turning counter-clockwise will decrease the
Turning the adjustment screw clockwise will reduce compensating pressure.
the pumps displacement. For the sizes PV016 –
The compensating pressure can be adjusted in a
PV092 the thread pitch is 1mm, for sizes PV140 –
range from 15 to 350 bar (approx. 100 bar/turn).
PV360 the thread pitch is 1.5 mm. The table shows
the displacement change per mm resp. per turn and By turning the pressure pilot cartridge housing the
the minimum adjustable displacement. compensator differential can be adjusted. It is factory
set to 15±1 bar and should not be changed (approx.
Note: All pumps are adjusted and tested after as-
20 bar/turn).
sembly in our factory. Only the compensator pressure
needs to be adjusted. That is done on the pilot valve Different compensator differential settings can cause
spindle. No other adjustments on the compensator instability or excessive power losses.
or the pump is required. Only after service or repair By using adapter kit PVCMCK** the standard pres-
a basic adjustment needs to be performed. sure compensator can be made remote controllable.
This adapter replaces one of the side plugs. Adapt-
ers are available for G1/4, M12x1.5 ISO 6149 and
7/16-20 UNF.
See also the remarlks in chapter 6.
6 Parker Hannifin
Chemnitz, Germany
compensator differential Please note: when mounting accessories (e. g.:

adjustment proportional pressure pilot valve) or external (remote)
control the integrated pilot valve first must be turned
lock nut in to avoid too early pressure limitation.
5. Standard pressure compensator for accessory

mounting, code ...MMZ
interface NG6 compensator differ-
DIN 24 340 ential adjustment
lock nut
lock nut
pressure
adjustment
4. Standard pressure compensator with D03

interface, code ...MM1
interface NG6 compensator differential
DIN 24 340 adjustment
lock nut Version ...MMZ is designed especially for compen-
sator accessory mounting (ordering code PVAC...,
see chapter 12).
Because the accessory packages come with their
own pilot valves, this version has no integrated pilot
catridge to avoid unwanted interaction.
For more details on the different compensator options
see also the PV compensator spare parts manual for
compensator design 45, Parker bulletin PVI-PVC-
45-GB.pdf.
lock nut
pressure Note:
adjustment Checking and adjusting the compensator differential
should always be done by using two pressure sen-
The standard pressure compensator code ...MM1 has sors/gages. Measuring one pressure only (pump
topside an NG6/Cetop 3/NFPA D03 interface for the outlet pressure) and assuming, that the pilot pres-
mounting of suitable pilot valves. This compensator sure at fully unloaded pilot valve resp. with unload
can for example be directly equipped with a propor- proportional pilot valve is 0 bar can lead to completely
tional pressure pilot valve for electrical pressure set- wrong adjustments.
ting (ordering code ...MMK, see figure on page 9). The different pilot valves can cause even at the
The pilot valve must be capable of pilot flows of ap- nominal pilot flow (1,2 - 1,4 l/min) already significant
prox. 1,2 l/min. Therefore a nominal flow range of back pressures which add to the compensator dif-
3 - 6 l/min is recommended. A too small as well as a ferential.
too large pilot valve can lead to unsatisfactory com- Only if the pilot pressure chamber is completely un-
pensator performance. loaded (e. g.: when one of the side plugs is removed or
In addition the compensator can be equipped with a the DCV is in stand-by mode) it can be assumed, that
directional control valve for stand-by (unloading) func- the pilot pressure is zero and pump outlet pressure is
tions (ordering code ...MMW, see figure on page 9). equal to the compensator differential setting.
7 Parker Hannifin
Chemnitz, Germany
6. Remote pressure compensator, codes ...MRC, 7. Load sensing compensator, codes ...MFC,
...MR1 and ...MRZ ...MF1 and ...MFZ
compensator differential The load sensing or flow compensator primarily
adjustment controls the pump output flow. To achieve this the
load pressure after a main stream throttle valve (load
lock nut sensing valve, not included in the shipment of the
pump) is connected to the load sensing port of the
compensator. The compensator control strategy is,
to keep the pressure drop constant across this main
stream throttle valve.
The integrated pilot valve maintains a pressure
compensation when the adjusted max. pressure is
reached. The pilot orifice Ø 0,8 mm is located in the
load sensing port adapter. This orifice replaces the
remote control port orifice in the control spool of the ...MM* and ...MR*
lock nut compensators, because pilot pressure is in the load
compensator pressure sensing compensator provided through the load
adjustment sensing line.
The remote pressure compensators code ...MR* compensator differential

are equipped with a remote control port. To this port adjustment
external pilot valves can be connected. The distance lock nut
between pump and pilot valve can be up to 15 m.
The pilot line should be designed, to avoid pressure
losses.
Especially at low environmental temperatures a too
narrow pilot line can result in a significant pressure
increase. The nominal pilot flow is in the range of
1.2 to 1.4 l/min.
Beside the version shown above (code ...MRC) also
a version ...MR1 with a topside NG6 / D03 interface is load sensing port
available as well as a version ...MRZ without integrated lock nut
pilot valve for the use with compensator accessories compensator pressure
code PVAC... . adjustment
For the compensators with code ...MM* and ...MR* the
pilot pressure pressure supply is maintained through Load sensing and pressure compensators only dif-
an orifice located in the control spool. ferentiate by the control spool and by the location of
the pilot orifice.
Beside the version shown above (code ...MFC) also
a version ...MF1 with a topside NG6 / D03 interface
is available as well as a version ...MFZ without inte-
pressure control spool pilot chamber grated pilot valve for the use with compensator ac-
cessories code PVAC... .
The following port options are available for remote
pressure and load sensing compensators:
thread and port thread

port code dimensions
1 G 1/4 BSPP
pilot orifice integrated pilot valve
3 7/16-20 UNF
7, 8 M12 x 1,5 ISO 6149-1
8 Parker Hannifin
Chemnitz, Germany
The length of the load sensing line can be up to 15 m. 8. Two spool load sensing compensator, codes
If the line is longer than 5 m it has to be considered, ...MTP and ...MTK
that low environmental temperatures and high fluid
viscosity can have a negative influence to the com- interface NG6, DIN24 340 load sensing
pensator performance. for pilot valve port
The line should be designed to avoid any significant
pressure drop. pressure control
Factory setting for the load sensing pressure differ- stage
ential is 10 bar ± 1 bar. This adjustment should only
be changed in exceptional cases.
The adjustment is possible by turning the pilot valve
housing after loosening the lock nut.
Please refer to the setting instructions on page 7.
All compensators described in chapters 3 - 6 can be
shipped with a directional control valve for stand-by flow control stage
operation (compensator codes ends with..W) or with
a proportional pilot valve for electrical pressure adjust-
ment (compensator code ends with ..K) The two spool compensator, code ...MT* has two
separate compensator valves for flow (load sensing)
and pressure compensation.
That results in a steeper pressure compensation
curve, which can be beneficial in certain applica-
tions.
The flow control stage has no integrated pilot valve,
because this would eliminate the effect of the two
spool control. The pressure stage has no integrated
pilot valve, because during flow control the T port of
the pressure compensator is under control pressure.
This would prevent the pilot valve from opening.
With the adapter kit PVCMCK.. the pressure compen-
sator can be made remote controlled.
On the topside interface any pressure pilot valve can
Compensator code ...MMW with directional control be mounted. See chapter 3 for requirements.
valve code D1VW2K*JW for stand-by operation The factory setting of the flow compensator is
(24 VDC, normally open) 10 ± 1 bar, the adjustment for the pressure compen-
sator is 15 ± 1 bar. These adjustments should not be
modified.
If different adjustments are required by the system or
by the load sensing valves used in the system, see
page 7 for setting instructions.
With ordering code ...MTP a manual adjustable pres-
sure pilot valve code PVAC1PM*S35 is mounted on
the elbow manifold.
With ordering code ...MTK a proportional pilot valve
code PVACRES-*35 is mounted on top. For electronic
pressure control a suitable power amplifier is required.
We recommend the digital modules PCD00... supplied
by Parker HCD.
Because the two spool compensator has no integrated
Compensator code ...MMK with proportional pressure pilot valves, for a stand-by function the compensator
pilto valve code PVACRES-*35 accessory PVAC1EM*C**35, including a directional
control valve and a pilot section, is required.
9 Parker Hannifin
Chemnitz, Germany
9. Horse power compensator, codes ...*L*, ...*C* compensator pilot cartridge

valve
Depending on its type, the horse power compensator
consists of a remote pressure compensator or a load
sensing compensator in combination with the horse
power pilot cartridge. The opening pressure of this
pilot cartridge depends on the actual displacement
of the pump. At large displacements the opening
pressure is low. As the displacement is reduced the
opening pressure is increased according to the form
of the contour sleeve in the pump. That leads to the
desired control characteristic (constant input horse
power).
That is achieved by having the pilot cartridge seat be-
ing guided by the contour sleeve. This contour sleeve
is firmly connected to the servo piston. The contour
represents the desired input horse power.
The horse power pilot cartridge is internally con-
nected to the compensator valve. Compensator valves
for horse power compensated pumps differ from contour sleeve
standard compensator valves only in the fact, that a Partial section through a horse power controlled
plug in a connecting hole is removed. pump
For a standard horse power compensator with order-
ing code ...*L* a modified remote pressure compen- adjustment spindle
sator is used. For a horse power compensator with
load sensing, code ...*C* a modified load sensing lock nut
compensator is used.
Constant horse power curve with adjustment
Horse power pilot cartridge

At the adjustment screw of the horse power pilot valve
a basic adjustment of the horse power compensator
can be made. After loosening the lock nut (self seal-
ing nut) the compensator control curve can be moved
by turning the adjustment screw (adjustment A in
the diagram left). This adjustment, done to meet the
required constant input horse power curve, is already
made during the factory test and should be modified
only in exceptional cases.
To adjust the correct constant horse power curve
a measuring device is required. An output power
measurement requires pressure and flow metering.
An input power measurement requires torque and
speed measurement or a measurement of the electric
motor current.
Adjustment A: tolerance compensation for optimized Note: For horse power control the load sensing dif-
performance; done at pilot cartridge. ferential is set to 15 ± 1 bar. Any change will result in
Adjustment B: maximum pressure setting; done at a deviation from the horse power setting.
integrated pressure pilot valve. Note: The setting is very sensitive, 0,1mm change
of the spindle changes the pressure approximately
20 bar.
10 Parker Hannifin
Chemnitz, Germany
10. Compensator accessories nected to the compensator valve. The lower pressure
10.1 Pressure relief pilot valve, code PVAC1P... defines the compensating pressure of the pump.
When the A solenoid (B-side) of the DCV is energized
The pressure relief pilot valve code PVAC1P... is opti- only the A-side cartridge is connected; the (higher)
mally tuned for the requirements of the compensator pressure adjusted there defines the compensating
valves of the series PV. It has a mounting interface pressure.
NG6 according to DIN 24340 and can be mounted
directly on top of all compensator valves with the When solenoid B is energized the valve spool con-
topside mounting interface. nects all four ports. Then the spring chamber of the
compensator valve is directly relieved to the case drain
Such a valve is only necessary for the compensators of the pump, the pump compensates at minimum
with elbow manifold (...MT1 and ...UPR) and for the compensating pressure (stand-by).
versions without integrated pressure pilot cartridge
(compensator code ends with..Z). Al other versions The directional control valve series D1VW has spool
include an integrated pilot valve. code 55. This spool code is used to avoid a blocked
spool position during transient.
lock nut This version is recommended, when during a ma-
chine cycle the pressure is to be switched between
set screw high and low.
For code PVAC2M... also a dual solenoid valve is
used. In neutral position all four ports are connected.
The compensator spring chamber is releived to case
drain, the pump is compensating at min. compensat-
ing pressure (stand-by).
After loosening the lock nut SW13 an adjustment of When energizing solenoid A (B-side) the spring
the compensating pressure for the pump is possible chamber is connected to the A-side pilot cartridge;
in a range of approx. 20 bar up to 350 bar. the pressure adjusted here controls the pump.
The pressure pilot valve is also available with a DIN When solenoid B is energized the spring chamber
lock. of the compensator is connected to pilot cartridge B;
then the pressure adjusted on this cartridge defines
10.2 Multiple pressure pilots PVAC1E..., the pump compensating pressure. The DCV of series
PVAC2P..., PVAC2E... und PVAC2M... D1VW has spool code 2.
For multiple pressure pilots, codes PVAC2P..., This version should be used, when stand-by operation
PVAC2E... and PVAC2M... a sandwich valve with should be the default situation.
two direct-action pressure cartridge valves is used Code PVAC1E... is similar to code PVAC2P..., with the
to pilot the pump. exception, that only one pilot cartridge is installed. In
neutral position of the D1VW the stand-by pressure
is selected.
Additional information can be found in:
compensator spare parts manual PVI-PVC-UK-
45 compensator accessories spare parts manual
PVI-PVAC-UK
pumps spare parts manuals PVI-***-UK-45 with *** =
For code PVAC2P... a single solenoid directional BG1 to BG5 according to pump frame size.
control valve is included for pressure selection. The p1 (>p2)
valve switches between low pressure setting and p1 p1
high pressure setting. During low pressure both pilot
cartridges are connected to the compensator, in the
high pressure setting (solenoid energized) only the p2 p2
A-side cartridge is connected. Therefore the B-side
pilot needs to be set for lower pressure. The directional
control valve series D1VW has spool code 6. A B A B A B
For code PVAC2E... for pressure selection a two- so-

lenoid DCV is included, which selects between low P T P T P T
pressure setting, high pressure setting and stand-by P T P T P T P T P T

pressure. In neutral position both cartridges are con- PVAC1P... PVACPP PVAC1E... PVAC2P... PVAC2M...
(PVAC2E...)
11 Parker Hannifin
Chemnitz, Germany
11. Trouble shooting guide
Pump delivers no output flow.

Drive motor does not turn.
Reason Motor is not connected correctly or one of the three phases has failed. Motor does not
turn smoothly when pump is disconnected from pump.
Solution Check motor connections, check electrical power supply.
Reason Pump mechanically blocked. Motor turns smoothly when disconnected from pump.
Solution Send pump to factory for service.
Drive motor only turns at slow speed.
Reason Motor is not selected properly. In star circuit not enough torque.
Solution Start pump at unloaded system. Use motor with more horse power.
Reason Pump is hydraulically blocked. No function of compensator, no pressure relief valve.
Pump stops after e few turns.
Solution Check function of pump compensator (see below). Start pump at unloaded system.
Drive motor turns, pump does not turn.
Reason Coupling is not or not correctly mounted.
Solution Check coupling assembly and correct it.
Drive motor turns and pump turns.
Reason Wrong direction of rotation.
Solution Change direction of motor rotation.
Reason Fluid reservoir empty or not filled to level, suction line ends above fluid level.
Solution Fill reservoir to required level, if necessary increase suction pipe length.
Reason Suction line is blocked. E. g. by plugs, cleaning tissues, plastic-plugs. Ball valve in the
suction line closed. Suction filter blocked.
Solution Check suction line for free flow. Open valves in suction line. Valves should be equipped
with electrical indicator. Check suction filter.
Reason Suction line not gas tight, pump gets air into suction port.
Solution Seal suction line against air ingression.
Reason Pressure line / system is not able to bleed air out.
Solution Unload pressure port, unload system before start, bleed air from pressure line.
Pump does not build up pressure, but delivers full flow at low pressure.
Reason Standard pressure compensator is set to minimum pressure.
Solution Adjust compensator setting to desired pressure.
Reason Orifice in remote pressure compensator blocked.
Solution Make sure orifice Ø 0.8 mm in control spool is free and open.
Reason No pressure pilot valve connected to port PR.
Solution Install suitable pressure pilot valve and adjust it to the desired setting.
Reason Multiple pressure pilot selector valve is not energized. Pump works in stand-by.
Solution Energize selector valve solenoid.
Reason No load sensing line connected.
Solution Connect system load sensing port to compensator.
Reason Load sensing valve is closed or too small.
Solution Open load sensing valve, use larger valve size.
Reason Too much pressure drop between pump and load sensing valve.
Solution Make sure connection is wide enough and has not too much pressure drop.
Reason Differential pressure at compensator is adjusted improperly (too low).
Solution Check differential pressure adjustment and correct it as described above.
12 Parker Hannifin
Chemnitz, Germany
Reason Horse power compensator setting changed.

Solution Check setting of horse power compensator and correct it, if required.
Reason Proportional displacement control is not connected as required.
Solution Check wiring; connect according to installation manual for electronic module.
Reason Displacement transducer (LVDT) adjustement changed.
Solution Correct zero setting at displacement transducer.
Reason Electronic module has no supply power.
Solution Make sure module is powered with 22 - 36 V DC.
Reason Plug instead of orifice Ø 0.8 mm in the load sensing line to pump.
Solution Install orifice as required.
Reason Cylinder block lifts from valve plate due to excessive wear.
Solution Send pump to factory for service.
Pump does not compensate.
Reason No orifice is in load sensing line to compensator code FFC.
Solution Install orifice Ø 0.8 mm as shown in circuit diagram (page 8).
Reason No pressure pilot valve connected to compensator or valve is blocked.
Solution Connect pressure pilot valve to compensator, make sure valve opens as required.
Reason Load sensing line connected incorrectly (e. g. upstream of load sensing valve)
Solution Connect load sensing line downstream (actuator side) of load sensing valve..
Reason No or too low pressure at pump outlet port.
Solution Pump outlet pressure must be at least 15 bar, because otherwise the bias spring in the
pump cannot be compressed.
Pump does not upstroke, sticks at zero displacement.
Reason Compensator is blocked due to contamination.
Solution Clean hydraulic fluid, clean compensator valve.
Reason Cable to LVDT or proportional solenoid is interrupted.
Solution Check wiring and make sure cable is ok. Replace if necessary.
Compensator is unstable.
Reason Compenstor spool sticks, due to contamination of hydraulic fluid.
Solution Clean hydraulic system, clean compensator valve.
Reason Compensator differential pressure changed (too low or too high).
Solution Adjust compensator differential pressure to required setting.
Reason Wrong pilot orifice or pressure pilot valve improperly selected.
Solution Select pilot orifice and pressure pilot valve as recommended.
Reason Dynamic critical system, e. g.: pressure compensator combined with pressure reducing
valve, load sensing (flow) compensator combined with flow control valve.
Solution Use remote pressure compensator instead of standard pressure compensator, install
orifice in load sensing line remote from compensator (as close as possible to load sens-
ing valve).
For additional questions, your need of spare parts or in
case of service needs please contact:
Parker Hannifin Manufacturing Germany GmbH & Co KG
Neefestr. 96
09116 Chemnitz
Tel.: +49-(0)371 / 3937-0
Fax: +49-(0)371 / 3937-488
Internet: www.parker.com
13 Parker Hannifin
Chemnitz, Germany
Position notification regarding Machinery Directive 2006/42/EG:
Products made by the Pump and Motor Division (PMD) of Parker Hannifin are excluded
from the scope of the machinery directive following the “Cetop” Position Paper on the
implementation of the Machinery Directive 2006/ 42/ EC in the Fluid Power Industry.
All PMD products are designed and manufactured considering the basic as well as the
proven safety principles according to:
•฀ SS฀EN฀ISO13849-2:2008-09,฀C.2฀and฀C.3฀and,฀
•฀ SS฀EN฀982+A1:2008,฀
so that the machines in which the products are incorporated meet the essential health and
safety requirements.
Confirmations for components to be proven component, e. g. for validation of hydraulic

systems, can only be provided after an analysis of the specific application, as the fact to be
a proven component mainly depends on the specific application.
Dr. Hans Haas

General Manager Pump and Motor Division Europe
Chemnitz, Chomutov, Trollhättan, Kingswinford
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
Please contact your Parker representation for a detailed ”Offer of Sale”.
Parker Hannifin HY30-3245-INST/UK

Manufacturing Germany GmbH & Co KG
Pump and Motor DivisionK
Neefestr. 96
D 09116 Chemnitz
Tel.: +49-(0)371-3937-0
Fax: +49-(0)371-3937-488
www.parker.com
Copyright  2010
by Parker Hannifin GmbH & Co KG
TABLE OF CONTENTS
PAGE
CHAPTER 1 INTRODUCTION ................................................. 1
CUSTOMER SERVICE............................................................ 3
OTHER CONFIGURATIONS.................................................. 3
CHAPTER 2 INSTALLATION .................................................. 4
MOUNTING ............................................................................. 4
PROCESS CONNECTIONS .................................................... 5
PROCESS MEDIA ................................................................... 6
POTENTIALLY EXPLOSIVE ATMOSPHERES
(HAZARDOUS LOCATIONS) ................................................ 6
ELECTRICAL CONNECTIONS ............................................. 7
CHAPTER 3 ADJUSTMENTS AFTER INSTALLATION ....... 8
SETPOINT ADJUSTMENT ..................................................... 8
CHAPTER 4 TROUBLESHOOTING ........................................ 9
CHAPTER 5 SPECIFICATIONS ............................................. 11
STANDARD ........................................................................... 11
OPTIONS ................................................................................ 14
WARRANTY INFORMATION ................................................. 15
Page ii Installation and Operation Manual

9.12 MANUALE PRESSOSTATO
IOM_14479_2 (09.16) Pages 45/59


NEO-DYN
MODEL 162P
ADJUSTABLE DIFFERENTIAL PRESSURE SWITCHES;
FOR EXPLOSIVE ATMOSPHERES
I N ST ALLAT I ON AN D
OPERAT I ON M AN U AL
PN 610-0016 Rev D
Manual No. 610-0016 Rev D
Neo-Dyn
28150 Industry Drive
Valencia, CA 91355
Tel: (661) 295-4000
Fax: (661) 294-1750
World Wide Web: www.neodyn.com
Copyright 2002
ITT Industries
Im p o rta nt Info rm a tio n

The product warranty applicable to this ITT Neo-Dyn® instrument
is as stated on page 15 of this manual.
Should any after-delivery problems arise, please contact
ITT Neo-Dyn’s Customer Service using the information above.
Our normal business hours are weekdays, 7:00 am to 3:30 PM,
Pacific Time.
Before installing this Pressure Switch, become familiar with the
installation and adjustment instructions in Chapters 2 and 3.
WARNING Indicates a hazard which can cause severe personal injury,
death, or substantial property damage if the warning is
ignored.
CAUTION Indicates a hazard which will or can cause minor personal injury
or property damage if the caution is ignored.
NOTE Indicates additional information about a particular item necessary
to the operation of the unit.
SPECIAL The Electrical Snap Switch Assemblies shall be installed such that
CONDITIONS the equipment wiring is protected from mechanical damage by the
FOR SAFE USE
use of metal conduit or a method providing equivalent protection.
The equipment wiring must not be subjected to tension or torque.
If it is to be terminated within a potentially explosive atmosphere,
a suitably certified termination facility must be used.
This document contains proprietary information, which is the

property of Neo-Dyn, a unit of ITT Industries. This document
may not be reproduced, either in part or in full, without the
consent of ITT Industries.
Enclosure 6N Pressure Switches Pagei
C HA PTER
1
INTRO DUC TIO N
The Neo-Dyn® Enclosure 6N Switches described in this manual

are weather and explosion-proof, electromechanical sensing
devices designed for a wide range of applications in pneumatic
and hydraulic systems up to 5,000 psig, and for use in Zone 1
Potentially Explosive Atmospheres (Division 1 hazardous
locations).
Wetted materials include a polyimide (Kapton) sensing
diaphragm, nitrile O-ring, corrosion resistant steel (CRES) and
helical springs of either zinc plated steel music wire or CRES.
Wetted material 1 switches also contain aluminum alloy materials.
Setpoint adjustments are easily made through the adjustable range
by turning an external adjustment nut shown in figure 1.
The standard configuration of these switches will switch up to 11 amp
at 125 or 250 VAC, 5 amp resistive at 28 VDC, or 0.5 amp
resistive at 125 VDC. When ordered with M Option, the switch is
rated for currents to one amp, but its bifurcated gold contacts will
reliably switch currents in the milliampere and microampere ranges.
These switches have CE Mark, weatherproof enclosures with IP
66 ingress protection and meet the requirements of NEMA 3. 3R,
3S, 4, 4X and 13. The electrical subassemblies are approved by
Underwriters Laboratories, FM, CSA International and ATEX.
Enclosure 6N Pressure Switches Page 1

Figure 1: Models 162P:
Adjustable Differential Pressure Switches
Dimensions are in inches
Chapter 5 on page 11 contains complete specifications for these

Adjustable Pressure Switches.
Page 2 Installation and Operation Manual

CUSTOMER SERVICE
If you have any questions about these Differential Pressure
Switches that are not covered in this manual, you can contact
Neo-Dyn or our representatives in several ways.
The Neo-Dyn customer service phone number is
(661) 295-4000. Our customer service department is open
from 7:00 am to 3:30 p.m. Pacific Time.
Our Internet site is www.neodyn.com; it includes lists of
sales representatives and distributors.
OTHER CONFIGURATIONS
WARNING The models described in this manual are also available in special
and factory-set configurations. For these units, follow the
installation and operating instructions herein, except adhere to
the pressure and electrical limits marked on the units.

C HA PTER
2
INSTA LLA TIO N
Installation of these Neo-Dyn® Enclosure 6N pressure switches is

straightforward. However, they must be installed by a qualified
electrician, in compliance with all local and national electrical
codes.
WARNING Electrical Hazard
WARNING Do not make electrical connections while power is on.
WARNING Always check for multiple circuits.
WARNING Always make sure grounding is adequate.
MOUNTING
The Pressure Switch can be mounted directly to the process
connections if there is no significant vibration and the fluid lines
are capable of supporting the weight. It can also be attached to a
flat surface, such as a wall or panel, using ¼-20 UNC screws into
the mounting holes shown in Figure 1. The holes are .25 inches
deep. Do not over tighten the screws.

PROCESS CONNECTIONS
The process connections are ¼” - 18 NPT female.
When installing the Pressure Switch, always:
 Make sure that the unit and your system have matching threads.
 Use the wrench flats provided.
 Seal all joints with pipe joint sealing compound.
CAUTION Avoid excessive torque on all threaded connections.
WARNING Do not exceed the marked Maximum Operating Pressure in
normal operation.
The marked Proof Pressure is provided to give the maximum
allowable pressure without causing permanent damage to the
pressure switch in the event of an over-pressure condition. Set
pressure relief/safety valves below this setting.

PROCESS MEDIA
Process media must be compatible with the wetted materials listed
in Chapter 5 starting on page 12. Compatibility is defined by an
“A” rating in the Chemical Resistance Guide for Metals and
Alloys, the Chemical Resistance Guide for Plastics, and the
Chemical Resistance Guide for Elastomers, all published by
Compass Publications, and available from the National
Association of Corrosion Engineers (NACE), Houston, Texas;
telephone 281 228-6200.
POTENTIALLY EXPLOSIVE ATMOSPHERES

(HAZARDOUS LOCATIONS)
Suitable for Zone 1, EEx d IIC explosive atmospheres, in
accordance with Potentially Explosive Atmospheres Directive
94/9/EC (ATEX)
Suitable for Division 1; Class 1, Groups A, B, C and D; Class II,
Groups E, F and G hazardous locations, in accordance with the
National Electric Code (NEC), and applicable UL, FM and CSA
specifications.

ELECTRICAL CONNECTIONS
Figure 2. Form C and CC schematics shown
below the decreasing setpoint.
18 AWG free leads 18 in (46 cm) long are standard, with a green
wire grounded to the case. 72 inch (183 cm) leads are available as
R Option, and other lead lengths may be ordered as special
configurations. The leads are intended for installation in conduit
capable of withstanding possible explosion pressures, and the
leads are factory sealed.
WARNING All field wiring must comply with requirements of the NEC or
applicable local or national electrical codes, including wire
gauges and insulation temperature ratings. Conduit seals may
be required.

C HA PTER
3
A DJUSTM ENTS A FTER
INSTA LLA TIO N
The factory-set setpoint or adjustable setpoint range is marked on

the nameplate of the switch. This section describes the
adjustments needed after an Adjustable Pressure Switch has been
properly installed.
SETPOINT ADJUSTMENT
Disconnect the electrical power. Check for multiple circuits.
1. Check the setpoints per paragraphs 3 and 4 below for precise
adjustments.
2. The adjustment nut (See Figure 1)can be rotated with an
open-end wrench or similar tool.
3. To check the increasing setpoint of these switches, connect a
pressure source and a calibrated differential pressure gauge or
transducer to the pressure ports and apply the system pressure
to both sides. Slowly apply increasing pressure to the “high
side” port until the switch actuates. Actuation can be noted by
listening to the audible snap of the Belleville spring, or with
an ohmmeter across the appropriate free leads.
4. To check the decreasing setpoint, follow step 3 above, then
slowly lower the pressure on the high side and note the value
at which the audible snap or an ohmmeter indicates
deactuation. Deadband may be calculated if desired by
subtracting the decreasing setpoint reading from the
increasing setpoint reading.

C HA PTER
4
TRO UBLESHO O TING
In-service problems are unlikely, but the following paragraphs

suggest ways to verify any problems that might arise:
1. Pressure Switch Leaks
If a leak is suspected, isolate the pressure switch from the rest
of the system. Connect the switch and a calibrated pressure
gauge downstream from a pressure source and shutoff valve.
Apply normal system pressure, isolate the gauge and Pressure
Switch from the pressure source with the shutoff valve for at
least one minute, and check for leaks as evidenced by a drop
in the gauge reading.
If a leak is verified, return the unit for repair. Contact ITT
directly, or your local sales representative or distributor (see
www.neodyn.com for a contact list).
2. Failure to Switch
If application of pressure 10% greater than the adjusted
setpoint fails to produce actuation, first check for
contamination in the process connection, and verify that the
expected pressure is reaching the sensing diaphragm.
If the Belleville spring can be heard to audibly snap, but an
ohmmeter indicates no electrical switching, the cause is
probably stuck or burned switch contacts, or the switch
element has moved away from the position where it was
synchronized with the snap action. Return the unit for repair.

If application of pressure 10% greater than the adjusted
setpoint fails to produce an audible snap of the Belleville
spring, there is probably a mechanical failure or binding due
to contamination. Return the unit for repair.
3. Calibration Shifts
If it is suspected that the setpoints have shifted, recheck them
per paragraphs 3 and 4 of Chapter 3. If you verify unstable or
drifting setpoints, return the unit for repair.

C HA PTER
5
SPEC IFIC A TIO NS
This section shows standard specifications and available options.

STANDARD
Interfaces
Weight: approximately 3 pounds (1.4 kg) each; 4 pounds (1.8 kg)
with the H option.
Conduit Connection: ½” - 14 NPT male
Pressure Ports: ¼” – 18 NPT female
Listing Agency Approvals
Switch Subassemblies UL, FM and CSA and SIRA (ATEX)
listed
CE Mark; Conforms with Council Directive: 94/9/EC and
97/23/EC.

Part Number
The part number contains information about which configurations
and options are included in your Adjustable Pressure Switch. To
determine the pressure range, electrical rating, and options,
compare the part number of your unit with the information in
Figure 3 below and the following tables.
162P 1 2 CC 6 BN
Model Series Options
Wetted Material Explosion-Proof Elec.
Range Number Elec. Form (C or CC)
Figure 3. Part Number Breakdown
NOTE Part number format varies for specials.
Wetted Materials
Table 1
No Description
1 Aluminum alloy port, teflon-coated polyimide (Kapton)
diaphragm and nitrile O-ring, CRES and zinc plated steel
music wire springs
4 UNS S31600 CRES port, teflon coated polyimide diaphragm and
nitrile O-ring and CRES springs
Pressure Ratings
Maximum Operating Pressure: 5000 psig (344.7 Bar)

Proof Pressure: 2500 psig (172.4 Bar) high over low or low over
high.

Weather Proof Ratings
Ingress protection IP66
Enclosure type 3, 3R, 3S, 4, 4X, 13 (NEMA)
Temperature Ranges for Pressure Media

Standard (Nitrile O-rings): -40°C (-40°F) to +121°C (+250°F)
C Option (EPR O-rings): -40°C (-40°F) to +121°C (+250°F)
B Option (Viton O-rings): -26°C (-15°F) to +121°C (+250°F)
Electrical and Ambient Temperature Ratings

Minimum ambient temperature is -40 °C (-40 °F), except with
B Option O-rings it is -26°C (-15°F)
Form C6N (SPDT):
11 amp @ 125 or 250 VAC to +75 °C (+167 °F) max, T5;
5 amp @ 125 or 250 VAC 5; amp resistive , 3 amp inductive @
28 VDC; .5 amp resistive, .04 amp inductive @ 125 VDC to
+70 °C (+158 °F) max, T6.
Form CC6N (DPDT):
11 amp @ 125 or 250 VAC to +65 °C (+149 °F) max, T4A;
5 amp @ 125 or 250 VAC; 5 amp resistive , 3 amp inductive @
28 VDC; .5 amp resistive, .04 amp inductive @ 125 VDC to
+70 °C (+158 °F) max, T6.
Form C6MN or CC6MN (SPDT or DPDT with M Option):
1 amp @ 125 VAC to +70 °C (+158 °F) max. T6

OPTIONS
The available options for standard switches are listed below.
These options can be combined; every included option will be
indicated in the part number of the unit.
Table 2
Option Description
A Epoxy-painted exterior
B Viton O-Ring - Refer to Wetted Materials
C EPR O-Ring - Refer to Wetted Materials
H Stainless Steel housing (standard with
Wetted material 4)
M Gold Electrical Contacts For Extremely Low
Current Applications
N CE mark
R 72 inch (183 cm) leads

W A RRA NTY INFO RM A TIO N
A. Warranty:
ITT Industries (ITT) warrants that at the time of shipment, the
products manufactured by ITT Neo-Dyn and sold hereunder, will
be free from defects in material and workmanship and will
conform to the specifications furnished or approved by ITT.
B. Warranty Adjustment:
If any defect within this warranty appears, the Buyer shall notify
ITT immediately.
ITT agrees to repair or furnish a replacement for, but not install,
any product which, within one (1) year from the date of shipment
by ITT shall, upon test and examination by ITT, prove defective
within the above warranty.
No product will be accepted for return or replacement without the
written authorization of ITT. Upon such authorization, and in
accordance with instructions by ITT, the product will be returned
with shipping charges prepaid by the Buyer. Replacements made
under this warranty will be shipped prepaid.
C. Exclusion from Warranty:
THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES
ALL OTHER EXPRESSED OR IMPLIED WARRANTIES OF
MERCHANTABILITY, OR FITNESS, OR OTHERWISE.
Components manufactured by any supplier other than ITT shall
bear only the warranty made by the manufacturer of that product,
and ITT assumes no responsibility for the performance or
reliability of the unit as a whole.
In no event shall ITT be liable for indirect, incidental or
consequential damages nor shall the liability of ITT arising in
connection with any products sold hereunder (whether such
liability arises from a claim based on contract, warranty, tort or
otherwise) exceed the actual amount paid by Buyer to ITT for the
products delivered hereunder.
The warranty does not extend to any product manufactured by
ITT, which has been subject to misuse, neglect, accident,
improper installation, or to use in violation of instructions
furnished by ITT.
The warranty does not extend to or apply to any unit, which has
been repaired or altered at any place other than at ITT’s factory or
service locations, by persons not expressly approved by ITT.
Neo-Dyn®
®
Neo-Dyn Series 162P Differential Pressure Switch
Adjustable high pressure differential switch. Rugged construction with efficient Nega-Rate® Belleville disc spring sensing
mechanism. Maintains set point at high system pressure. Available in all stainless steel construction with hermetically
sealed electrical assembly for corrosive atmospheres.
Operating Pressure Data

Adjustable Adjustable Set Point Range Proof Pressure
Range Deadband Maximum Recommended
Number Increasing Decreasing (approximate) System Pressure Simultaneous High/Low Low/High
2 6 to 50 1 to 45 5 5000 7500 2500 2500
4 20 to 90 10 to 80 10 5000 7500 2500 2500
6 30 to 200 10 to 180 20 5000 7500 2500 2500
8 180 to 350 150 to 320 30 5000 7500 2500 2500
9 325 to 1000 225 to 900 100 5000 7500 2500 2500
All values given in psid.
Standard Specifications Ordering Sequence — Select desired option for each category
Electrical OPTIONS
Snap action electrical switch assembly
listed by Underwriters’ Laboratories, Inc., Wetted Material
Factory Mutual and CSA International 1 Aluminum port, Teflon coated polyimide diaphragm, steel, and Buna-N O-Ring
Electrical Connection 4 Stainless steel ports, Teflon coated polyimide diaphragm and Buna-N O-Ring
1/2 NPT male conduit connection with Adjustable Range
PVC insulated 18 AWG, 2 1 psid dec. to 50 psid inc. (0.1 bar dec. to 3.4 bar inc.)
18" long leads 4 10 psid dec. to 90 psid inc. (0.7 bar dec. to 6.2 bar inc.)
Pressure Connections 6 10 psid dec. to 200 psid inc. (0.7 bar dec. to 13.8 bar inc.)
1/4 NPT Female 8 150 psid dec. to 350 psid inc. (10.3 bar dec. to 24.1 bar inc.)
Temperature Range* 9 225 psid dec. to 1000 psid inc. (15.5 bar dec. to 69.0 bar inc.)
Ambient: - 40°F to + 180°F Electrical Form
(- 40°C to + 82°C) C 11 amp, 1/4 hp at 125 or 250 VAC; 5 amp resistive, 3 amp inductive at 28 VDC;
Media: - 40°F to + 300°F .5 amp resistive at 125 VDC
(- 40°C to + 149°C) CC 11 amp, 1/4 hp at 125 or 250 VAC; 5 amp resistive, 3 amp inductive at 28 VDC;
.5 amp resistive at 125 VDC
*Temperature limits change with
O-Ring selection. See Electrical Enclosure
Assembly specification sheet for 6 Explosion proof, hermetically-sealed electrical assembly, EX d IIC.
Temperature Class Ratings. Part Numbers 057-0770 & 057-0772 (Form C) and 057-0771 & 057-0773 (Form CC).
Agency listings include Underwriters Laboratories, Inc., CSA International, Factory Mutual,
Adjustment and Inmetro. Division 1 and 2, Class I, Groups A, B, C, and D; Class II, Groups E, F, and G.
External 1/2" hex head NEMA 4X, 7, and 9; IP66. Leads are factory sealed and Pressure Switches are Dual Seal Certified.
Note: Turn clockwise to increase
set point; approximately Miscellaneous
24 turns through range A Epoxy paint exterior — extra protection for severe environments
Shipping Weight B Viton O-Ring
Aluminum: Approximately 3 lbs C EPR O-Ring
Stainless Steel: Approximately 7 lbs D SIL approval and marking, per IEC61508 (includes FMEA report)
I 3/4 NPT conduit box with terminal strip (Groups C & D only, not available with N option)
M Gold electrical contacts for extremely low current applications
Order Miscellaneous N ATEX and IECEx with CE Mark
Option “D” R 72" Electrical free leads
Special (Consult representative or factory)
• Non-catalog adjustable range and/or set point, deadband a nd proof pressure
• Chemical seals installed
Ordering Procedure Example

When factory presetting is desired, Series
stipulate set point, increasing or Wetted Material
decreasing, and system pressure Adjustable Range
Electrical Form
Insert available option number or Enclosure
letter designation as required Miscellaneous
Explosion Proof
Hermetically Sealed
162P 1 2 C 6 _
(NEMA 4X,7, 9 and 13)
Field Adjustable
1 to 1000 psid Series 162P
Envelope Dimensions
5.4
Free Leads
18" Long 1.90
3.13 Approx.
18 AWG
3.25
Conduit
4.25 Connection 2.25
¹⁄₂ NPT
1.12
2.13
External Adjustment 1.12
¹⁄₂" Hex
2.25
Low Pressure Port
¹⁄₄ NPT High Pressure Port
¹⁄₄ NPT
1.75
.87
2.25
4.0 ¹⁄₄ - 20 UNC - 3B x .25 Deep

Mtg. Holes (2 places)
Electrical Form
FORM "C" FORM "CC"

(SPDT) HIGH (DPDT) HIGH
P P
RED NC1 RED NC1

BRN C1 BRN C1
BLU NO1 BLU NO1
GRN P BLK NC2
LOW
YEL C2
VIO NO2
GRN P
LOW
Neo-Dyn®
28150 Industry Drive
Valencia, CA 91355
tel: 661 295-4000
fax: 661 294-1750 AER0935_37 7/13
www.neodyn.com Specifications and dimensions subject to change.
9.13 SCHEDA TECNICA PK3
IOM_14479_2 (09.16) Pages 46/59

Operating manual for ball valves
In accordance with Directive 97/23/EC
1. Labeling of ball valves and valves valve can be switched using a hand lever or drive. The design of the drive
must be suited to the conditions of use of the ball valve.
The application of the PED (Pressure Equipment Directive) has been man-
datory since 29.5.2002. The operating instructions of the corresponding manufacturer are valid for
MHA:%.4'2!&'MB(#O+'HOLDSCERTIÚCATIONTHATINCLUDESCOMPLI drive parts, e.g. for drives and position switches. Please observe machine-
ance with DIN EN ISO 9001 and correspondence with Directive 97/23/EG, RYDIRECTIVE%'FORÚTTINGSANDDRIVES
including Module H1.
Valves that are destined for use within the European Economic Area are 3. Installation notes
CLASSIÚEDINCATEGORIES)TO)))INACCORDANCEWITHINCREASINGPOTENTIAL
HAZARD Prior to installation checks must be carried out to test whether the ball
4HENOMINALDIAMETERPRESSUREANDÛUIDGROUPHAZARDOUSORNON valve design corresponds to the required design and is suitable for the
HAZARDOUSÛUIDS ARETAKENINTOACCOUNTFORTHECLASSIÚCATION intended use. The installation of ball valves may only be carried out by
QUALIÚEDPERSONNELANDWHILETHEBALLVALVEANDPIPESYSTEMAREUNPRES
&LUIDGROUPINCLUDESHAZARDOUSÛUIDSINACCORDANCEWITH!RTICLEOF SURIZED4HEPIPELINESMUSTBEINTRODUCEDTOTHEÚTTINGSWITHOUTTENSION
Directive 97/23/EG. The valve valves must be inspected for damage and contamination before
installation. Damaged ball valves must not be installed.
p0OTENTIALLYEXPLOSIVE All the pipelines must be rinsed before the ball valves are installed.
p%XTREMELYÛAMMABLE Residue in the pipelines can damage internal parts and this can result in
p(IGHLYÛAMMABLE malfunction or complete failure of the ball valve.
p&LAMMABLEIFTHEMAXPERMITTEDTEMPERATUREISABOVETHEÛASHPOINT
p 4OXIC Please ensure during installation of the ball valves that no external tensi-
p/XIDIZING ons or vibrations are transferred to the ball valve.
When the piping is screwed in the screw on the ball valve must be held
&LUIDGROUPINCLUDESALLÛUIDSTHATDONOTHAVEANYOFTHECHARACTERISTICS with a suitable tool. The ball valve connections must not be subjected
INÛUIDGROUP to any additional torsional moment that would change their installation
position and thus prevent provision of function.
"ALLVALVESWITHANOMINALDIAMETEROFMORETHAN$.FORÛUIDGROUP Overheating of the seals must be prevented on ball valves with welded
MUSTBELABELEDAS#%"ALLVALVESFORÛUIDSINÛUIDGROUPARENOT ends by using suitable measures. When welding is carried out it must also
labeled with a CE mark. The buyer is obliged to inform the manufacturer/ be ensured that no welding particles enter the internal space. Welding
SUPPLIERIFBALLVALVESAREDESTINEDFORAPPLICATIONINÛUIDGROUP)FNO residue must be removed.
INFORMATIONISPROVIDEDONTHEMEDIUMFORUSEITISASSUMEDTHATÛUIDS "ALLVALVESWITHÛANGECONNECTIONSMUSTBECENTEREDBYSCREWINGTHE
FROMÛUIDGROUPWILLBEUSED COUNTERÛANGEBEFOREALLTHESCREWSONTHEÛANGECONNECTIONARETIGHTENED
CROSSWISE!NUNDAMAGEDSEALMUSTBEUSEDBETWEENTHEÛANGESAS
The ball valve and seal materials are selected by the manufacturer in prescribed in the norm. The spacer bolts or connecting screws must be
accordance with customer information such as medium, pressure, tempe- SELECTEDINACCORDANCEWITHTHEÛANGETYPES7ITHTHREADHOLESITMUSTBE
RATUREANDOTHERUSE SPECIÚCREQUIREMENTS)FTHECONDITIONSOFUSEVARY ensured that the maximum screwing depth is not exceeded.
from the information provided then the lifespan of the ball valve may be
reduced or the ball valve may malfunction. The material combinations and Switching must be carried out as a function test after the ball valve has
CONDITIONSFORUSETHATARESPECIÚEDBASEDONTHEDESIGNCANBEFOUNDIN been installed. No parts of the ball valve (e.g. cover, connecting piece)
the following labeling on the ball valve. MAYBERELEASEDORSCREWEDDOWN)NTHECASEOFMEDIATHATAREHAZAR
DOUSTOHEALTHÛAMMABLEOREXPLOSIVEITMUSTBEENSUREDTHATTHEPIPE
1st Line: Germany x-y country of manufacture, x = calendar system and ball valve are completely emptied.
week, y = year
7ATCHOUTFORANYRESIDUEÛOWINGTHROUGH!PPROPRIATEPROTECTIVE
2nd Line: MHA manufacturer CLOTHINGMUSTBEWORN4HEÚTTINGMAYNEEDTOBEPLACEDINTHEPIPING
using lifting gear.
3rd Line: BKH-DN13-G1/2 valve type, nominal diameter, connection
TYPESIZE Please observe the switch position of the ball valve according to the
4th Line: PN500 - 1123 nominal pressure, MHA material combi- piping plan. Pressure stage, connection and construction length of the
nation piping system must correspond to the ball valve. The operating instruc-
tions of the relevant manufacturer must be taken into account with regard
to system parts.
(For more information on MHA material combinations, please see p. 242.)
4. Initial operation
2. General
All operating instructions must be read and observed prior to initial
"ALLVALVESAREPRESSURIZEDFORTHETRANSPORTATIONSHUTTINGOFFORREDIREC operation and assembly work must be inspected. Initial operation of a
TIONOFMEDIAÛOW(AZARDSAREPRESENTEDBYÚTTINGSINTHEHIGH PRESSURE SYSTEMMAYONLYBECARRIEDOUTBYQUALIÚEDPERSONNEL4HEPIPINGSYSTEM
area if there is a case of improper or incorrect use or if the safety notes in must be bled prior to initial operation. Air bubbles in the piping system
these operating instructions are not observed. can cause explosions in the event of a sudden increase of pressure. This is
why the operating pressure should be increased in stages.
The customer must take the operating pressures (pressure surges/impulse If the ball valve is stored for a long period, or if it is at a standstill for a
pressures) into account during the planning and design of ball valves. longer period in one switch position, then the torsional moment for the
Pressure information in the catalog refers to static loads. The correspon- ÚRSTSWITCHINGPROCESSISSUBSTANTIALLYABOVETHEACTUALTORSIONALMOMENT
ding pressure reductions must be taken into account for pulsating or (pull-off moment).
changing loads.
)FBALLVALVESAREINSTALLEDINTHEPIPINGSYSTEMASENDÚTTINGSTHEREIS
Ball valves are only suitable for installation in piping systems with con- particular risk of death from parts sheering off. Professional execution is
nections at the same pressure load and corresponding connections or bet- absolutely essential in this case.
WEENÛANGESOFTHESAMEPRESSURELOADANDTHESAMEÛANGECONNECTION
Two-way ball valves open and close by turning the selector shaft by 90°.
!ÛOWDISPLAYSHOWSTHEPOSITIONTHEBALLVALVEISSWITCHEDTO4HEBALL
270 10.04.2015
5. Maintenance / Inspection #AUTION$ANGERTOHUMANLIFEØ
3PECIÚCWARNINGNOTESEGREGARDINGTHEWEARINGOFGLOVESFORSWITCHING
When the piping system is drained the ball valves must be drained via a must be heeded (the ball valves take on the temperature of the medium).
switch position of 45°. Ball valves may only be dismantled and maintained !NYSTRUCTURALMODIÚCATIONTOTHEBALLVALVEPARTICULARLYTHEADDITIONOF
by trained, specialist personnel. No makeshift seals of any kind are permit- drill holes and the welding on of objects (plates, mounts etc.) is strictly
ted. Ball valves must be inspected at regular intervals for leaks, malfunc- prohibited.
tion and damage. The maintenance intervals depend on the conditions of )NTHEEVENTOFMALFUNCTIONSTHEBALLVALVEMUSTBEEXCHANGEDBYQUALIÚED
USEOFTHEÚTTING PERSONNELWITHTHEPIPESYSTEMINANUNPRESSURIZEDANDDRAINEDCONDI
tion. Systems must be switched off before the ball valve is dismantled.
In order to retain functionality the ball valve must be switched at least eve-
ry six months in the event of longer standstill periods. If discrepancies to Only the manufacturer is permitted to carry out repairs. If the ball valve
the desired status are discovered during this maintenance work, measures ISDISMANTLEDWITHOUTPERMISSIONANDBYUNQUALIÚEDPERSONNELTHISWILL
must be undertaken immediately to ensure safe operating conditions render any warranty or damage claim made against the manufacturer null
(exchange or repair). and void. National regulations on accident prevention and the local safety
regulations of the operator are not replaced by these operating instruc-
tions and must always be regarded as overriding.
6. Removal notes 4HEFOLLOWINGMUSTBEENSUREDBEFOREANYREPAIRWORK

p /NAUTOMATEDÚTTINGSTHEPOWERSUPPLYTOTHEDRIVESMUSTBE
4HEREMOVALOFBALLVALVESMAYONLYBECARRIEDOUTBYQUALIÚEDPERSONNEL suspended prior to repair and maintenance work.
and while the ball valve and piping are not under pressure. The ball valve p )TMUSTBEENSUREDTHATNOTHIRDPARTYCANSTARTUPTHESYSTEM
must be set to a semi-open position in order to prevent pressure from p4HEPIPELINESMUSTBEDRAINEDANDPRESSURECUSHIONSRELIEVED
being trapped. p )NFORMATIONMUSTBECOLLECTEDREGARDINGPOSSIBLEHAZARDSTHATCOULDBE
caused by residue operating material and protective gloves, goggles etc.
)FMEDIAAREUSEDTHATAREHAZARDOUSTOHEALTHÛAMMABLEOREXPLOSIVE must be worn if necessary.
the piping and the ball valve must be completely drained. Watch out for p ,EAVEÚTTINGSTOCOOL$ONOTEXCEEDLIMITSWITHREGARDTOPRESSURE
ANYRESIDUESÛOWINGTHROUGH!PPROPRIATEPROTECTIVECLOTHINGMUSTBE temperature or media.
worn.
7. Warning notes
Please take note of these operating instructions. The manufacturer of the
ball valves does not accept any liability if these operating instructions are
not heeded.
Ball valves must only be used for the purpose stated by the manufacturer.
The manufacturer will also not accept liability in the event of damage
caused by the incorrect installation and use of ball valves or by incorrect
USEBYUNQUALIÚEDPERSONNEL Lock valve adapter during No welding, boring or other
Ball valves must always be switched fully in principle. They may only be pipe installation! MODIÚCATIONATTHEVALVEØ
used in the switch positions fully closed or fully open.
"ALLVALVESARENOTSUITABLEFORTHERESTRICTIONORREGULATIONOFÛOWQUANTI
ties and are not approved for this use. Indifferent switching positions lead
to damage to the seals in the ball area, which result in leaks or altered
torsional moments that can be accompanied by temperature rises at the
surface.
Tools (e.g. pliers, hammers, open-end wrenches, extensions etc.) may not
bar
be used to switch the ball valves. The use of such tools can lead to damage
to switching elements and casings. Ball valves may not be switched by
force.
Particular usage or environmental conditions (moisture, vibrations,

No actuation with additional Do not disassembly while
SWITCHINGFREQUENCYELECTROMAGNETICÚELDPOTENTIALLYEXPLOSIVEAREAOR tooling! PRESSURIZEDØ
ANTI STATICSETC MUSTBECLEARLYDEÚNEDWHENTHEBALLVALVESAREORDERED
in order to ensure functional design. Ball valves may only be used for
suitable media.
No viscous or hardenable media may be used.

Contamination is to be avoided. Contaminated media lead to damage to
sealing elements. This creates leaks that lead to the failure of the ball val-
VE4HETEMPERATURELIMITSTHATAREPROVIDEDFORTHEÚTTINGMUSTBEUPHELD
in order to prevent early failure of the ball valve.
Ball valves must be stored in a dry and clean condition as delivered. Pro-
tective caps must only be removed just before actual installation.
Unpacked ball valves must be protected from direct UV and/or sunlight.

In potentially explosive areas the switches on the ball valves must be limi-
ted to a maximum of 10 per minute in order to avoid self-warming. Excee-
ding the operating pressure quoted or operating at temperatures outside
the quoted range may lead to leaks or destruction of the ball valve.
18.12.2015 271
Selector ball valve for manifold mounting PK3
Stainless Steel
K
SW1
H2
H1
H
LW
h
m
l
SW2
B
AVAILABLE SIZES
Manifold
L l7
DN6 - DN50 (1/4“ to 2“)
! Pressure inlet only from center port (port 2)!
ACCESSORIES ON REQUEST & MATERIAL CODE DESCRIPTION
Materials 442A 4428

• Locking devices page 229
Body Stainless Steel Stainless Steel
• Actuators 224 - 225
Ball Stainless Steel Stainless Steel
• Position switches on request
Stem Stainless Steel Stainless Steel
• Detent on request
Ball seats POM POM
O-rings NBR FPM
Tmin / Tmax -30°C / 100°C -20°C / 100°C
Porting pattern L=SB58 L=SB58
GENERAL DIMENSIONS
Type l L l7 B H h m V SW1 SW2 K LW H1 H2 Lever Weight

[Kg]
PK3-DN6 26 57 6 40 43 35 19,5 6 7 19 80 5 - 67 Zn 0,60
PK3-DN10 29 70 10 55 59 45 24,5 11 9 30 115 10 - 93 Zn 1,30
PK3-DN13 42,5 98 10 60 69 55 34 11 9 32 115 13 - 104 Zn 2,30
PK3-DN20 51 117 10 70 88 70 37,5 14 14 46 200 20 92 - Zn 3,90
PK3-DN25 62 135 10 80 98 80 44,5 14 14 50 200 25 102 - Zn 5,70
PK3-DN32 75 165 11 100 121 100 54,5 16,5 17 70 320 30 130 - Al 11,00
PK3-DN40 84,5 200 17 130 131 110 57 16,5 17 80 320 38 140 - Al 18,70
PK3-DN50 106 240 15 150 150 129 71 16,5 17 90 320 48 159 - Al 28,80
130 10.04.2015
Selector ball valve for manifold mounting PK3
Stainless Steel
CONNECTION
d4/xt
d3
d5 (DN40)
3 2 1
b
d1
h1
l4 l6
d2
o-rings belong
O-rings
to delivery l5
included l1 l3 l3
l2
Manifold
ORDER CODE PER MA-
CONNECTION DIMENSIONS TERIAL COMBINATION
Type l1 l2 l3 l4 l5 l6 b d1 d2 h1 d3 d4 t d5 Dimension of Torque O-ring PN 442A 4428

screws (min)(1) of screws [bar] L=SB58 L=SB58
in Nm(1)
PK3-DN6 8,5 35 - 8,5 35 17,5 27 6 11,8 1,9 6,5 10,5 6,8 - 4 x M6x40 - 12.9 14 7x2,5 500 31909 38376
PK3-DN10 7,5 55 - 10 44 19 40 9,5 14,9 1,9 8,4 13,5 8,5 - 4 x M8x50 - 12.9 35 10x2,5 500 31914 38377
PK3-DN13 7,5 83 41,5 16 58 26,5 45 13 24,9 1,9 8,4 13,5 7 - 6 x M8x60 - 12.9 35 20x2,5 420 38370 38378
PK3-DN20 10 97 48,5 20 69 31 51 20 29 2 10,5 16,5 10,5 - 6 x M10x80 - 12.9 70 23,47x2,62 420 38371 38379
PK3-DN25 10 115 57,5 24 81 38 60 25 34,9 2,3 10,5 16,5 10,5 - 6 x M10x90 - 12.9 70 29x3 420 38372 38380
PK3-DN32 12 136 68 29 96 46 78 32 40 2 13 19 12 - 6 x M12x110 - 12.9 110 34,59x2,62 420 59605 59606
PK3-DN40 28,5 112 56 28,5 112 56 95 38 47,7 2,3 16,5 25 19 36 6 x M16x120 - 12.9 300 42x3 420 38374 38382
PK3-DN50 38 136 68 38 136 68 112 48 59,8 2,3 21 31 21,5 - 6 x M20x140 - 12.9 600 54x3 420 38375 38383
(1)
Fixing screws not included.
We recommend screws as per ISO4762 (DIN 912). FLOW CHARACTERISTICS PK3
The indicated property classes and torques represent our ∆p‐Q characteris5cs
recommended guidelines at a friction coeficient of 14%. PK3
DN50
1000
DN40
DN32
DN25
DN20
DN16/12
100
PORTING PATTERNS
DN10
Q(l/min)
Q [l/min]
DN6
LLu SB58
10
! Pressure inlet only from center port (port2)!
PK3 with cross-over low Further porting patterns 1

0 0,5 1 1,5 2 2,5 3 3,5 4
Operation 90° page 250 to 255
∆p [bar]
L-bore ∆p (bar)
10.04.2015 131
9.14 MANUALE RELIEF VALVE HAWE
IOM_14479_2 (09.16) Pages 47/59

Valvola di sicurezza certificata
tipo MV..X.., SV..X..
pressione di esercizio pmax = 450 bar Per la valvola di sicurezza certificata tipo CMVX 2.. vedere D 7710 TÜV
portata Qmax = 100 l/min
Come valvole di sicurezza per recipienti a pressione in impianti oleodinamici tenendo conto dei seguenti regolamenti:
o direttiva 97/23 CE sui dispositivi in pressione
o regolamento sulla sicurezza del funzionamento del 27.09.2002 / Direttiva sull’uso delle attrezzature di lavoro 2009/104/CE
o regole tecniche „A/D Regelwerk“ 2000, foglio di istruzioni A2, ultima edizione
1. Generalità
Sono disponibili tre grandezze costruttive in tre
diverse varianti di esecuzione che si distinguono per
la forma del corpo. La scelta conformemente alle
tabelle nei paragrafi 2.1, 2.2 e 2.3 avviene entro i
campi di volta in volta ammissibili pmin ... pmax
secondo il valore della pressione p (bar), al quale la
valvola deve reagire e a seconda della portata della
pompa Qpompa (l/min) che alimenta il circuito
idraulico (Qpompa $ Qammiss ).
La pressione impostata desiderata (inizio della
manovra) va indicata insieme alla sigla di ordina-
zione. La valvola viene impostata su questo valore Valvola ad Valvola di Valvola per Valvola da
e piombata, la pressione è indicata per ultima nella angolo per mon- passaggio per montaggio a avvitare
sigla stampigliata sull‘elemento. taggio su tubi montaggio su piastra (pagina 2)
(pagina 1) tubi (pagina 2) (pagina 2)
2. Modelli disponibili, dati principali

2.1 Valvola ad angolo per montaggio su tubi
Esempio di ordinazione: MVX 42 B - 350
Tipo, sigla di ordinazione Sigla del pezzo # Nomi- Portata Pressione di Filetto
nale cono ammissibile manovra p d’attacco
corpo portamolla e sede Qammiss desiderata entro ISO 228/1
in ghisa in zinco pmin ... pmax
sferoidale pressofuso (mm) (l/min) (bar)
MVSX 41 E MVX 41 E 90 ... 160 MVSX 41 e
MVSX 42 E MVX 42 E 8
80 ... 160 MVX 41
TÜV.SV.14 - 738.4.F.8.p = G 1/4
MVSX 41 C MVX 41 C
MVSX 42 C MVX 42 C 4 8 161 ... 315
MVSX 42 e
MVSX 41 B MVX 41 B MVX 42
TÜV.SV.14 - 738.4.F.10.p 10 316 ... 450 = G 3/8
MVSX 42 B MVX 42 B
MVSX 52 E MVX 52 E
MVSX 53 E MVX 53 E
TÜV.SV.13 - 708.5.F.20.p 20 80 ... 100 2.3
MVSX 52 e
MVSX 52 E MVX 52 E MVX 52
TÜV.SV.13 - 708.5.F.40.p 40 101 ... 140 = G 3/8
MVSX 53 E MVX 53 E
MVSX 52 E MVX 52 E 5
50 141 ... 160 MVSX 53 e
TÜV.SV.13 - 708.5.F.50.p
MVSX 52 D MVX 52 D = G 1/2
MVSX 53 D MVX 53 D 50 161 ... 210
MVSX 63 E MVX 63 E
TÜV.SV.13 - 709.6.F.30.p 30 100 ... 140
MVSX 64 E MVX 64 E
MVSX 63 E MVX 63 E MVSX 63 e
TÜV.SV.13 - 709.6.F.60.p 60 141 ... 160
6 = G 1/2
MVSX 63 D MVX 63 D
MVSX 64 D MVX 64 D 80 161 ... 210
TÜV.SV.13 - 709.6.F.80.p MVSX 64 e
MVSX 63 C MVX 63 C MVX 64
MVSX 64 C MVX 64 C 80 211 ... 315 = G 3/4
MVSX 63 B MVX 63 B
TÜV.SV.13 - 709.5.F.60.p 5 60 316 ... 450
MVSX 64 B MVX 64 B
HAWE HYDRAULIK SE
STREITFELDSTR. 25 • 81673 MÜNCHEN D 7000 TÜV
© 1983 by HAWE Hydraulik Agosto 2013-01
D 7000 TÜV Pagina 2
2.2 Valvola di passaggio per montaggio su tubi

Esempio di ordinazione: SVX 42 C - 200
Tipo, Sigla del pezzo # Nominale Portata Pressione di manovra p Filetto

sigla di cono e sede ammissibile desiderata entro d’attacco
ordinazione (mm) Qammiss (l/min) pmin ... pmax (bar) ISO 228/1
TÜV.SV.10 - 1109.4.F.3.p 3 80 ... 120

SVX 42 E SVX 42
4
TÜV.SV.10 - 1109.4.F.4.p 4 120 ... 160
TÜV.SV.10 - 1109.4.F.3,5.p 3,5 160 ... 250 = G 3/8
SVX 42 C 4
TÜV.SV.10 - 1109.4.F.6.p 6 250 ... 300
SVX 42 B TÜV.SV.10 - 1109.4.F.6.p 4 6 300 ... 430
2.3 Valvola per montaggio a piastra

Esempio di ordinazione: MVPX 4 E - 100
Tipo, Sigla del pezzo # Nominale Portata Pressione di manovra p

sigla di cono e sede ammissibile desiderata entro
ordinazione (mm) Qammiss (l/min) pmin ... pmax (bar)
MVPX 4 E 10 80 ... 160

MVPX 4 C TÜV.SV.14 - 738.4.F.10.p 4 10 161 ... 315
MVPX 4 B 10 316 ... 450
TÜV.SV.13 - 708.5.F.20.p 20 80 ... 100
MVPX 5 E
TÜV.SV.13 - 708.5.F.25.p 5 25 101 ... 160
MVPX 5 D TÜV.SV.13 - 708.5.F.30.p 30 161 ... 210
TÜV.SV.13 - 709.6.F.30.p 30 100 ... 140
MVPX 6 E
TÜV.SV.13 - 709.6.F.60.p 6 60 141 ... 160
MVPX 6 D TÜV.SV.13 - 709.6.F.50.p 50 161 ... 210
MVPX 6 C TÜV.SV.13 - 709.6.F.60.p 60 211 ... 315
MVPX 6 B TÜV.SV.13 - 709.5.F.60.p 5 60 316 ... 450
2.4 Valvola da avvitare

Esempio di ordinazione: MVEX 6 E - 100 - 3/4 A
Tabella 1
Tipo, Sigla del pezzo # Nominale Portata Pressione di manovra p

sigla di cono e sede ammissibile desiderata entro
ordinazione (mm) Qammiss (l/min) pmin ... pmax (bar)
MVEX 4 E 10 80 ... 160

MVEX 4 C TÜV.SV.14 - 738.4.F.10.p 4 10 161 ... 315
MVEX 4 B 10 316 ... 450
TÜV.SV.13 - 708.5.F.10.p 10 100 ... 140
MVEX 5 E
TÜV.SV.13 - 708.5.F.16.p 5 16 141 ... 160
MVEX 5 D TÜV.SV.13 - 708.5.F.20.p 20 161 ... 210
TÜV.SV.13 - 709.6.F.90.p 90 100 ... 140
MVEX 6 E
100 141 ... 160
TÜV.SV.13 - 709.6.F.100.p 6
MVEX 6 D 100 161 ... 210
MVEX 6 C 100 211 ... 315
MVEX 6 B TÜV.SV.13 - 709.5.F.30.p 5 30 316 ... 450
Tabella 1: Blocchi di collegamento per tipo MVEX 6 Simboli di idraulici
- 1/2 A P e R = G 1/2, senza valvola di scarico

- 3/4 A P e R = G 3/4, senza valvola di scarico
3. Altri parametri
Denominazione e versione valvola di sicurezza ad azione diretta a sede conica
Posizione di montaggio a piacere
Senso di flusso PdR, P = attacco sul lato di mandataß; R = ritorno (senza pressione)
Fluidi in pressione olio idraulico secondo DIN 51524 parti 1 - 3: ISO VG 10 - 68 secondo DIN 51519.
Adatta anche per fluidi biodegradabili di tipo HEPG (glicole polialchilenico) e HEES (esteri sintetici)
a temperature di esercizio fino a ca. +70°C
Viscosità di esercizio ca. 12 ... 230 mm2/s
Classe di purezza 21/18/15 secondo ISO 4406
Temperatura ambiente: ca. -40 ... +80°C
olio: -20 ... +80°C; badare al campo di viscosità! Vedere anche D 5488/1 posizione 3.
Fluidi in pressione biodegradabili: osservare le indicazioni dei produttori. Non oltre +70°C per
riguardo verso la compatibilità del liquido con le guarnizioni.
Sovraccaricabilità statica 2 x pmax
4. Dimensioni Tutte le misure in mm, ci riserviamo modifiche!
Tipo MVSX .. e MVX .. Tipo SVX .. Tipo MVPX .. È rappresentata la grandezza costruttiva 4;
per le grandezze costruttive 5 e 6
vedere tipo MVEX
SW
foro di posizionamento
per la spina elastica
SW #3 mm
Tipo a b b1 c d e e1 g
MVPX 4.. 7 28 35 8 6 14 22 M8
MVPX 5.. 8 32 40 8 9 18 27 M8
Massa MVPX 6.. 10 35 50 10 12 22 34 M10

(peso)
Tipo a a1 b d1 h h1 h2 SW ca. (kg)
MV(S)X 41..
15 24 24 5,5 46 61 86 22 0,2
MV(S)X 42.. Tenuta ermetica degli Massa
attacchi P ed R con (peso)
MV(S)X 52..
18 30 29 6,5 49 66 95 27 0,3 Tipo h h1 O-ring NBR 90 Sh ca. (kg)
MV(S)X 53..
MVPX 4.. 39,5 20 8x2 0,3
MV(S)X 63..
20 35 36 6,5 62 82 117 32 0,5
MV(S)X 64.. MVPX 5.. 44 21 10x2 0,5
SVX 42.. - - - - - - 110 22 0,2 MVPX 6.. 53,5 26 13,95x2,62 0,8
Tipo MVEX .. Attenzione: Osservare le istruzioni per l‘avvitamento del paragrafo 5!
MVEX 4.. MVEX 5..

MVEX 6..
SW Tipo h h1 D e d t t1
MVEX 4.. 49,5 26 18H8 12 6 12 15
MVEX 5.. 55 27 25H8 11,5 9 9 16
SW
MVEX 6.. 67 32 25H8 14 12 10 19
SW1 SW1
anello di Tipo SW SW1 G

tenuta
MVEX 4.. 17 27 M 22x1,5
anello di
sostegno MVEX 5.. 27 32 M 28x1,5
O-ring MVEX 6.. 30 36 M 30x1,5
foro di
Tipo Anello di O-ring Anello di Massa
attacco:
tenuta NBR 90 Sh sostegno (peso)
Numero di ca. (kg)
disegno
A 22x27x1,5
MVEX 4.. 12,37x2,62 5660 002 0,2
DIN 7603-St
A 28x34x2
MVEX 5.. 20,29x2,62 3771 003 0,3
DIN 7603-Cu
A 30x36x2
MVEX 6.. 20,29x2,62 3771 003 0,4
DIN 7603-Cu
Tipo MVEX 6.-.. - 3/4 A

- 1/2 A
Raccordi filettati ISO 228/1:
P, R S M
- 3/4 A G 3/4 G 1/2 G 1/4
- 1/2 A G 1/2 G 1/2 G 1/4
5. Istruzioni su montaggio, esercizio e manutenzione

Effettuare l‘installazione delle valvole di sicurezza con particolare accuratezza. Osservare quanto prescritto dalla direttiva sui
dispositivi in pressione. I controlli regolari vanno effettuati secondo i regolamenti nazionali per valvole di sicurezza e impianti.
Il senso di flusso va rispettato in ogni caso. L‘attacco del tubo di mandata ”P” e del tubo di ritorno ”R” deve avvenire secondo lo
schizzo del paragrafo 1 „Generalità“.
Il tubo di ritorno (”R”) va collegato al serbatoio, le condotte occorrenti devono avere dimensioni sufficientemente grandi. Per
avvitare il corpo dei tipi MVX, MVSX e tipo SVX non si devono superare i momenti torcenti indicati.
Attenzione: Quando si serrano i raccordi fare forza in senso opposto.
Le viti di fissaggio delle valvole con montaggio a piastra tipo MVPX, le valvole a frutto tipo MVEX vanno serrate con i momenti
torcenti necessari.
Per serrare il tipo MVEX nella foratura di attacco del corpo di attacco usare solo l‘apertura della chiave SW1!
Attenzione: Non danneggiare il filo di piombatura!
Momenti di serraggio per avvitare agli attacchi ”P” e ”R”
Tipo Momenti di serraggio Tipo Momenti di serraggio Tipo Momenti di serraggio

(Nm) (Nm) (Nm)
P R P R P R
MVSX 41 45 45 MVX 41 45 40 SVX 42 70 70
ghisa 42 70 70 zinco 42 70 65
sferoi- 52 70 70 presso- 52 70 65
dale 53 140 140 fuso 53 140 90
63 140 140 63 140 90
64 230 230 64 230 90
Momenti di serraggio delle viti di fissaggio o della valvola a frutto (vedere pagina 4)
Tipo Momenti di serraggio Tipo Momenti di serraggio

g (Nm) SW1 (Nm)
4.. M8 25 4.. 27 80
MVPX 5.. M8 25 MVEX 5.. 32 120
6.. M10 50 6.. 36 160
Per proteggere la valvola da danneggiamenti esterni, badare che la posizione di montaggio sia sicura o predisporre un dispositivo
di protezione.
Durante il montaggio e l‘esercizio, nella valvola di sicurezza non devono entrare particelle di sporco.
Rispettare la classe di purezza richiesta nel paragrafo 3 „Ulteriori parametri“!
o
CERTIFICATE
w
Industrie Service
TfiV~
The Certification Body of
TOV SUD Industrie Service GmbH,
a Notified Body of the Pressure Equipment Directive (PED),
Z E R TIFIKAT
certifies that
CERTIFICA TE
(Konformltiltsbtschelnlgutlll) 1 ~ol canrormrty)
EG-Il<~umullilerprufuno
~c tyPN<><omiMIJC>n
nuh RlehUinle !J71231EG l o<è<>Jd;ng to dir...llriS•712lii!!C
HAWE Hydraulik SE larti!ikat.f<lr. IC..rtiflic• ~.; 07 2:02 11).42 Z 046'211310
StreitfeldstraRe 25 Namo unc:l An-• ch•fft do& i'le~ller~S HAWE Hydraullk SE
81673 Miinchen, Germany t<amo ond • - ol ~~Oli Sttoitfol<hi!tallii l !l
m•nqf"""'-' 0·81673 Mllnohen
with the production plani
85356 Frelslng, KulturstraBe 44, Germany
Hiermit wird bexhelrligt, dass das lil'lle!'l gerl!lnnte E:G-EI<o~.rnu$1or alo A11forde1ungen der
Ridrtlii'IOA! 971231EG erfull. '1/o< ru...~Y OOf1lt; lllotlho 1)'11'> .,.....,ouon
m.ernlone<J ll<ll~ Mfill!: ""' roqulrernam.
<lf-"'•9712:l.EC,
implemented, operates and maintains a quality
assurance system as described in the Pressure Equipment
Directive (97/23/EC) Annex Ili, Modula D Gepraft naeh Aìchtlinie 97JZ,IIEG EG,I;Iaumu51orpnlhmg (Modui iB )
T&it&d li00Drl1.~ 10 97J2.1JEC .EC ~...,• ...,,• .,.oo (wo<Mo 8)
for the scope of
P<llf!)enclli-Nr ·11..., ror.on No,: 1042 p 046211 aiO
production of directly acting spring loaded safety valves ~eohrèibvng des Ba~mustel6 Slehornilit~Wondl
for hydraulic fluids (Otl\.d(gerllt). <11m.1 "llt.<n<J. rO<Jo-.let
~""'ol~ll>rooatKo ""'""<"'""): lypon t.IVX, ~M')!. I.!VEX ....t MVSX lo dto tlo~l!iom <, ~ u'ldil
ace. to EC Type-Examlnatlons ~o!l..,,...mcnm.... Plar.onault>a"' Ocler EM!W>,.ut»o!Lll.
TemFJ4!'!11'""" "'!ochan - 20"C ,.,d 80 •c
fQr Hl'<h.ulil<ll~.jjll~ ~!mi>ll H.,..1...,rang.obe
The audi! with the report number IS·DDB· MUC-Q-031-1 3 proves that the Elnoie]ljrbdi:o zwtO<hen BIO ~n<l ~:;o b<or
quality assurance system fulfils the PED requirements. Fertigy~sstatte/~>iaoo or '"•I>Uiadul<t: HA,Wt: Hydr;~M!ik SE,
Strelt:fe1d~ln.l'>e 25; 0 · 81673 Miinchan
GO:ltlg b!sllf81d unu 01.10.2022
The manufacturer is authorized to previde the pressure equipment
produced within the scope of the assessed quality assurance system with
the following Notified Body number:
CE0036 Hannovar, 13 03.2013
Certificate No.: DGR-0036-QS-843-13
l~;rt,;!.~~
valid until August 11111 , 2016
Mannheim, July 101h, 2013

Notified Body No.: 0036
TOV SOD Industrie Sruvice GmbH T el.: +49 621 39 51 15 Member of
DudenstraBe 28 Fa)(: +49 621 39 55 94
•~IKill ~11.'0*1· 111U
68167 Mannhelm e-mail:
CO NFEOERATION EUROPÉENE TIN NORO S,.IOms Gnt>H a O>. l«# T..
-+4S-(O>l!o11~a&S~f!ll2
Mri<J""' o<>1
~ol (§:>
Germany martina.)ohn@tuev-sued.de
C§V
O"ORGANISMES OE CONTROLE
Antl'I:N 1
0.30f1Ht .-..mnfl'oler, Oem.•fT'I
Fa
fl-mià Nnn04t&,..~d d~
~q,a..... l"p:(....... ~
lUV"'
TÙV SOD lndustry Services PED-QA-Certificatioo Body · 68167 Mannheim · Germany ,i-
<.
:
Industrie Service
ZERTIFIKAT
Certificate
EG-Baumusterprufung (Modul B) nach Richtlinie 97/23/EG
EC Type-examlnatlon (Module B) according to Oirective 97/23/EC
Zertifikat-Nr.: IS-DDB-MAN-05-05-9992-002
Certificate No.:
Name und Anschrift HAWE Hydraulik GmbH & Co KG

des Herstellers: StreitfeldstraBe 25
Name and postal address of manufacturer: D-81673 Miinchen
Hiermit wird bescheinigt, daB das unten genannte EG-Baumuster die Anforde-
rungen der Richtlinie 97/23/EG erfOIIt.
We herewith certify that the fype mentioned below meets the requirements of the Directive 97123/EC.
Prufbericht Nr.: P-IS-DDB-MAN-05-05-9992-002

Test report No.:
Geltungsbereich: Sicherheitsventil tor Hydraulikanla-

Scope of examination: gen, Typ SVX 42 ...
(Einstelldruck 80 - 430 bar)
Fertigungsstatte: HAWE Hydraulik GmbH & Co KG

Manufacturing plani: StreitfeldstraBe 25
D-81673 Miinchen
Mannheim, 18. Mai 2005

(Ort, Datum)
(Piace, date)
Bitte beachten Sie die Hinweise auf der zweiten Seite.
P/ease note the remarl<s on the second page..
TOV Industrie Service GmbH Tel.: (06 21) 395-257 Mitglied der
TOV SOD Gruppe Fax: (06 21) 395-594 CONFéOERATION EUROPÉEN
Abteilung Druckbehalter www.tuev-sued.de
DudenstraBe 28
D-68167 Mannheim
C§V
O"ORGANISMES DE CONTRO~E
Zertifi...t-$icherheltsventii·SVX42 •.·1S·DDS.MANOS.OS.9992.002.doc OGR Zertifikot Modul B.dot

9.15 SCHEDA TECNICA VALVOLA DI MASSIMA FLUCOM
IOM_14479_2 (09.16) Pages 48/59

C,.l:,u~11m7 VALVOLE DI MASSIMA PRESSIONE l 02.120 l
y PILOTATE CON DRENAGGIO INTERNO LP l 30
l 01.96 l
l T A L
Caratteristiche tecniche Cavita' (Per dimensioni vedere catalogo 17.000) s 30/2
Portato max. (l/min.) 90
Pressione max. in ingresso (bar) 420
Pressione max. sullo linea 1 (bar) 210

35 est a 50 ·c Campo di viscosita' del fluido (est) 2.8 ... 380
420
Campo temperatura del fluido ("C) -20 +80
-.::-
'lf
280
6" Trafilamento max. (cm '/min.) 25
"- 140 Massa (kg) 0.180
L_ <l
o Pressione di apertura 95% del valore di taratura

o 30 60 90 Pressione di richiusura 85% del valore di taratura
Q (l/min.)
Pressione di apertura definita con 1 l/min.
Taratura standard eseguita con 10 l/min.

Fluido idraulico; olio minerale HM e HV sec. ISO 6074
Filtraggio richiesto; 19/15 ISO 4466 (25 !' assoluti)
Guarnizioni standard in Poliuretano e Buna N
Dimensioni
IN OX 28
~sr~~N~
47
pA~il
""1
27 Ch. 13 8 co
~
x
N
v N
_c "'
u 1 "" ""
\ .......
~ ...,
o 1'-
2 N
"" l ""
'? '
\Coppia di serraggio 50-60 Nm
Sigle e codici di ordinazione
LP l 30/D~N~INOX
-, ......
LP l 30 ~
Tipo valvola Codici gruppi completi:
rrQnJm l LPI 30/D-N-INOX 31 011 263

LPI 30/0-N-INOX 31 011 264
Molle standard
Tipo Campo di taratura Taratura test Set guarnizioni esterne 90 620 103
D ~ 14 ... 210 bar 140 bar
Q ~
105 ... 420 bar 315 bar Le valvole LPI 30 possono essere
montate sui corpi serie 30-LO, per
dimensioni vedere catalogo 16.01 O
Tipo di regolazione
N = Regolazione standard @:
INOX ~ Parti esterne
9.16 SCHEDA TECNICA RITEGNO FLUCOM
IOM_14479_2 (09.16) Pages 49/59

E_Lu~Dm7 VALVOLE DIREZIONALI A DUE VIE DI RITEGNO l os.xxx l
l T A L y CON OTTURATORE A PISTONCINO c E 50 ..
l
01.12
l
Caratteristiche tecniche Cavita' (Per dimensioni vedere catalogo 17.000) s 50/2
Portata nominale (l/min.) 135
Molla tipo Z Pressione max. (bar) 420
12
35 eSt a 50 ·c / Mollo tipo 5
Pressione di apertura (bar) 0.35-3.5-5-8
9
L--- / Molla tipo M
(est)
L.--::::: :,.....---
L
o Mollo tipo P
Campo di viscosita' del fluido 2.8 - 380
.o
1--4/Ò--2 6
::.-
Q_
<l 3
/ Campo temperatura del fluido ('C) -20 +80
!---'" Massa (kg) 0.230
o
o 35 70 105 140 Fluido idraulico; olio minerale HM e HV sec. ISO 6074
Q (l/min.) Filtraggio richiesto; 19/15 ISO 4466 (25 l" assoluti)
Guarnizioni standard in Poliuretano e Buna N
Dimensioni
13 39
5 38
go N
x
n
aJ n
N
B 2
l
H c
ao
~~
c 2 n
B
N
'"
B
c
'
)=l
.1 /
\ Coppia di serraggio 100-120 Nm
Sigle e codici di ordinazione
CAE 50 --
p
CAE 50 ~
Tipo valvola Codici gruppi completi:
CAE 50/P 52 DII 100
IDI CAE
CAE
CAE
50/M
50/5
50/Z
52 DII 101
s 12001
52 DII 116
Set guarnizioni esterne 90 620 106

Molle standard
p ~
0.35 bar
Le valvole CAE 50 possono essere
M ~
3.5 bar
montate sui corpi serie 50-LO, per
5 ~
5 bar dimensioni vedere catalogo 16.010
z ~
8 bar
9.17 SCHEDA TECNICA RITEGNO TOGNELLA
IOM_14479_2 (09.16) Pages 50/59

FT2257/6
VALVOLE
UNIDIREZIONALI
IN LINEA
(A PISTONCINO)
Vengono inserite in rami del circuito ove si voglia realizzare libera circolazione di
flusso in un verso e impedire il passaggio in quello opposto.
Una duratura ed ermetica tenuta è assicurata dall’otturatore conico, il quale
costituisce una soluzione meccanica di totale affidabilità.
La molla di contrasto, in materiale ad alta resistenza, viene alloggiata in condizio-
ne da non chiudersi a pacco in fase di apertura. La configurazione esterna del
corpo facilita la presa durante le operazioni di montaggio.
Sono fornibili con diverse tarature della pressione di apertura
(0,5 standard e 2-4-6-8-10 bar).
A richiesta
• Filettature NPT
materiali esempio per l’ordinazione

Corpo Acc. Inox AISI 316 Codice Tipo Taratura
Valvola ritegno Acc. Inox AISI 630 FT 2257/6 12 –
Molla Acc. Inox AISI 316
Fond. Filett. Acc. Inox AISI 316

dimensioni
A
Tipo B C CH Peso kg
UNI 338
18 1/8”G 8,5 46 17 0,075
14 1/4”G 12,5 63 22 0,165
38 3/8”G
1/2”G
12,5
15,5
68
80,5
27
32
0,260
0,415
21
12
34 3/4”G 17 99,5 36 0,605
100 1”G 20 117 46 1,170
114 11/4”G 22 134,5 55 1,850
112 1 1/2”G 24 159 65 3,130
200 2”G 27 198 75 4,900
dati tecnici
Pressione Min. press. Temperatura Grado di
Tipo
esercizio bar scoppio bar esercizio °C filtrazione µm
18 400 1600 -20° / +130°C 25
14 400 1600 -20° / +130°C 25
38 400 1600 -20° / +130°C 25
12 400 1600 -20° / +130°C 25
34 400 1600 -20° / +130°C 25
100 320 1300 -20° / +130°C 25
114 320 1300 -20° / +130°C 25
112 320 1300 -20° / +130°C 25
200 320 1300 -20° / +130°C 25

bar
FT 2257/6 - 18
25
CADUTA DI PRESSIONE ∆p
20
15 -18/6
-18/4 -18/8
10
5 Olio 3,2°E ÷ 50°C

-18/0,35
-18/2
0 10 12 14 16 18 20 22 24 26 28
l/min
PORTATA Q
bar
FT 2257/6 - 14
12 -14/8
10
8 -14/6
6 -14/4
4 -14/0,35
-14/2
2 Olio 3,9°E ÷ 50°C
0 5 10 15 20 25 30 35
l/min
PORTATA Q
bar
FT 2257/6 - 38
10
-38/8
8
-38/6
6
-38/4
4
-38/2 -38/0,35
2
Olio 3,9°E ÷ 50°C
0 10 20 30 40 50
l/min
PORTATA Q
bar
FT 2257/6 - 12
10 -12/8
8 -12/6
-12/4
4
-12/2
-12/0,35
2
Olio 3,9°E ÷ 50°C
0 10 20 30 40 50 60 70 80
l/min
PORTATA Q
bar
FT 2257/6 - 34
10 -34/8
8 -34/6
6
-34/4
4
-34/2
2 -34/0,35
Olio 3,9°E ÷ 50°C

0 10 20 30 40 50 60 70 80 90
l/min
PORTATA Q
bar
FT 2257/6 - 100
-100/8
Olio 3,9°E ÷ 50°C
10
-100/6
6 -100/4
-100/2
2
-100/0,35
0 20 40 60 80 100
l/min
PORTATA Q
bar
FT 2257/6 - 114
10
-114/8
8
-114/6
6
-114/4
4
-114/2
2
-114/0,35
Olio 3,9°E ÷ 50°C
0 200 250 300 350 400

l/min
PORTATA Q
bar
FT 2257/6 - 112
10
4
23
2
Olio 4°E ÷ 50°C
0 100 200 300 400 500 600 700

l/min
PORTATA Q
bar
FT 2257/6 - 200
6
Olio 4°E ÷ 50°C
0 100 200 300 400 500 600 700 800 900

l/min
PORTATA Q
9.18 SCHEDA TECNICA FILTRO COOLER
IOM_14479_2 (09.16) Pages 51/59

FRI
Maximum pressure 20 bar

Flow rates to 1500 l/min
Te c h n i c a l d a t a
Filter housing (Materials)
• Filter body: Aluminium: FRI 255
Anodized Aluminium: FRI 025-040-100-250-630 Filter housings Δp pressure drop
Phosphated Steel: FRI 850
The curves are plotted utilising mineral oil
• Cover: Nylon (only for: FRI 255)
with density of 0,86 kg/dm3 to ISO 3968.
Anodized Aluminium (all the other
• Valve: Nylon - Steel Δp varies proportionally with density.
Pressure
• Working pressure: 20 bar (2 MPa)
Temperature
FRI 025 - 040 - 100
• From -25°C to +110°C 0,6
1/2”
Bypass valve
• Opening pressure 2,4 bar ±10%
3/4”
0,4
Δp bar
Δp Elements type
• Microfibre filter elements series N: 10 bar 1”
0,2
• Fluid flow through the filter element from OUT to IN.
Seals
• Standard NBR series A
0
0 50 100 150 200 250
• Optional FPM series V
Flow rate l/min
FRI FILTERS ARE PROVIDED FOR VERTICAL MOUNTING
Weights (kg)
Length 1 FRI 250 - 255 - 630
• FRI 025 1,0 0,6
• FRI 040 2,0 1 1/2”
• FRI 100 3,8
0,4
Δp bar
• FRI 250 6,3

• FRI 255 4,2 2 1/2”
• FRI 630 13,8 0,2
• FRI 850 48,0
Volumes (dm3) 0
Length 1
0 200 400 600 800 1000
• FRI 025 0,28
Flow rate l/min
• FRI 040 0,70
• FRI 100 1,09
• FRI 250 2,60 FRI 850
• FRI 255 3,2
0,6
• FRI 630 7,05
RETURN FILTER
• FRI 850 21,5 0,4

Δp bar
3 1/2”
0,2
0
0 500 1000 1500 2000 2500
Flow rate l/min
108
Valves
Bypass valve pressure drop
FRI 025 FRI 250 - 255

6 6
4 4
Δp bar
Δp bar
2 2
0 0
0 18 36 54 75 90 0 60 120 180 250 300
Flow rate l/min Flow rate l/min
FRI 040 - 100 FRI 630 - 850

6 6
4 4
Δp bar
Δp bar
2 2
0 0
0 30 60 90 120 150 0 400 800 1200 1600 2000
Recommended maximum flow rate

- Pressure drop of filter assembly equal to Δp 0,5 bar.
- Oil kinematic viscosity 30 mm2/s (cSt).
- Density 0,86 kg/dm3.
Filtration
Length A03 A06 A10 A16 A25 P10 P25 M25-M60-M90
FRI 025 1 6 10 16 19 43 43 47 50*
Flow rate l/min
Filtration
FRI 040 1 18 22 42 44 80 80 80 80*
Flow rate l/min
Filtration
FRI 100 1 32 33 88 91 140 140 140 140*
Flow rate l/min
Filtration
FRI 250 - 255 1 143 178 270 300 350 350 350 350*
Flow rate l/min
Filtration
RETURN FILTER

FRI 630 1 240 278 507 575 700 700 700 700*
Flow rate l/min
Filtration
Length A03 A06 A10 A16 A25 P10 P25 M25-M60-M90 *
FRI 850 1 440 540 970 1140 1600 1600 1600 1600* Maximum
Flow rate l/min flow reccommended
109
FRI 025 - 040
Indicator port
T2 Plug - A/F 30
Optional E
H6
8
H2
H4
H1
H3
H5
Flat seal
Ø D1
1,5
A
Plug
A
Holes on the tank

D5
45°
3
ØD
Ø D2
Ø D4
45°
RETURN FILTER
Thread connections
A Filter H1 H2 H3 H4 H5 H6 D1 D2 D3 D4 D5 E F
Type Length mm mm mm mm mm mm mm mm mm mm mm mm mm
FRI 025 FRI 040
G1 G 1/2” G 3/4”
FRI 025 140 73 6,5 21 62,5 115 83,5 89 84,5 95 M5 44 46
G2 1/2” NPT 3/4” NPT
FRI 040 180 86 10 38 105 135 121 132 122 138 M6 57 60
G3 SAE 8 - 3/4” - 16 UNF SAE 12 - 1 1/16” - 12 UN
110
FRI 100 - 250 - 630
Indicator port
T2 Plug - A/F 30
Optional E
H6
8
H2
A
Flange connections
H4
H3
Flat seal
H5
H1
Ø D1
A
1,5
Blind flange
A
F2
A
Plug
F1
Holes on the tank

D5
45°
3
ØD
Ø D2
Ø D4
45°
Thread connections Flange connections*

A A
Type Type
FRI 100 FRI 250 FRI 630 FRI 100 FRI 250 FRI 630
RETURN FILTER
G1 G 1” G 1 1/2” G 2 1/2” F1 1” SAE 3000 psi/M 1 1/2” SAE 3000 psi/M 2 1/2” SAE 3000 psi/M
G2 1” NPT 1 1/2” NPT 2 1/2” NPT F2 1” SAE 3000 psi/UNC 1 1/2” SAE 3000 psi/UNC 2 1/2” SAE 3000 psi/UNC
G3 SAE 16 - 1 5/16” - 12 UN SAE 24 - 1 7/8” - 12 UN SAE 32 - 2 1/2” - 12 UN
*Connections table “DN/SAE flange” see page 39
Filter H1 H2 H3 H4 H5 H6 D1 D2 D3 D4 D5 E F1 F2
Length mm mm mm mm mm mm mm mm mm mm mm mm mm mm
FRI 100 245 106 12 51 140 175 135 146 136 154 M6 67 73 90
FRI 250 335 129 14 59 177 265 162 174 163 180 M8 82 86 108
FRI 630 391 166 16 80 218 300 237 253 238 275 M10 116 122 143
111
FRI 255 FRI 850
Indicator port
T2 Plug - A/F 30
T
280
Optional
Indicator port 88
550
178
8
123
240
A
A
43
130
10
Seal
331
Ø 162
12
O-Ring
Flat seal
Ø 237
1,5
677
A
Holes on the tank Holes on the tank

M8
M14
45°
45°
63 39
Ø1 Ø2
45°
45°
Ø 180 Ø 275
Ø 300
Ø 174
RETURN FILTER
FRI 255 - Thread connections FRI 255 - Flange connections* FRI 850 - Flange connections*
Type A T Type A T Type A
G1 F1 1 1/2” SAE 3000 psi/M G 1/8” F1 3 1/2” SAE 3000 psi/M
G 1 1/2” G 1/8”
G2 F2 1 1/2” SAE 3000 psi/UNC G 1/8” F2 3 1/2” SAE 3000 psi/UNC
1 1/2” NPT G 1/8”
G3 SAE 24 - 1 7/8” - 12 UN G 1/8”
G4 G 1 1/4” G 1/8” *Connections table *Connections table
G5 1 1/4” NPT
“DN - SAE flange” see page 39 “DN - SAE flange” see page 39
G 1/8”
G6 SAE 20 - 1 5/8” - 12 UN G 1/8”
112
Spar e par ts
3a
1 3c
3d
3e 3b
FILTER Series
Item Description Q.ty FRI 025 FRI 040
1 Filter assembly 1 See order table

2 Filter element 1 See order table
NBR FPM NBR FPM
3 Seal Kit 1
02050213 02050220 02050214 02050221
O-R 3106 O-R 4137
3a Filter element top seal 1
Ø 25,65 x 2,62 Ø 34,52 x 3,53
O-R 3093 O-R 4137
3b Filter element bottom seal 1
RETURN FILTER
Ø 23,47 x 2,62 Ø 34,52 x 3,54

O-R 3243 O-R 4350
3c Cover seal 1
Ø 61,60 x 2,62 Ø 88,50 x 3,53
3d Head seal 1 01026404 01026400
Plug seal GAS thread 1 01017055 01017030
3e O-R 1064 O-R 1092
Plug seal SAE thread 1
Ø 16,36 x 2,20 Ø 23,47 x 2,95
113
Spar e par ts
3a 3a
1 3c 1 3c
2 2
3d 3d
3f 3b 3e 3b
FILTER Series
Item Description Q.ty FRI 100 FRI 250 FRI 630

NBR FPM NBR FPM NBR FPM
3 Seal Kit 1
02050215 02050222 02050216 02050223 02050217 02050224
O-R 4137 O-R Metric O-R 177
Ø 34,52 x 3,53 Ø 50 x 4 Ø 74,61 x 3,53
O-R 4137 O-R Metric O-R 177
Ø 34,52 x 3,53 Ø 50 x 4 Ø 74,61 x 3,53
O-R 4387 O-R 4475 O-R 233
3c Cover seal 1
Ø 98,02 x 3,53 Ø 120,20 x 3,53 Ø 181,00 x 6,99
RETURN FILTER
3d Head seal 1 01026401 01026402 01026403

O-R 2131 O-R 3193 O-R 3325
Plug seal GAS thread 1
Ø 33,05 x 1,78 Ø 48,89 x 2,62 Ø 82,22 x 2,62
3e
O-R 1117 O-R 1172 O-R 1234
Plug seal SAE thread 1
Ø 29,74 x 2,95 Ø 43,69 x 3 Ø 59,36 x 3
O-R 4131 O-R 150 O-R 171
3f Blind flange seal 1
Ø 32,93 x 3,53 Ø 46,04 x 3,53 Ø 68,26 x 3,53
114
Spar e par ts
1 3a
3c
3d
3b
3e
FILTER Series
Item Description Q.ty FRI 850

NBR FPM
3 Seal Kit 1
02050218 02050225
O-R 4337
RETURN FILTER
Ø 85,32 x 3,53
O-R 4337
Ø 85,32 x 3,53
O-R 233
3c Cover seal 1
Ø 181,00 x 6,99
3d Head seal 1 01026320 01026326
3e Plug seal 1 01017055
115
Spar e par ts
3c
1 3a
3d
3b
FILTER Series
Item Description Q.ty FRI 255

NBR FPM
3 Seal Kit 1
02050013 02050014
O-R Metric
Ø 50 x 4
RETURN FILTER
O-R Metric
Ø 50 x 4
O-R Metric
3c Cover seal 1
Ø 113 x 4
O-R 4650
3d Head seal 1
Ø 164,70 x 3,53
Contamination retainer
4 binder 1 01060301
116
Or dering information FRI
Filter assembly 1 2 3 4 5 6 8
FRI
Example: FRI 040 B A G1 A10 N P01
Filter element 1 5 7 8
CU
Example: CU 040 A10 N P01
1 - Style 5 - Filter element

Filter Filter element A03 Inorganic microfibre 3 μm
025 025 A06 Inorganic microfibre 6 μm Absolute filtration
Inorganic
040 040 A10 Inorganic microfibre 10 μm Microfibre
100 100 A16 Inorganic microfibre 16 μm
ßx (c) ≥ 1000
255 250
M25 Wire mesh 25 μm
630 630 Nominal
M60 Wire mesh 60 μm Filtration
850 850
P10 Resin - Impregnated paper Nominal

2 - By-pass valve Filtration
P25 Resin - Impregnated paper
B With bypass
S Without bypass 6 - Δp Filter element
N Δp 10 bar
3 - Filter seals & Treatment
7 - Filter element seals
A NBR
N NBR
V FPM
V FPM
NBR, Filter body anodized. Filter element
W compatible with fluid HFA, HFB, HFC W* NBR (only for filter element type Axx and Mxx)
(only for filter element type Axx and Mxx)
Z* FPM (only for filter element type Axx and Mxx)
FPM, Filter body anodized. Filter element
Z compatible with fluid HFA, HFB, HFC 8 - Option
(only for filter element type Axx and Mxx)
P01 MP Filtri standard
* Compatible with fluid HFA, HFB, HFC
4 - Connections
FRI 025 FRI 040 FRI 100 FRI 255

Type A Type A Type A Type A
G1 G 1/2” G1 G 3/4” G1 G 1” G1 G 1 1/2”
G2 1/2” NPT G2 3/4” NPT G2 1” NPT G2 1 1/2” NPT
G3 SAE 8 - 3/4” - 16 UNF G3 SAE 12 - 1 1/16” - 12 UN G3 SAE 16 - 1 5/16” - 12 UN G3 SAE 24 - 1 7/8” - 12 UN
F1 1” SAE 3000 psi/M G4 G 1 1/4”
F2 1” SAE 3000 psi/UNC G5 1 1/4” NPT
G6 SAE 20 - 1 5/8” - 12 UN
FRI 630 FRI 850 FRI 250 F1 1 1/2” SAE 3000 psi/M
F2 1 1/2” SAE 3000 psi/UNC
Type A Type A Type A
G1 G 2 1/2” F1 3 1/2” SAE 3000 psi/M G1 G 1 1/2”
G2 2 1/2” NPT F2 3 1/2” SAE 3000 psi/UNC G2 1 1/2” NPT
RETURN FILTER
G3 SAE 32 - 2 1/2” - 12 UN G3 SAE 24 - 1 7/8” - 12 UN

F1 2 1/2” SAE 3000 psi/M F1 1 1/2” SAE 3000 psi/M
F2 2 1/2” SAE 3000 psi/UNC F2 1 1/2” SAE 3000 psi/UNC
For Clogging Indicator:

See page 318
MP Filtri - The filter functions as described in this bulletin are valid exclusively for original MP Filtri
filter elements and replacement parts. All rights reserved.
The data in this publication are purely guideline. MP Filtri reserves the right to make changes to the models described herein at any time it deems fit in relation to technical or commercial requirements.
The colours of the products shown on the cover are purely guideline. Copyright. All rights reserved.
04/2016 - rev. 00 117

9.19 SCHEDA TECNICA FILTRO IN PRESSIONE
IOM_14479_2 (09.16) Pages 52/59

FHB
Maximum pressure 320 bar

Flow rates to 485 l/min
Te c h n i c a l d a t a
Filter housing (Materials)
• Head: Cast iron (chemical heat treatment)
• Housing: Steel (chemical heat treatment)
Filter housings Δp pressure drop
• Bypass valve: Steel
The curves are plotted utilising mineral oil
• Check valve: Steel
with density of 0,86 kg/dm3 to ISO 3968.
Pressure
Δp varies proportionally with density.
• Working pressure: 320 bar (32 MPa)
• Test pressure: 480 bar (48 MPa)
• Burst pressure: 960 bar (96 MPa)
• Pulse pressure fatigue test: 1.000.000 cycles FHB 050 - 065
0,90
with pressure from 0 to 320 bar (32 MPa)
Check Valve
Temperature
• From -25°C to +110°C
0,60
Δp bar
Bypass valve
• Opening pressure 6 bar ±10% 0,30
• Other opening pressures on request.
Δp Elements type 0,00

• Microfibre filter elements series N: 20 bar 0 20 40 60 80 100
• Microfibre filter elements series H: 210 bar Flow rate l/min
(excluded FHB 065 - 135 - 320)
• Microfibre filter elements series S: 210 bar
(only for FHB 050)
• Wire mesh filter elements series N: 20 bar FHB 135
• Fluid flow through the filter element from OUT to IN. 0,90
Seals Check Valve

• Standard NBR series A 0,60
Δp bar
• Optional FPM series V
FHB FILTERS ARE PROVIDED FOR VERTICAL MOUNTING

0,30
Weights (kg)
Length 1 2 3 4 5
• FHB050 2,61 2,98 3,39 3,86 5,04 0,00
0 40 80 120 160 200
• FHB065 3,33 3,69 4,90 - -
Flow rate l/min
• FHB135 6,61 8,21 9,21 - -
• FHB320 12,95 15,08 17,37 26,77 -
Volumes (dm3)
Length 1 2 3 4 5 FHB 320
• FHB050 0,21 0,30 0,40 0,52 0,81 0,90
• FHB065 0,20 0,27 0,49 - - Check Valve
PRESSURE FILTER
• FHB135 0,40 0,73 0,94 - -

0,60
• FHB320 0,91 1,63 2,40 3,59 -
Δp bar
Connections
0,30
• FHB: Manifold mounting
0,00
0 75 150 225 300 375
Flow rate l/min
170
Valves
Bypass valve pressure drop
FHB 050 - 065 FHB 320

15 15
10 10
Δp bar
Δp bar
5 5
0 0
0 12 24 36 48 60 0 50 100 150 200 250
FHB 135
15
10
Δp bar
0
0 18 36 54 72 90
Flow rate l/min
Recommended maximum flow rate

- Pressure drop of filter assembly equal to Δp 1,5 bar.
- Oil kinematic viscosity 30 mm2/s (cSt).
- Density 0,86 kg/dm3.
Filtration Filtration
Length A03 A06 A10 A16 A25 M25 Length A03 A06 A10 A16 A25
FHB 050 1 42 44 78 80 100 130 FHB 050 1 30 40 58 60 74
2 53 58 83 93 112 132 2 46 50 75 85 107
3 65 69 93 100 118 133 3 59 62 87 95 115
4 82 86 105 108 122 134 4 74 79 100 102 118
5 102 104 119 122 127 136 5 90 92 105 112 125
Serie N - Flow rate l/min Serie H - Flow rate l/min
FHB 065 1 25 32 55 62 87 90 FHB 065 1 23 25 49 57 80
2 33 50 70 76 100 105 2 32 38 66 75 94
3 60 70 96 103 117 120 3 59 68 95 100 115
FHB 135 1 67 72 119 129 176 200 FHB 135 1 48 55 97 100 159
2 109 116 152 154 224 230 2 90 110 137 140 182
3 153 155 200 205 226 235 3 126 141 175 187 206
PRESSURE FILTER
FHB 320 1 130 143 238 285 340 440 FHB 320 1 110 117 191 200 300
2 259 282 390 408 450 465 2 200 230 318 325 390
3 330 368 440 450 460 475 3 268 312 379 387 430
4 367 390 445 463 480 485 4 310 332 387 392 435
171
FHB 050 - 065 FHB 135
110
85 72
58 Ø 18
Ø 10,5
Ø 20 Nr. 4 holes
Ø 16 Nr. 2 holes
22
OUT
74
55
26
35
30
17
20
IN
H
Ø 68
Ø 77
A/F 30
100
A/F 30
125
93 104
44 50
15 Indicator port 22
T2 Plug - A/F 30 Indicator port
Optional T2 Plug - A/F 30
Optional
OUT OUT
IN IN
Bypass plug
Bypass plug A/F 30
A/F 30
PRESSURE FILTER
FHB 050 FHB 065 FHB 135

Length H Length H Length H
Filter mm Filter mm Filter mm
1 185 1 194 1 268
2 222 2 225 2 381
3 264 3 327 3 456
4 312
5 434
172
FHB 320
140 FHB 320 length 4

95 Ø 23
Nr. 4 holes
Ø 30
A/F 3
26
58
52
28
A/F 3
Ø 125
H
A/F 30
550 mm
150 mm
Oil drain plug
P02
P01
Ø 101
G 3/8” - A/F 8
Style P01
Standard maintenance from head.
Style P02
Maintenance option from housing base.
A/F 30
150
157
65
34 Indicator port
T2 Plug - A/F 30
Optional
OUT
IN
Bypass plug
A/F 46
PRESSURE FILTER
FHB 320
Length H
Filter mm
1 301
2 424
3 556
4 709
173
Spar e par ts 3m 3h
4
5
3d
3e
6
3m 3h
3g
3n
3a
3b
3c
3f
FILTER Series
Item Description Q.ty FHB 050 FHB 065 FHB 135 FHB 320

NBR FPM NBR FPM NBR FPM NBR FPM
3 Seal Kit 1
02050412 02050413 02050266 02050277 02050270 02050281 02050273 02050284
O-R 3093 O-R 4100 O-R 3106 O-R 144
3a Filter element seal 1
Ø 23,67 x 2,62 Ø 24,99 x 3,53 Ø 26,65 x 2,62 Ø 39,69 x 3,53
O-R 3225 O-R 159 O-R 3256 2 pcs O-R 3350
3b Bowl seal 1
Ø 56,82 x 2,62 Ø 55,56 x 3,53 Ø 64,77 x 2,62 Ø 88,57 x 2,62
Parbak 139 Parbak 277 Parbak 144 2 pcs Parbak 153
3c Bowl anti-extrusion ring 1
Ø 56,03 x 2,18 Ø 54,53 x 3 Ø 63,96 x 2,18 Ø 89,36 x 2,18
01030058 01030046 01030058 01030046 01030058 01030046 01030058 01030046
3d Gasket 1
(HNBR) (FPM) (HNBR) (FPM) (HNBR) (FPM) (HNBR) (FPM)
O-R 2050 O-R 2050 O-R 2050 O-R 2050
3e O-Ring indicator 1
Ø 12,42 x 1,78 Ø 12,42 x 1,78 Ø 12,42 x 1,78 Ø 12,42 x 1,78
G 1/4” G 1/4” G 1/4” G 1/8”
3f Drain plug 1
with bonded seal with bonded seal with bonded seal with bonded seal
3g Protective seal 1 01026521 01026521 01026509 01026510
O-R 3143 (90 Sh A)
3h Bp or Non-Bp seal 1 Bonded seal G 1/2” Bonded seal G 1/2” Bonded seal G 1/2”
Ø 36,14 x 2,62
PRESSURE FILTER
O-R 2050 O-R 2050 O-R 2050 O-R 3106

3m Bp or Non-Bp seal 1
Ø 12,42 x 1,78 Ø 12,42 x 1,78 Ø 12,42 x 1,78 Ø 26,65 x 2,62
O-R 3075 O-R 3075 O-R 3093 O-R 4131
3n Connection seal 2
Ø 18,72 x 2,62 Ø 18,72 x 2,62 Ø 23,67 x 2,62 Ø 32,92 x 3,53
4 Indicator connection plug 1 T2H T2V T2H T2V T2H T2V T2H T2V
5 Bypass assembly 1 02001312 02001385 02001312 02001385 02001312 02001385 02001381 02001382
6 Non-bypass assembly 1 02001314 02001386 02001314 02001386 02001314 02001386 02001383 02001384
174
Or dering information FHB
Filter assembly 1 2 3 4 5 6 7a
FHB F1
Example: FHB 065 2 B A F1 A10 N P01
Filter element 1 2 5 4 6 7b
HP
Example: HP 065 2 A10 A N P01
1 - Style 5 - Filter element

Filter Filter element A03 Inorganic microfibre 3 μm
A06 Inorganic microfibre 6 μm Absolute filtration
050 050 Inorganic
065 065 A10 Inorganic microfibre 10 μm Microfibre

ßx (c) ≥ 1000
Nominal
Filtration
2 - Filter length
050 1 2 3 4 5 6 - Max filter element differential pressure
065 1 2 3 N Δp 20 bar
135 1 2 3 H Δp 210 bar (only for FHB 065 - 135 - 320)
320 1 2 3 4 S Δp 210 bar (only for FHB 050)
7 - Option
3 - Valves
a - Filter
S Without bypass
B With bypass
Maintenance from base of housing
T Without bypass + check valve* P02 (only FHB 320 length 4)
D With bypass + check valve*
Pxx Customer request
*Reduced cross-section oilways
b - Filter element
4 - Filter seals Pxx Customer request
A NBR
V FPM
Indicator plug:
Phosphated Steel plug T2 has
to be ordered separately.
Code
T2H Seal NBR
T2V Seal FPM
PRESSURE FILTER
For Clogging Indicator:

See page 318
MP Filtri - The filter functions as described in this bulletin are valid exclusively for original MP Filtri
filter elements and replacement parts. All rights reserved.
The data in this publication are purely guideline. MP Filtri reserves the right to make changes to the models described herein at any time it deems fit in relation to technical or commercial requirements.
The colours of the products shown on the cover are purely guideline. Copyright. All rights reserved.
04/2016 - rev. 00 175

9.20 SCHEDA TECNICA NEEDLE VALVE REVA
IOM_14479_2 (09.16) Pages 53/59

Technical features
Max working pressure (BAR) 250

Fluid viscosity range (cSt) 2.8 - 380
Temperature range ( C) -55 +60
Mass (Kg) 0,125
Hydraulic fluid : mineral oils
Recommended filtration: 19/15 ISO4466(25 absolutes)
Seals in MFQ
50
3
45,4 (OPEN)
CLOSE)
1
38,4
Torque 60Nm
3 1 LEVER AISI316 19.102.346

2 1 O-Ring MFQ-70Sh OR2-116 (Di18,72x2,62)
1 1 BIDIRECTIONAL FLOW REGUALTOR INOX FT2267/2-14-MFQ
POS. Q.ty Denomination Material Type or Drawing
3
2
1
0 19.02.16 FIRST Nardone
REV. DATA DESCRIZIONE MODIFICA DISEGNATO CONTROLLATO
DENOMINAZIONE TOLLERANZE GENERALI

NEEDLE VALVE CLASSE MEDIA UNI 5307
GRUPPO NOTA SCALA

LOW TEMPERATURE/MFQ 1:1
COMMESSA FOGLIO N. DI FOGLI
1 1
PROPRIETA' N. DISEGNO
S.r.l.
MATERIALE OLEODINAMICA REVA
REGGIO EMILIA
RIPRODUZIONE E
ITALY
DIVULGAZIONE VIETATA. 49.020.247
9.21 SCHEDA TECNICA NEEDLE VALVE TOGNELLA
IOM_14479_2 (09.16) Pages 54/59

FT2290
ESCLUSORI
PER MANOMETRO
A SPILLO
- IN LINEA -
Gli esclusori a spillo FT 2290 (in linea) vengono normalmente utilizzati a protezione
del manometro in quanto assolvono la duplice funzione di attutire lo shock della
pressione, in fase di apertura, e di isolare lo stesso dalla linea in pressione. Sottoposti
a severi controlli offrono sicurezza di affidabilità e di durata. Particolare attenzione
merita l’adozione di un dado girevole che consente all’utilizzatore di allacciare il
manometro, orientato nella posizione a lui più consona, con una singola operazione
di bloccaggio. La guarnizione, fornita di serie, e inserita nel dado stesso, impedisce
qualsiasi trafilamento tra il raccordo e il manometro. Idonei per pressioni fino a 400
bar e temperature da -20° / +130°C possono essere montati a pannello mediante l’in-
serimento di apposite ghiere (G) fornibili a richiesta.
A richiesta
• Completi di ghiere (G) indicare se KM o esagonali
• Filettature NPT
dimensioni
Tipo A1 UNI A2 B ØC D E ØF G H L M N P S OR ES Peso kg
338 UNI 339
14 1/4”G 1/4”Gc 13 5,6 20 61,5 34 12 M15x1 53 15 2 8,5 33 2018 18 0,125
12 1/2”G 1/2”Gc 16 6,5 32 83 40 12,5 M20x1 82,5 19 6 11 40 2021 27 0,413
materiali esempio per l’ordinazione

Corpo Acc. Inox AISI 316 Tipo Ghiera Tipo
Codice
a pannello ghiera
Spillo Acc. Inox AISI 316
FT 2290 14 G KM
OR Viton
FT 2290 12 G KM
Anello antiestrusione PTFE
Manopola Nylon 66
istruzioni di montaggio
77
2
montaggio a pannello
1° Svitare la vite (1) Spessore pannello A max Foro pannello ØB
2° Estrarre il volantino (2) 5 16
3° Introdurre la ghiera (3) di tipo KM o esagonale

9.22 SCHEDA TECNICA NEEDLE VALVE INDRA
IOM_14479_2 (09.16) Pages 55/59

Istruzioni generali
per l’installazione,
la manutenzione e la sicurezza
delle valvole per strumentazione
con otturatore a spillo
• Valvole per strumentazione
• Manifold per strumentazione
• Monolange per strumentazione
General instruction
for installation, maintenance
and safety information
for instrumentation valve
and manifold needle type
• Instrumentation Valve
• Instrumentation Manifold
• Instrumentation Monolange
Rev. 01 - 03/2015 - it-eu

1
3.4 Per valvole e manifold con attacchi a saldare dovran- 3.4 For valve and manifold having welding ends
AVVERTENZA WARNING no essere presi opportuni accorgimenti atti ad evitare particular care to be observed during welding
PRIMA DI OGNI INTERVENTO DEPRESSURIZ- CIRCUIT MUST BE DE-PRESSURIZED PRIOR TO che l’eccessivo calore generato dalla saldatura dan- to avoid that excess heat may cause damage
ZARE IL CIRCUITO. ANY INTERVENTION. neggi l’integrità delle guarnizioni interne compromet- to the seals, so to compromise its tightness.
tendone la tenuta. Un eccessivo riscaldamento della Extremely high heat excess during welding may
valvola/manifold durante la fase di saldatura potreb- also cause deformation of some parts of the val-
1.0 Istruzioni di Sicurezza 1.0 Safety Instruction be causarne la deformazione permanente. ve/manifold construction.
1.1 Ogni intervento di installazione e manutenzione 1.1 Qualiied personnel only can be authorized to 3.5 Per le valvole con opzione “montaggio a pannello” 3.5 For valve with “panel mounting” option will
sulle valvole/manifold deve essere eseguito da perform installation and maintenance of the val- sarà necessario procedere come segue: proceed as follows:
personale qualiicato e con circuito completa- ve/manifold supplied and any intervention must • Rimuovere la vite o il dado di bloccaggio del • Remove the screw or the nut of the Tee-bar or
mente depressurizzato (la pressione nel circuito be carried out with completely depressurized volantino o “T–bar” Knob
deve essere = zero). circuit (pressure in the circuit must be = zero). • Rimuovere il volantino o “T–bar” • Remove Tee-bar or Knob
• Inserire la valvola nel foro praticato nel pannello • Insert the valve through the hole on the panel
1.2 La rimozione della valvola/manifold e/o di tappi 1.2 Removal of the valve/manifold from its installation • Assemblare i componenti rimossi in precedenza • Re-assemble Tee-bar or Knob as in origin
posti sugli siati deve essere eseguita solo con and/or dismounting plugs on the drain ports must
circuito completamente depressurizzato (la pres- be carried out with completely depressurized cir-
sione nel circuito deve essere = zero). cuit (pressure in the circuit must be = zero).
AVVERTENZA WARNING
1.3 I “bonnet” e le “spine di blocco antisvitamento del 1.3 “Bonnet” and “Bonnet locking pin” cannot be re-
bonnet” non devono essere rimossi dalla loro sede moved from its seats from the valve body. Prima di collegare un qualsiasi strumento di misu- Line circuit must be drained and keep clean from
sul corpo valvola. ra e/o controllo è indispensabile eseguire lo spur- residual before connecting of any measurement
go della linea al fine di eliminare eventuali residui or controls instrumentation through the valve/
1.4 La coppia massima di torsione per l’azionamento 1.4 Max torque for operating of the valve/manifold di lavorazioni meccaniche o altro che, se presenti, manifold. Contaminating parts in the circuits
del bonnet è di 0,8 Nm (0,6 LB•ft). bonnets is 0,8 Nm (0,6 LB•ft). potrebbero interferire con il corretto funzionamen- may interfere with the correct operation of
to dello strumento a valle, oltre a causare possi- the valve/manifold, unless for possible major
1.5 Evitare urti o colpi sulle valvole superiori a 40 Nm 1.5 Strokes and impacts higher than 40 Nm (30 LB•ft) bili maggiori danni dovuti alla presenza di residui damage caused by the presence of residuals in
(30 LB•ft). must be avoided to the valve/manifold bodies. contaminanti. Si consiglia quindi di pressurizzare the line pressure. It is advisable therefore to drain
e spurgare il circuito alcune volte prima e dopo the circuit before and after the valve/manifold
1.6 I dati tecnici riportati sulla valvola/manifold devono 1.6 Marking of the technical data’s on the body valve/
l’installazione della valvola/manifold stessa. In installation by pressurization and draining of
essere sempre leggibili. Verniciature o quant’altro manifold must be always legible. Painting or else
particolare, in presenza di fluidi di processo con the circuit. Especially in presence of particular
possa impedire l’identiicazione dei dati tecnici resulting in hiding of the technical data’s, must be
particelle contaminanti, è indispensabile collocare type of media containing contaminating parts
deve essere evitato. avoided.
dei filtri a monte della valvola. Soltanto dopo aver it is advisable to interpose filters on the valve/
2.0 Istruzioni di Funzionamento 2.0 Operating Instruction completato tali operazioni sarà possibile installare manifold inlet. Then measurement or controls
la prevista strumentazione di misura e controllo. instrumentation can be safely installed.
2.1 Ruotando il volantino (T-bar) o la maniglia in senso 2.1 By rotating bonnet Tee-bar or knob clockwi-
orario, l’otturatore del bonnet chiude il passaggio se the valve close the flow pattern (around 5
(occorrono circa 5 rotazioni complete per la chiu- complete turns stop flow pattern completely).
sura del passaggio). I bonnet provvisti di cap- Bonnets provided with stainless steel dust 4.0 Istruzione di Manutenzione 4.0 Maintenance Instruction
puccio antipolvere in acciaio inox permettono di cap allow visual status of the bonnet (open or
Le valvole ed i manifold sono progettati e costruiti per Indra Valve and manifold are designed and manufac-
visualizzare lo stato del bonnet (aperto o chiuso). closed).
un esercizio continuo con minima o totale assenza di tured for continuous operation, with minimum and/or
3.0 Istruzione di Installazione 3.0 Installation Instruction manutenzione. zero maintenance.
Tuttavia le istruzioni che seguono sono utili al man- Nevertheless, the instruction given with the present ma-
3.1 Ogni intervento di installazione delle valvole deve 3.1 Qualiied personnel only can be authorized to per- tenimento dell’eficienza delle valvole/manifold fornite nual should be intended for the preservation of the efi-
essere eseguito da personale qualiicato. form installation of the valve/manifold supplied. alla nostra clientela: ciency of the valve and manifold supplied to customers:
3.2 L’installazione dovrà essere effettuata in modo 3.2 Installation must be carried out caring that the 4.1 Veriicare l’eficienza delle tenute periodicamente 4.1 Check periodically seal eficiency by absence of
tale da mantenere visibili le informazioni marcate marking and all technical data’s marked on the (assenza di perdite). leakages.
sul corpo della valvola: valve/manifold body will remain visible as:
• Nome del costruttore (Indra) • Manufacturer name (Indra) 4.2 Eliminazione delle perdite con circuito in pressione: 4.2 Leakages elimination while circuit pressurized:
• Codice prodotto • Product code - Aprire completamente la valvola ruotando il vo- - Open valve completely, by rotating Tee-bar or
• Rating • Rating lantino in senso antiorario (Fig. ”A” pos. 1) Knob anticlockwise (Fig. ”A” pos. 1)
• Materiale di costruzione • Material - Rimuovere il dado/vite di serraggio del volantino - Remove Tee-bar locking screw (Fig. ”A”
• Lotto di rintracciabilità • Lot of production for traceability (Fig. ”A” pos. 11) pos. 11)
• Marcature aggiuntive se richieste • Additional marking as it might be requested - Rimuovere il volantino (Fig.”A” pos. 1) - Remove Tee-bar (Fig. ”A” pos. 1)
- Rimuovere il cappuccio antipolvere (Fig. ”A” pos. 2) - Remove Tee-bar dust cap (Fig. ”A” pos. 2)
3.3 Le valvole NON devono essere utilizzate come 3.3 Valve and manifold cannot be used and/or inten- - Allentare e svitare di 2-3 iletti il dado di bloccag- - Lose and unscrew by two/three threads the
supporto per altre apparecchiature. ded as support of other installed equipments. gio (Fig. ”A” pos. 4) locking nut (Fig. ”A” pos. 4)
2 3
- Serrare gradualmente il dado di compressione, - Gradually tighten the compression nut by 1-2
evitando avanzamenti eccessivi, 1-2 mm max, mm turns, avoiding strong sudden tightening, AVVERTENZA WARNING
ino ad eliminazione totale della perdita (Fig. “A” till leakages elimination (Fig. ”A” pos. 3 - see Il serraggio del dado di compressione (Fig.”A” pos. Tightening of the compression nut must be carried
pos. 3 - vedere tabella coppie di torsione in fondo) also torque table at the bottom) 3) deve essere effettuato con avanzamenti gradua- out smoothly, with 2-3 mm turns, avoiding strong
- dopo l’eliminazione della perdita serrare nuo- li di 2-3 mm per volta, evitando serraggi repentini sudden tightening, till leakages elimination. After
- After elimination of the leakages retighten the
vamente il dado di bloccaggio (Fig. “A” pos. 4) fino ad eliminazione delle perdite. Azionare una o tightening operation completed the bonnet must
locking nut (Fig. ”A” pos. 4)
- Riposizionare il cappuccio antipolvere (Fig. “A” più volte il bonnet per l’assestamento delle tenute be actioned one or more time for settlements of
pos. 2) - Re-assemble dust cap (Fig. ”A” pos. 2) interne. the internal seals and checks of eventual leakages.
- Riposizionare il volantino (Fig. ”A” pos. 1) - Re-assemble Tee-bar (Fig. ”A” pos. 1) Eventuali perdite saranno eliminate secondo le Leakages, if any, can be eliminated by applying to
- Riavvitare il dado/vite di serraggio del volantino istruzioni del punto 4.2. the procedure as per above point 4.2.
- Screw-in Tee-bar locking screw (Fig. ”A” pos. 11)
(Fig. “A” pos. 11)
- Veriicare l’eliminazione della perdita - Check for positive elimination of the leakages
4.4 Veriicare periodicamente l’apertura e la chiu- 4.4 Check periodically smooth opening/closing of the
sura della valvola, in particolare se inattiva per valve, especially when not actioned for a long pe-
lunghi periodi. Se lo sforzo risultasse eccessivo, riod of time. If the torque would be in excess of e.g.
AVVERTENZA WARNING ad esempio 1 Nm (0,74 LB •ft), provvedere alla 1 Nm (0,74 LB•ft), replacement of the full bonnet
Qualora la perdita persista con il dado di com- If leakages still occur while the compression sostituzione del bonnet (vedi paragrafo 4.5). would be recommended (see following para 4.5).
pressione completamente serrato, si dovrà prov- nut has been totally tightened replacement of
vedere alla sostituzione degli anelli di tenuta (vedi the bonnet internal seal might be necessary, 4.5 Rimozione e sostituzione del bonnet. 4.5 Removal and replacement of the bonnet.
paragrafo 4.3). (see para 4.3).
AVVERTENZA WARNING
Ogni intervento sulle valvole deve essere effettua- Operation on the valve must be carried out by
4.3 Eliminazione delle perdite con circuito depres- 4.3 Leakages elimination with depressurized circuit to da personale qualificato. Prima di procedere qualified personnel. Before proceeding to bon-
surizzato: (P=0): alla sostituzione del bonnet il circuito deve essere net replacement the line must be completely
- Aprire completamente la valvola ruotando il - Open valve completely, by rotating Tee-bar or tassativamente depressurizzato (la pressione nel depressurized (pressure in the circuit must be
volantino in senso antiorario (Fig. ”A” pos. 1) Knob anticlockwise (Fig. ”A” pos. 1) circuito deve essere = zero). = zero).
- Rimuovere il dado/vite di serraggio del volan- - Remove Tee-bar locking screw (Fig. ”A” pos. 11)
tino (Fig. ”A” pos. 11)
- Remove Tee-bar (Fig. ”A” pos. 1) - Aprire la valvola completamente con rotazione - Open valve completely by rotating Tee-bar or
- Rimuovere il volantino (Fig. ”A” pos. 1) antioraria del bonnet (Fig. ”A” pos. 1) Knob anticlockwise (Fig. ”A” pos. 1)
- Rimuovere il cappuccio antipolvere (Fig. ”A” - Remove Tee-bar dust cap (Fig. ”A” pos. 2) - Rimuovere la spina di blocco del bonnet - Remove bonnet locking pin from the valve body
pos. 2) - Lose and unscrew the locking nut (Fig. ”A” - Rimuovere il “bonnet” dal corpo valvola svitan- - Remove the bonnet from the valve body by me-
- Allentare il dado di bloccaggio (Fig. ”A” pos. 4) pos. 4) dolo dalla base esagonale tramite l’utilizzo di ans of a suitable wrench holding it from the hex
- Rimuovere il dado di compressione, svitando un’apposita chiave (Fig. ”A” pos. 6) base (Fig. ”A” pos. 6)
- Unscrew completely and remove the com- - Disporre del bonnet di ricambio e collocare la sua - Obtain the spare bonnet and place it in a vice
in senso antiorario (Fig. ”A” pos. 3) pression nut (Fig. ”A” pos. 3) base esagonale in una morsa (Fig. ”A” pos. 6) from its hex base (Fig. ”A” pos. 6)
- Rimuovere l’anello di compressione interno
- Remove the compression ring located inside - “Aprire” il bonnet di ricambio ruotando il suo vo- - Turn spare bonnet Tee bar in open position by
(Fig. ”A” pos. 8)
the bonnet body (Fig. ”A” pos. 8) lantino in senso antiorario (Fig. ”A” pos. 1) rotating Tee-bar or Knob anticlockwise till it stops
- Rimuovere gli anelli di tenuta interni con l’au- - Ripulire la sede ed i iletti del corpo valvola da (Fig. ”A” pos. 1)
silio di un attrezzo a punta (es. cacciavite) - Remove the Ptfe or Graphite sealing ring lo-
eventuali depositi - Clean body threads and seat from eventual detri-
(Fig. ”A” pos. 9) cated inside the bonnet body by means of a
- Predisporre del sigillante e/o anti grippante sulla mental deposits
- Sostituire gli anelli di tenuta interni (Fig. ”A” suitable tool, e.g. screwdriver (Fig. ”A” pos. 9) ilettatura maschio del bonnet di ricambio (Fig. - Provide sealant for anti-gripping for spare bonnet
pos. 9) - Replace Ptfe or Graphite sealing ring with new ”A” pos. 5) male thread (Fig. ”A” pos. 5)
- Reinserire all’interno l’anello di compressio- rings supplied meantime (Fig. ”A” pos. 9) - Avvitare il bonnet a mano sul corpo valvola ino a - Hand screw spare bonnet to the valve body till it
ne (Fig. ”A” pos. 8) incontrare resistenza stops
- Re-locate the compression ring inside the
- Serrare gradualmente il dado di compressio- - Serrare il bonnet dalla sua base esagonale (Fig. - Tighten spare bonnet from hex base (Fig. ”A”
bonnet body (Fig. ”A” pos. 8)
ne (Fig. ”A” pos. 3 - vedere tabella coppie di ”A” pos. 6) con apposita chiave pos. 6) by means of a suitable wrench
torsione in fondo) - Screw-in and gradually tighten the compres- - Reinserire la spina di blocco - Insert the locking pin in its hole on the valve
sion nut (Fig. ”A” pos. 3 - see also torque ta- - Effettuare 5-10 manovre complete di apertura/ body
- Serrare nuovamente il dado di bloccaggio
ble at the bottom) chiusura del bonnet - Operate the new bonnet for 5-10 opening/closing
(Fig. ”A” pos. 4)
- Pressurizzare il circuito per veriicare l’esistenza full turns
- Riposizionare il cappuccio antipolvere (Fig. - Re-tighten the locking nut (Fig. ”A” pos. 4)
di eventuali perdite - Circuit pressurization for leakage check
”A” pos. 2) - Re-assemble dust cap (Fig. ”A” pos. 2)
- Riposizionare il volantino (Fig. ”A” pos. 1)
- Re-assemble Tee-bar (Fig. ”A” pos. 1) AVVERTENZA WARNING
- Riposizionare il dado/vite di serraggio del vo-
lantino (Fig. ”A” pos. 11) - Screw-in Tee-bar locking screw (Fig. ”A” pos. 11) Eventuali perdite saranno eliminate secondo le Leakages, if any, can be eliminated by applying
istruzioni del punto 4.2. to the procedure as per above point 4.2.
- Pressurizzare il circuito - Circuit pressurization for leakage check
4 5
COPPIA DI TORSIONE PER AZIONAMENTO BONNET GRAFICO PRESSIONE / TEMPERATURA
BONNET TORQUE PRESSURE / TEMPERATURE GRAPH
Valvole serie 6000 / 10000 PSI

max 0,8 Nm (0,6 LB•ft)
Valve / manifold 6000 / 10000 PSI
COPPIA DI TORSIONE PER DADO DI SERRAGGIO TENUTE

COMPRESSION NUT TORQUE
(Fig. “A” pos. 3)
Valvole serie 6000 / 10000 PSI

10 Nm (7,4 LB•ft)
Valve / manifold 6000 / 10000 PSI
Fig. A
6 7
INDRA srl
l
Ufici/Ofices: Via Novara, 10/B-C - 20013 Magenta (MI) - Italy
Tel. +39 02 972 986 63 - Fax +39 02 972 918 55
e-mail: indra@indra.it - Web site: www.indra.it
8
Valvole a Sede Morbida - Femmina/Femmina
Soft Seat Needle Valves - Female/Female
Mod. 060 - 062
Applicazioni Applications
Intercettazione di strumenti di pressione Pressure instruments isolation
(manometri, pressostati, trasmettitori, ecc.) (gauges, switches, transmitters, etc.)
Connessioni Connections
Filettate secondo ANSI-ASME B1.20.1 Threaded to ANSI-ASME B1.20.1
ISO 228 - ISO 7/1 ISO 228 - ISO 7/1
Rating Rating
Standard: 6000 PSI (420 bar) Standard: 6000 PSI (420 bar)
Tenute Seals
Standard: PTFE (T ≤ 200° C) Standard: PTFE (T ≤ 200° C)
Peculiarità Features
Otturatore svincolato dallo stelo Not rotating trim
Spina di blocco del bonnet Bonnet locking pin
Protezione antipolvere Dust cup
Facile manovrabilità Easy operation
Come ordinare
Ordering Information
Modello / Model - FxF * Connessioni OUT Materiale Tenuta
Connections OUT Seal material
060 Montaggio standard / Standard mounting
062 Montaggio a pannello / Panel mounting B 1/4” NPT-F T PTFE
C 3/8” NPT-F
D 1/2” NPT-F
E 3/4” NPT-F
F 1” NPT-F
060 B B L T * * *
* NPT standard *Connessioni IN Materiali / Materials

Aggiungere / Add: Connections IN
L S.S. 316L Opzioni / Options
R = BSPT thread
Vedere tabella / See table
G = BSPP thread B 1/4” NPT-F S.S. 316 / 316L (Dual grade)
DL
Es / Ex: DR = 1/2’’ BSPT
C 3/8” NPT-F S.S. 316 Nace
N
D 1/2” NPT-F C.S. A 105
C
E 3/4” NPT-F C.S. A 350 LF2
LF2
F 1” NPT-F Duplex F51
D
SD Superduplex
M Monel 400
X A richiesta / On demand
Mod. 060 Mod. 062

45
45
M Apertura max - Max open
M Apertura max - Max open

OUT
OUT
IN
IN
H
W L W L
Dimensioni L W H M
Dimensions
B 1/4’’ 60 32 29,5 94
Mod. 060-062 • Rev. 0
C 3/8’’ 60 32 29,5 94
D 1/2’’ 65 32 29,5 94
E 3/4’’ 71 35 32,5 97
F 1’’ 80 44 40 106
Le dimensioni, espresse in “mm”, sono indicative e possono subire variazioni senza preavviso. / Dimensions are in “mm” for reference only, and may be changed without notice.
www.indravalves.it • indra@indra.it • Tel. +39 02 97298663

9.23 SCHEDA TECNICA STOP VALVE MHA
IOM_14479_2 (09.16) Pages 56/59

1. Labeling of ball valves and valves valve can be switched using a hand lever or drive. The design of the drive
must be suited to the conditions of use of the ball valve.
The application of the PED (Pressure Equipment Directive) has been man-
datory since 29.5.2002. The operating instructions of the corresponding manufacturer are valid for
MHA:%.4'2!&'MB(#O+'HOLDSCERTIÚCATIONTHATINCLUDESCOMPLI drive parts, e.g. for drives and position switches. Please observe machine-
ance with DIN EN ISO 9001 and correspondence with Directive 97/23/EG, RYDIRECTIVE%'FORÚTTINGSANDDRIVES
including Module H1.
Valves that are destined for use within the European Economic Area are 3. Installation notes
CLASSIÚEDINCATEGORIES)TO)))INACCORDANCEWITHINCREASINGPOTENTIAL
HAZARD Prior to installation checks must be carried out to test whether the ball
4HENOMINALDIAMETERPRESSUREANDÛUIDGROUPHAZARDOUSORNON valve design corresponds to the required design and is suitable for the
HAZARDOUSÛUIDS ARETAKENINTOACCOUNTFORTHECLASSIÚCATION intended use. The installation of ball valves may only be carried out by
QUALIÚEDPERSONNELANDWHILETHEBALLVALVEANDPIPESYSTEMAREUNPRES
&LUIDGROUPINCLUDESHAZARDOUSÛUIDSINACCORDANCEWITH!RTICLEOF SURIZED4HEPIPELINESMUSTBEINTRODUCEDTOTHEÚTTINGSWITHOUTTENSION
Directive 97/23/EG. The valve valves must be inspected for damage and contamination before
installation. Damaged ball valves must not be installed.
p0OTENTIALLYEXPLOSIVE All the pipelines must be rinsed before the ball valves are installed.
p%XTREMELYÛAMMABLE Residue in the pipelines can damage internal parts and this can result in
p(IGHLYÛAMMABLE malfunction or complete failure of the ball valve.
p&LAMMABLEIFTHEMAXPERMITTEDTEMPERATUREISABOVETHEÛASHPOINT
p 4OXIC Please ensure during installation of the ball valves that no external tensi-
p/XIDIZING ons or vibrations are transferred to the ball valve.
When the piping is screwed in the screw on the ball valve must be held
&LUIDGROUPINCLUDESALLÛUIDSTHATDONOTHAVEANYOFTHECHARACTERISTICS with a suitable tool. The ball valve connections must not be subjected
INÛUIDGROUP to any additional torsional moment that would change their installation
position and thus prevent provision of function.
"ALLVALVESWITHANOMINALDIAMETEROFMORETHAN$.FORÛUIDGROUP Overheating of the seals must be prevented on ball valves with welded
MUSTBELABELEDAS#%"ALLVALVESFORÛUIDSINÛUIDGROUPARENOT ends by using suitable measures. When welding is carried out it must also
labeled with a CE mark. The buyer is obliged to inform the manufacturer/ be ensured that no welding particles enter the internal space. Welding
SUPPLIERIFBALLVALVESAREDESTINEDFORAPPLICATIONINÛUIDGROUP)FNO residue must be removed.
INFORMATIONISPROVIDEDONTHEMEDIUMFORUSEITISASSUMEDTHATÛUIDS "ALLVALVESWITHÛANGECONNECTIONSMUSTBECENTEREDBYSCREWINGTHE
FROMÛUIDGROUPWILLBEUSED COUNTERÛANGEBEFOREALLTHESCREWSONTHEÛANGECONNECTIONARETIGHTENED
CROSSWISE!NUNDAMAGEDSEALMUSTBEUSEDBETWEENTHEÛANGESAS
The ball valve and seal materials are selected by the manufacturer in prescribed in the norm. The spacer bolts or connecting screws must be
accordance with customer information such as medium, pressure, tempe- SELECTEDINACCORDANCEWITHTHEÛANGETYPES7ITHTHREADHOLESITMUSTBE
RATUREANDOTHERUSE SPECIÚCREQUIREMENTS)FTHECONDITIONSOFUSEVARY ensured that the maximum screwing depth is not exceeded.
from the information provided then the lifespan of the ball valve may be
reduced or the ball valve may malfunction. The material combinations and Switching must be carried out as a function test after the ball valve has
CONDITIONSFORUSETHATARESPECIÚEDBASEDONTHEDESIGNCANBEFOUNDIN been installed. No parts of the ball valve (e.g. cover, connecting piece)
the following labeling on the ball valve. MAYBERELEASEDORSCREWEDDOWN)NTHECASEOFMEDIATHATAREHAZAR
DOUSTOHEALTHÛAMMABLEOREXPLOSIVEITMUSTBEENSUREDTHATTHEPIPE
1st Line: Germany x-y country of manufacture, x = calendar system and ball valve are completely emptied.
week, y = year
7ATCHOUTFORANYRESIDUEÛOWINGTHROUGH!PPROPRIATEPROTECTIVE
2nd Line: MHA manufacturer CLOTHINGMUSTBEWORN4HEÚTTINGMAYNEEDTOBEPLACEDINTHEPIPING
using lifting gear.
3rd Line: BKH-DN13-G1/2 valve type, nominal diameter, connection
TYPESIZE Please observe the switch position of the ball valve according to the
4th Line: PN500 - 1123 nominal pressure, MHA material combi- piping plan. Pressure stage, connection and construction length of the
nation piping system must correspond to the ball valve. The operating instruc-
tions of the relevant manufacturer must be taken into account with regard
to system parts.
(For more information on MHA material combinations, please see p. 242.)
4. Initial operation
2. General
All operating instructions must be read and observed prior to initial
"ALLVALVESAREPRESSURIZEDFORTHETRANSPORTATIONSHUTTINGOFFORREDIREC operation and assembly work must be inspected. Initial operation of a
TIONOFMEDIAÛOW(AZARDSAREPRESENTEDBYÚTTINGSINTHEHIGH PRESSURE SYSTEMMAYONLYBECARRIEDOUTBYQUALIÚEDPERSONNEL4HEPIPINGSYSTEM
area if there is a case of improper or incorrect use or if the safety notes in must be bled prior to initial operation. Air bubbles in the piping system
these operating instructions are not observed. can cause explosions in the event of a sudden increase of pressure. This is
why the operating pressure should be increased in stages.
The customer must take the operating pressures (pressure surges/impulse If the ball valve is stored for a long period, or if it is at a standstill for a
pressures) into account during the planning and design of ball valves. longer period in one switch position, then the torsional moment for the
Pressure information in the catalog refers to static loads. The correspon- ÚRSTSWITCHINGPROCESSISSUBSTANTIALLYABOVETHEACTUALTORSIONALMOMENT
ding pressure reductions must be taken into account for pulsating or (pull-off moment).
changing loads.
)FBALLVALVESAREINSTALLEDINTHEPIPINGSYSTEMASENDÚTTINGSTHEREIS
Ball valves are only suitable for installation in piping systems with con- particular risk of death from parts sheering off. Professional execution is
nections at the same pressure load and corresponding connections or bet- absolutely essential in this case.
WEENÛANGESOFTHESAMEPRESSURELOADANDTHESAMEÛANGECONNECTION
Two-way ball valves open and close by turning the selector shaft by 90°.
!ÛOWDISPLAYSHOWSTHEPOSITIONTHEBALLVALVEISSWITCHEDTO4HEBALL
270 10.04.2015
5. Maintenance / Inspection #AUTION$ANGERTOHUMANLIFEØ
3PECIÚCWARNINGNOTESEGREGARDINGTHEWEARINGOFGLOVESFORSWITCHING
When the piping system is drained the ball valves must be drained via a must be heeded (the ball valves take on the temperature of the medium).
switch position of 45°. Ball valves may only be dismantled and maintained !NYSTRUCTURALMODIÚCATIONTOTHEBALLVALVEPARTICULARLYTHEADDITIONOF
by trained, specialist personnel. No makeshift seals of any kind are permit- drill holes and the welding on of objects (plates, mounts etc.) is strictly
ted. Ball valves must be inspected at regular intervals for leaks, malfunc- prohibited.
tion and damage. The maintenance intervals depend on the conditions of )NTHEEVENTOFMALFUNCTIONSTHEBALLVALVEMUSTBEEXCHANGEDBYQUALIÚED
USEOFTHEÚTTING PERSONNELWITHTHEPIPESYSTEMINANUNPRESSURIZEDANDDRAINEDCONDI
tion. Systems must be switched off before the ball valve is dismantled.
In order to retain functionality the ball valve must be switched at least eve-
ry six months in the event of longer standstill periods. If discrepancies to Only the manufacturer is permitted to carry out repairs. If the ball valve
the desired status are discovered during this maintenance work, measures ISDISMANTLEDWITHOUTPERMISSIONANDBYUNQUALIÚEDPERSONNELTHISWILL
must be undertaken immediately to ensure safe operating conditions render any warranty or damage claim made against the manufacturer null
(exchange or repair). and void. National regulations on accident prevention and the local safety
regulations of the operator are not replaced by these operating instruc-
tions and must always be regarded as overriding.
6. Removal notes 4HEFOLLOWINGMUSTBEENSUREDBEFOREANYREPAIRWORK

p /NAUTOMATEDÚTTINGSTHEPOWERSUPPLYTOTHEDRIVESMUSTBE
4HEREMOVALOFBALLVALVESMAYONLYBECARRIEDOUTBYQUALIÚEDPERSONNEL suspended prior to repair and maintenance work.
and while the ball valve and piping are not under pressure. The ball valve p )TMUSTBEENSUREDTHATNOTHIRDPARTYCANSTARTUPTHESYSTEM
must be set to a semi-open position in order to prevent pressure from p4HEPIPELINESMUSTBEDRAINEDANDPRESSURECUSHIONSRELIEVED
being trapped. p )NFORMATIONMUSTBECOLLECTEDREGARDINGPOSSIBLEHAZARDSTHATCOULDBE
caused by residue operating material and protective gloves, goggles etc.
)FMEDIAAREUSEDTHATAREHAZARDOUSTOHEALTHÛAMMABLEOREXPLOSIVE must be worn if necessary.
the piping and the ball valve must be completely drained. Watch out for p ,EAVEÚTTINGSTOCOOL$ONOTEXCEEDLIMITSWITHREGARDTOPRESSURE
ANYRESIDUESÛOWINGTHROUGH!PPROPRIATEPROTECTIVECLOTHINGMUSTBE temperature or media.
worn.
7. Warning notes
Please take note of these operating instructions. The manufacturer of the
ball valves does not accept any liability if these operating instructions are
not heeded.
Ball valves must only be used for the purpose stated by the manufacturer.
The manufacturer will also not accept liability in the event of damage
caused by the incorrect installation and use of ball valves or by incorrect
USEBYUNQUALIÚEDPERSONNEL Lock valve adapter during No welding, boring or other
Ball valves must always be switched fully in principle. They may only be pipe installation! MODIÚCATIONATTHEVALVEØ
used in the switch positions fully closed or fully open.
"ALLVALVESARENOTSUITABLEFORTHERESTRICTIONORREGULATIONOFÛOWQUANTI
ties and are not approved for this use. Indifferent switching positions lead
to damage to the seals in the ball area, which result in leaks or altered
torsional moments that can be accompanied by temperature rises at the
surface.
Tools (e.g. pliers, hammers, open-end wrenches, extensions etc.) may not
bar
be used to switch the ball valves. The use of such tools can lead to damage
to switching elements and casings. Ball valves may not be switched by
force.
Particular usage or environmental conditions (moisture, vibrations,

No actuation with additional Do not disassembly while
SWITCHINGFREQUENCYELECTROMAGNETICÚELDPOTENTIALLYEXPLOSIVEAREAOR tooling! PRESSURIZEDØ
ANTI STATICSETC MUSTBECLEARLYDEÚNEDWHENTHEBALLVALVESAREORDERED
in order to ensure functional design. Ball valves may only be used for
suitable media.
No viscous or hardenable media may be used.

Contamination is to be avoided. Contaminated media lead to damage to
sealing elements. This creates leaks that lead to the failure of the ball val-
VE4HETEMPERATURELIMITSTHATAREPROVIDEDFORTHEÚTTINGMUSTBEUPHELD
in order to prevent early failure of the ball valve.
Ball valves must be stored in a dry and clean condition as delivered. Pro-
tective caps must only be removed just before actual installation.
Unpacked ball valves must be protected from direct UV and/or sunlight.

In potentially explosive areas the switches on the ball valves must be limi-
ted to a maximum of 10 per minute in order to avoid self-warming. Excee-
ding the operating pressure quoted or operating at temperatures outside
the quoted range may lead to leaks or destruction of the ball valve.
18.12.2015 271
Ball valve for manifold mounting PKH
Stainless Steel
K
SW1
H2
H1
H
LW
h
m
l
SW2
B
AVAILABLE SIZES
Manifold
DN6 - DN50 (1/4“ to 2“)

L l7
ACCESSORIES ON REQUEST & MATERIAL CODE DESCRIPTION
Materials 442A 4428

• Locking devices page 229
Body Stainless Steel Stainless Steel
• Actuators 224 - 225
Ball Stainless Steel Stainless Steel
• Position switches on request
Stem Stainless Steel Stainless Steel
• Detent on request
Ball seats POM POM
O-rings NBR FPM
Tmin / Tmax -30°C / 100°C -20°C / 100°C
GENERAL DIMENSIONS
Type l L l7 B H h m V SW1 SW2 K LW H1 H2 Lever Weight

[Kg]
PKH-DN6 26 57 6 40 43 35 19,5 6 7 19 80 6 - 67 Zn 0,60
PKH-DN10 29 70 10 55 59 45 24,5 11 9 30 115 10 - 93 Zn 1,30
PKH-DN13 42,5 98 10 60 69 55 34 11 9 32 115 13 - 104 Zn 2,32
PKH-DN20 51 117 10 70 88 70 37,5 14 14 46 200 20 92 - Zn 4,02
PKH-DN25 62 135 10 80 98 80 44,5 14 14 50 200 25 102 - Zn 5,70
PKH-DN32 75 165 11 100 121 100 54,5 17 17 70 320 32 130 - Al 11,00
PKH-DN40 84,5 200 17 130 131 110 57 17 17 80 320 38 140 - Al 18,78
PKH-DN50 106 240 15 150 150 129 71 17 17 90 320 48 159 - Al 29,55
126 10.04.2015
Ball valve for manifold mounting PKH
Stainless Steel
CONNECTION
d4/xt
d3
d5 (DN40)
b
d1
h1
l4
d2
o-rings belong
O-rings
to delivery l5
included l1 l3 l3
l2
Manifold
ORDER CODE PER MA-
CONNECTION DIMENSIONS TERIAL COMBINATION
Type l1 l2 l3 l4 l5 b d1 d2 h1 d3 d4 t d5 Dimension of Torque O-ring PN 442A 4428

screws (min)(1) of screws [bar]
in Nm(1)
PKH-DN6 8,5 35 - 8,5 35 27 6 11,8 1,9 6,5 10,5 6,8 - 4 x M6x40 - 12.9 14 7x2,5 500 21337 28244
PKH-DN10 7,5 55 - 10 44 40 9,5 14,9 1,9 8,4 13,5 8,5 - 4 x M8x50 - 12.9 35 10x2,5 500 10053 29747
PKH-DN13 7,5 83 41,5 16 58 45 13 24,9 1,9 8,4 13,5 7 - 6 x M8x60 - 12.9 35 20x2,5 420 25439 18041
PKH-DN20 10 97 48,5 20 69 51 20 29 2 10,5 16,5 10,5 - 6 x M10x80 - 12.9 70 23,47x2,62 420 28598 38365
PKH-DN25 10 115 57,5 24 81 60 25 34,9 2,3 10,5 16,5 10,5 - 6 x M10x90 - 12.9 70 29x3 420 33708 32060
PKH-DN32 12 136 68 29 96 78 32 40 2 13 19 12 - 6 x M12x110 - 12.9 110 34,59 x 2,62 420 59601 59602
PKH-DN40 28,5 112 56 28,5 112 95 38 47,7 2,3 16,5 25 19 36 6 x M16x120 - 12.9 300 42x3 420 36117 38367
PKH-DN50 38 136 68 38 136 112 48 59,8 2,3 21 31 21,5 - 6 x M20x140 - 12.9 600 54x3 420 38368 38369
(1)
Fixing screws not included.
We recommend screws as per ISO4762 (DIN 912). FLOW CHARACTERISTICS PKH
The indicated property classes and torques represent our ∆p‐Q characteris5cs
recommended guidelines at a friction coeficient of 14%. PKH
DN50
1000
DN40
DN32
DN25
DN20
DN16/12
100
DN10
Q(l/min)
Q [l/min]
DN6
10
1
0 0,5 1 1,5 2 2,5 3 3,5 4
∆p∆p [bar]
(bar)
10.04.2015 127
9.24 SCHEDA TECNICA STOP VALVE EFFEBI
IOM_14479_2 (09.16) Pages 57/59

MONOBLOCK AISI 316L ®
FIRE SAFE FIRE SAFE

PTFE + CARBOGRAPHITE
ISO 10497:2010 BS 6755 - API 6 FA
API 607
* su richiesta
S. 800 - 1500 S. 3000 PN 160/120/64

PTFE DELRIN PTFE + CARBOGRAPHITE
art. art. art.

2660X2... F/F gas 1/4" - 4" 2655E2... F/F gas 1/4" - 4" 2655D2... F/F gas 1/4" - 4"
art. art. art.
2660X5... F/F NPT 1/4" - 4" 2655E5... F/F NPT 1/4" - 4" 2655D5... F/F NPT 1/4" - 4"
art. art. art.
2662 SW 1/4" - 4" 2656E SW 1/4" - 4" 2656D4 SW 1/4" - 4"
art. art. art.
2663 BW 1/4" - 4" 2657E BW 1/4" - 4" 2657D4 BW 1/4" - 4"
CARATTERISTICHE PRINCIPALI STD: IMPIEGHI GENERALI:
• ESECUZIONE COSTRUTTIVA: AISI 316L. VALVOLA di Intercettazione (ON-OFF) per: Impianti industriali ad
• PRESCRIZIONI GENERALI: BS EN ISO 17292:2004. alta pressione e temperatura, per impianti chimici e petrolchimici,
• CERTIFICAZIONI: FIRE SAFE secondo BS 6755 - API 6 FA - API 607 per impianti idraulici e pneumatici, per vapore ino a 195°C.
(solo PTFE+CRB). Per utilizzi speciali veriicare la compatibilità con le caratteristiche
• A RICHIESTA: FIRE SAFE ANSI/API STD. 607 ISO 10497:2010 del processo e la resistenza alla corrosione anche mediante la
Nace MR 0.175 (non disponibile su bulloneria). apposita tabella.
• ATTACCHI: F/F Rp UNI ISO 7/1 (UNI EN 10226)
DIN2999 ilettatura cilindrica ESECUZIONI SPECIALI:
SW ANSI B16.11 a saldare di tasca
BW ANSI B16.25 a saldare di testa. • ATTACCHI: F/F NPT ANSI B1.20.1.
S.800-1500 sch.80 std. • VALVOLE SGRASSATE: per ossigeno Max 20 bar.
S.3000-S.6000 sch.160 std. • Foratura di equilibrio sulla sfera.
• PRESSIONI: • Peek per alte temperature ino a +280°C - (ino al 2").
SERIE 800: PN64 1/4” - 4” PTFE. • A richiesta sch. diverse dallo standard indicato.
SERIE 1500: PN100 1/4” - 2” PTFE. • Dispositivo di bloccaggio (aperto/chiuso).
PN 160/120/64: PN160 1/4” - 1” CARBOGRAFITE • Volantino ovale ino a 1"
PN120 1”1/4 - 2” CARBOGRAFITE • Per ulteriori richieste speciali consultare il nostro servizio
PN64 2”1/2 - 4” CARBOGRAFITE. tecnico/commerciale.
SERIE 3000: PN210 1/4” - 4” DELRIN (max 70°C).
• LIMITI DI TEMPERATURA:
-20°C / +180°C - PTFE
ino +200°C - PTFE+CARBOGRAFITE
(condizione ottimale da 60°C a 200°C).
-20° / +70°C - DELRIN.
• STELO: antiscoppio e con dispositivo antistatico.
• ORGANO DI MANOVRA: leva. Colori disponibili nero, rosso.
232 UNI EN ISO 9001: 2008 ISO 14001:2004

MONOBLOCK®
AISI 316L
COSTRUZIONE ELENCO DEI PARTICOLARI E DEI MATERIALI
1 CORPO AISI 316L 1
2 MANICOTTO FEMMINA AISI 316L 1
3 SFERA AISI 316L 1
4 STELO AISI 316L 1
5 SEDE PTFE 2
6 ANELLO DI TENUTA LATERALE PTFE 1
8 ANELLO DI TENUTA SUPERIORE PTFE 2
10 TENUTA SUPERIORE PTFE 1
SISTEMA DI 11 RONDELLA PREMIGUARNIZIONE S.S. 1
TENUTA SUPERIORE 12 FERMO DI POSIZIONE S.S. 1
A DOPPIA GUARNIZIONE
13 MOLLE A TAZZA 50CrV4 2
14 DADO DI BLOCCAGGIO S.S. 1
17 DADO BLOCCA LEVA S.S. 1
18 LEVA DI MANOVRA S.S. 1
35 SPINA S.S. 1
SEZIONATO
ATTACCHI SW
In fase di saldatura dei tronchetti SW e BW

raffreddare adeguatamente il corpo della
valvola per non danneggiare le tenute.
Il corpo non deve superare MAI i 120°C. Le
scorie e le impurità NON DEVONO penetrare
all’interno della valvola.
ATTACCHI BW
VALVOLE INDUSTRIALI
SIZE A B D E L LBW M N S R WEIGHT g. GAS WEIGHT g. SW WEIGHT g. BW Kv
1/4" 72 10 42 148 67 95 11 14,3 9,53 13,7 610 610 630 11
3/8" 72 10 42 148 67 95 11,4 17,8 9,53 17,2 615 615 650 11
1/2" 75 15 50 148 75 105 15 22 9,53 21,3 930 930 1050 20
3/4" 85 20 60 180 90 125 16,3 27,3 12,7 26,7 1550 1550 1600 60
1" 95 25 68 180 105 140 19,1 34 12,7 33,4 2265 2265 2350 100
1"1/4 100 30 81 240 120 160 21,4 42,8 12,7 42,2 3300 3300 3400 130
1"1/2 105 38 94 240 135 180 21,4 48,9 12,7 48,3 4850 4850 5400 170
2" 115 48 105 280 155 220 25,7 61,4 15,88 60,3 6490 6490 6800 280
2"1/2 130 65 130 380 190 250 30,2 73,81 15,22 73,1 13000 13000 13400 510
3" 145 73 150 380 205 280 33,3 90 15,88 88,9 17000 17000 17500 770
4" 200 94 185 470 230 330 39,3 115,7 19,1 114,3 24000 24000 24500 1200
COPPIE DI SPUNTO (BREAKAWAY) in Nm DIAGRAMMA PRESSIONE / TEMPERATURA
DN 10 15 20 25 32 40 50 65 80 100 (Bar)
size 1/4" - 3/8" 1/2" 3/4" 1" 1"1/4 1"1/2 2" 2"1/2 3" 4"
0 10 12 16 21 54 65 86 140 183 270
PN - bar
64 15 18,6 23 27 80 83,6 126,6 190 240 350

100 17 22,6 25,2 29,6 88 92,9 131 210 260 389
160 19,5 24,7 26,6 31,3 98 105 145 250 305 455
210 23,4 27,6 30 34,8 110 117 160 380 380 505
I valori in Nm possono variare in funzione del materiale dei

seggi, della temperatura e del tipo di luido. 250(°C)
Considerare un coeficiente di sicurezza = 1,5. PTFE PTFE+CRB PEEK DELRIN
Per speciiche sul diagramma pressione temperatura vedi pagina 434
233
9.25 SCHEDA TECNICA VALVOLA PROTEZIONE SERBATOIO
IOM_14479_2 (09.16) Pages 58/59

TANK PROTECTION VALVE
S.r.l. DWG. 19.102.830 36.16
REGGIO EMILIA
BODY INOX-AISI316L
Technical features
Temperature range ( C) -55 +60
Pressure craking (BAR) 0,15
Mass (Kg) 1,4
Seal material : MFQ
Dimension 60
80
4,5
M5
30
DRILLING SURFACE:
N 4 HOLES M5 ON 50
N 1 HOLES 30
50
9.26 DOCUMENTAZIONE TUBI FLESSIBILI
IOM_14479_2 (09.16) Pages 59/59

Medium Pressure 1BSLSJNQ/P4LJWF)PTF
Standard 492
492
Elite No-Skive Compact
EN 857 1SC – ISO 11237 Type 1SC
t No-Skive hose construction

Primary Applications – Compact design
Demanding medium pressure hydraulic applications t/JUSJMF /#3
JOOFSUVCF
– extended fluid compatibility
Type Approvals t&YDFFEJOH&/*40TQFDJmDBUJPOTGPS
Details please find on pages Ab-16 to Ab-19 pressure, bend radius and abrasion
resistance
Applicable Specifications
EN 857 1SC – ISO 11237 Type 1SC
Construction Recommended Fluids

Tube: Nitrile (NBR) Petroleum and water-glycol based fluids, lubricating oils,
Reinforcement: One high-tensile steel wire braid air and water. For air above 1.7 MPa, the hose cover
Cover: Synthetic rubber must be pin-pricked.
Consult the chemical compatibility section on
Temperature Range ............¡$VQUP¡$ pages Ab-24 to Ab-32 for more detailed information.
Exception: Air ....................................NBY¡$
Water ...............................NBY¡$
Fitting Series 46
Pressure Rating
NBY min.
1BSU/VNCFS Hose Hose working burst min. bend
weight
I.D. O.D. pressure pressure radius
492 <tab>Hose
DN
DN Inch
Zoll Size
size mm
mm mm
OD MPa
MPa1 psi
psi1 MPa
MPa2 psi
psi2 mm
Bend kg
weight
492-4 6 1/4 -4 6.4 11.5 28.0 4060 112.0 16240 75 0.18
492-5 8 5/16 -5 7.9 13.6 25.0 3625 100.0 14500 85 0.21
492-6 10 3/8 -6 9.5 15.5 22.5 3260 90.0 13050 90 0.25
492-8 12 1/2 -8 12.7 18.9 19.0 2755 76.0 11020 130 0.33
492-10 16 5/8 -10 15.9 22.2 15.0 2175 60.0 8700 150 0.41
492-12 19 3/4 -12 19.1 26.0 15.0 2175 60.0 8700 180 0.56
492-16 25 1 -16 25.4 33.3 11.0 1595 44.0 6380 230 0.75
492-20-WR 31 1 1/4 -20 31.8 40.0 7.5 1085 30.0 4350 335 0.93
Part Number without a suffix: the hose cover has a smooth appearance. Part Number with a suffix (WR): the hose cover has a wrapped appearance.
The combination of high temperature and high pressure could reduce the hose life.
Also available in reels up to size -16 under part number 492-xx-RL
Hose layline example
Ca-28 Catalogue 4400/UK

Suction 811
811
No-Skive Suction and Return Line
SAE 100R4
t No-Skive hose construction

t)FMJDBMXJSFUPQSFWFOUDPMMBQTF
under vacuum
t4NBMMCFOESBEJJ
Primary Applications
All Markets: General applications
Type Approvals
Details please find on pages Ab-16 to Ab-19

Tube: Synthetic rubber Petroleum and water-glycol based fluids, lubricating oils,
Reinforcement: Two fibre spiral, one helical wire air and water.
Cover: Oil and weather resistant Consult the chemical compatibility section on
synthetic rubber pages Ab-24 to Ab-32 for more detailed information.
Temperature Range ............¡$VQUP¡$

Exception: Air ....................................NBY¡$ Fitting Series
Water ...............................NBY¡$ Up to size - 32 48
For size -40 and -48 fittings series on request
Hose
Pressure Rating
NBY min.
7BDDVN weight
811 <tab>Hose_vac
DN
DN Inch
Zoll Size
size mm
mm mm
OD MPa
MPa1 psi
psi1 MPa
MPa2 psi
psi2 kPa
VAC mm
Bend kg
weight
811-12 19 3/4 -12 19.1 30.0 2.1 300 8.3 1200 85 65 0.63
811-16 25 1 -16 25.4 38.0 1.7 250 6.9 1000 85 75 0.96
811-20 31 1 1/4 -20 31.8 45.0 1.4 200 5.5 800 85 100 1.22
811-24 38 1 1/2 -24 38.1 52.0 1.0 150 4.1 600 85 130 1.55
811-32 51 2 -32 50.8 64.0 0.7 100 2.8 400 85 150 1.87
811-40 63 2 1/2 -40 63.5 75.0 0.4 62 1.6 248 85 180 2.45
811-48 76 3 -48 76.2 90.0 0.4 62 1.6 248 85 230 3.20
*1 = the vacuum values listed in the table are vacuum pressure values in kPa. For an absolute value subtract the table value from 101 kPa.
** size -12 and size -16 = on Parkrimp 2 crimping press or adjustable crimpers only.

PARKER 811-12 SUCTION HOSE SAE 100R4-12 19 mm (3/4) 3Q81 PARKER 811-12 SUCTION

Standard 462
462
Elite No-Skive Compact
Exceeds EN 857-2SC – ISO 11237 Type 2SC
Primary Applications t No-Skive hose construction

Demanding medium pressure hydraulic applications in all – Compact design
markets t/JUSJMF /#3
JOOFSUVCF
– extended fluid compatibility
Type Approvals t&YDFFEJOH&/*40TQFDJmDBUJPOTGPS
Details please find on pages Ab-16 to Ab-19 pressure, bend radius and abrasion
resistance
Applicable Specifications
Exceeds EN 857-2SC – ISO 11237 Type 2SC

Tube: Nitrile (NBR) Petroleum and water-glycol based fluids, lubricating oils,
Reinforcement: Two high-tensile steel wire braids air and water. For air above 1.7 MPa, the hose cover
Cover: Synthetic rubber must be pin-pricked.
Consult the chemical compatibility section on
Temperature Range ............¡$VQUP¡$ pages Ab-24 to Ab-32 for more detailed information.
Exception: Air ....................................NBY¡$
Water ...............................NBY¡$ Fitting Series
Size -4 up to -16 46 48
462-20-WR 46
462-20 48
Pressure Rating
NBY min.
weight
462 <tab>Hose
DN
DN Inch
Zoll Size
size mm
mm mm
OD MPa
MPa1 psi
psi1 MPa
MPa2 psi
psi2 mm
Bend kg
weight
462-4 6 1/4 -4 6.4 13.4 42.5 6160 170.0 24640 75 0.30
462-5 8 5/16 -5 7.9 15.0 40.0 5800 160.0 23200 85 0.35
462-6 10 3/8 -6 9.5 17.2 35.0 5075 140.0 20300 90 0.42
462-8 12 1/2 -8 12.7 20.4 31.0 4495 124.0 17980 130 0.52
462-10 16 5/8 -10 15.9 23.9 28.0 4060 112.0 16240 160 0.66
462-12 19 3/4 -12 19.1 27.7 28.0 4060 112.0 16240 195 0.86
462-16 25 1 -16 25.4 35.4 21.0 3045 84.0 12180 250 1.17
462-20-WR * 31 1 1/4 -20 31.8 45.1 17.2 2495 68.8 9980 335 1.80
462-20 ** 31 1 1/4 -20 31.8 45.1 17.2 2495 68.8 9980 335 1.80
From size -4 to -16, smooth cover, both 462-20-WR and 462-20 wrapped cover
Also available in reels up to size -12 under part number 462-xx-RL
* 462-20-WR only with fitting series 46
** 462-20 only with fitting series 48

Conexiones Standard
Conexiones BSP
Hembras giratorias 90° rosca BSP cono 60°
Acero Inoxidable AISI 316-L 1/1
Artículo DN R1 L L1 L2 HEX 1 ØC
841070203 3/16" 1/8" BSP

841070403 3/16" 1/4" BSP 56 24 31,5 19 4
841070404 1/4" 1/4" BSP 56 28 31,5 19 4
841070405 5/16" 1/4" BSP 64 28 31,5 22 5
841070604 1/4" 3/8" BSP 56 28 33 22 4
841070605 5/16" 3/8" BSP 64 28 37 22 5,5
841070606 3/8" 3/8" BSP 68 29,5 39 22 7
841070804 1/4" 1/2" BSP 56 28 34 27 4
841070806 3/8" 1/2" BSP 68 29,5 40 27 7
841070808 1/2" 1/2" BSP 72 30,5 44 27 9,5
841071010 5/8" 5/8" BSP 85 34 53 30 12
841071208 1/2" 3/4" BSP 72 30,5 48 32 9,5
841071210 5/8" 3/4" BSP 85 34 55 32 12
841071212 3/4" 3/4" BSP 105 39 63 32 15
841071612 3/4" 1" BSP 105 39 66,5 41 15
841071616 1" 1" BSP 126 47 79,5 41 19
841072020 1"1/4 1"1/4 BSP 153 54,5 94,5 50 26
841072424 1"1/2 1"1/2 BSP 176 58 111,5 55 32
841073232 2" 2" BSP 212 72 139 70 44
La información recogida en esta ficha (Catálogo) es de carácter orientativo y puede ser modificada sin previo aviso. DICSA no se hace responsable de una incorrecta utilización
del producto, salvo las referentes a defectos de fabricación.
Impreso el: 07/07/2016 a las 19:50

Conexiones Standard
Conexiones BSP
Hembras giratorias rectas rosca BSP cono 60°
Artículo DN R1 L L1 HEX 1 ØC
841000202 1/8" 1/8" BSP 36,5 22 14 2

841000203 3/16" 1/8" BSP 38,5 24 14 3
841000204 1/4" 1/8" BSP 43 28 14 4
841000403 3/16" 1/4" BSP 39,5 24 19 3
841000404 1/4" 1/4" BSP 44 28 19 4
841000405 5/16" 1/4" BSP 44,5 28 19 5,5
841000406 3/8" 1/4" BSP 46 29,5 19 7
841000604 1/4" 3/8" BSP 45,5 28 22 4
841000605 5/16" 3/8" BSP 46 28 22 5,5
841000606 3/8" 3/8" BSP 47,5 29,5 22 7
841000608 1/2'' 3/8" BSP 48 30,5 22 9,5
841000806 3/8" 1/2" BSP 48,5 29,5 27 7
841000808 1/2" 1/2" BSP 51 30,5 27 9,5
841000810 5/8" 1/2" BSP 53,3 34 27 12
841001008 1/2" 5/8" BSP 50 30,5 30 9,5
841001010 5/8" 5/8" BSP 54,8 34 30 12
841001208 1/2" 3/4" BSP 52 30,5 32 9,5
841001210 5/8" 3/4" BSP 56,8 34 32 12
841001212 3/4" 3/4" BSP 63 39 32 15
841001612 3/4" 1" BSP 66,5 39 41 15
841001616 1" 1" BSP 74,5 47 41 19
841002016 1" 1''1/4 BSP 75,5 47 50 19
841002020 1"1/4 1"1/4 BSP 84,5 54,5 50 26
841002420 1"1/4 1"1/2 BSP 88,5 54,5 55 26
841002424 1"1/2 1"1/2 BSP 92 58 55 32
841003224 1''1/2 2" BSP 91,5 58 70 32
Impreso el: 07/07/2016 a las 19:50

Conexiones Standard
Conexiones BSP
Hembras giratorias rectas rosca BSP cono 60°
Artículo DN R1 L L1 HEX 1 ØC
841003232 2" 2" BSP 105 72 70 44
Impreso el: 07/07/2016 a las 19:50

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PI 1.110
OLAER INDUSTRIES GmbH Zum Gunterstal 4 D-66440 Blieskastel

Tel.: 06842 / 92 04-0 Fax: 06842 / 92 04-15 E-Mail: info@olaer.de Web: www.olaer.de
Blasenspeicher Serie EHV Standard-Baureihe, 330 - 350 bar

Bladder accumulator range EHV standard range, 330 - 350 bar
Abnahme / Approval
Die Speicher dieser Serie sind grundsätzlich nach der Europäischen
Druckgeräterichtlinie 97/23/EG hergestellt, geprüft und dokumentiert.
Andere Abnahmen auf Anfrage.
All accumulators of this range are manufactured, approved and certified according Directive
97/23/EC of the European Parliament. Other approvals on request.
Temperaturbereich / Temperature range

Standardausführung: -15 °C bis +80 °C
Standard: -15 °C to +80 °C
Weitere Details der Standard-Baureihe sind in der Dokumentation

doc.1-100 zusammengefasst.
Further details of the standard range are summarized in the documentation doc.1-100.
max. Betriebs- Abmessungen

Gasvolumen Gewicht
Typ druck Q max. Dimensions
Gas volume Weight
Type MWP l/min
V0 (L) (kg) A B C øD ød E F øG øH SW1
(bar)
EHV 0,2 - 350 /… 0,17 350 1,7 150 265,5 39 26 56 16 200,5 G ½" 27 38 24
EHV 0,5 - 350 /… 0,6 350 2,5 240 257 54 26 90 16 177 G ¾" 36 50 32
EHV 1 - 350 /… 1 350 5 240 329,5 54 68 114 22 207,5 G ¾" 36 50 32
EHV 1,6 - 350 /... 1,6 350 7 240 395 54 26 114 16 315 G ¾" 36 50 32
EHV 2,5 - 350 /… 2,4 350 10 450 549 66 68 114 22 415 G 1 ¼" 53 67 50
EHV 4 - 350 /… 3,7 350 16 450 435,5 66 68 168 22 301,5 G 1 ¼" 53 67 50
EHV 5 - 350 /… 5 350 17 450 898 66 68 114 22 764 G 1 ¼" 53 67 50
EHV 6 - 350 /… 6 350 20 450 561,5 66 68 168 22 427,5 G 1 ¼" 53 67 50
EHV 10 - 350 /... L 10 350 28 450 826,5 66 68 168 22 692,5 G 1 ¼" 53 67 50
EHV 10 - 330 /... K 9,2 330 32 900 585,5 101 68 226,5 22 416,5 G 2" 76 101 70
EHV 12 - 330 /… 11,2 330 35 900 685,5 101 68 226,5 22 516,5 G 2" 76 101 70
EHV 20 - 330 /... 18,1 330 53 900 895,5 101 68 226,5 22 726,5 G 2" 76 101 70
EHV 24 - 330 /... 22,5 330 61 900 1030,5 101 68 226,5 22 861,5 G 2" 76 101 70
EHV 32 - 330 /... 33,4 330 85 900 1419 101 68 226,5 22 1250 G 2" 76 101 70
EHV 50 - 330 /... 48,7 330 123 900 1927 101 68 226,5 22 1766 G 2" 76 101 70
Fertigungstoleranzen sind nicht berücksichtigt / Manufacturing tolerances are not considered. Stand 11/11
PI 1.110
EHV 330 - 350 bar
Position
3 Körper Shell
4 Blase komplett ød* Bladder assembly
5 Blase Bladder
13 Haltemutter Lock nut
14 Gasfüllventil komplett Gas valve assembly
15 Körper Gasfüllventil Gas valve body
16 Gasventileinsatz Gas valve core
17 O-Ring O-ring
18 O-Ring O-ring
19 Hutmutter Cap
24 Schutzkappe Protective cap
25 Ölventil komplett Oil port assembly
Ölventilkörper m. Oil port body with poppet
26
Ventilteller valve
33 Geteilter Ring Anti extrusion ring
37 O-Ring O-ring
38 Stützring Back-up-ring
39 Distanzring Washer
40 Nutmutter Locking ring
46 Firmenschild Name plate
50 O-Ring O-ring
Bei Ersatzteilbestellung sind folgende Angaben wichtig:

For spare part order the following informations are important:
Körper nicht als Ersatz lieferbar

Shell not available as spare part
Firmenschilddaten sind anzugeben

Name plate datas must be indicated
* ød ist bei der Bestellung anzugeben

* ød has to be indicated
Beispiel Example
d = ø16 mm EHV 0.5
d = ø22 mm EHV 2.5
Product Data Sheet
October 2013
00813-0100-4690, Rev NB
Rosemount 2088 Absolute and Gage Pressure

Transmitter
 Performance of 0.065% with High Accuracy option

 Lightweight, compact design for cost-effective installation
 Protocols available include 4-20 mA HART® and 1-5 Vdc HART Low Power
 Absolute and gage pressure ranges up to 4,000 psi (276 bar)

 Rangeability of 50:1
Rosemount 2088 October 2013
Rosemount 2088 Pressure Transmitter Product Offering

Proven Reliability for Gage and Absolute
Applications
 Available protocols include 4-20 mA HART® and 1-5 Vdc

HART Low Power
 Fully Configurable LCD to display process variable, percent

of range, and diagnostic messages
 Lightweight, compact design enables easy installation
 Choice of Stainless Steel or Alloy C-276 wetted materials
Unlock the Value of Devices with the Smart

Wireless THUM™ Adapter
 Gain access to field intelligence and improve quality, safety,

availability, operations, and maintenance costs
 Remotely manage devices and monitor health
 Enable new wireless measurement points
 Utilize existing loop power
Proven, Reliable, and Innovative DP Level

Technologies
 Connect to virtually any process with a comprehensive

offering of process connections, fill fluids, direct mount or
capillary connections and materials
 Quantify and optimize total system performance with QZ

option
Instrument Manifolds – Quality, Convenient,

and Easy
 Designed and engineered for optimal performance with

Rosemount transmitters
 Save installation time and money with factory assembly
 Offers a variety of styles, materials, and configurations
Contents
Rosemount 2088 In-line Pressure Transmitter . . . page 3 Product Certifications . . . . . . . . . . . . . . . . . . . . . . .page 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . .page 14
2 www.rosemount.com
October 2013 Rosemount 2088
Rosemount 2088 In-line Pressure Transmitter
Configuration Transmitter Output Code

S
4-20 mA HART®
- 2088 with Selectable HART

N
1-5 Vdc Low Power
Additional Information
Specifications : page 8
Product Certifications : page 11
Dimensional Drawings : page 14
Table 1. Rosemount 2088 Pressure Transmitter Ordering Information
★ The Standard offering represents the most common options. The starred options (★) should be selected for best delivery.
__The Expanded offering is manufactured after receipt of order and is subject to additional delivery lead time.
Model Product description
Standard Standard
2088 Pressure Transmitter ★
Code Measurement Type
Standard Standard
A Absolute ★
G Gage ★
Code Pressure Ranges
Standard Standard
2088G 2088A
1 -14.7 to 30 psi /(-1,01 to 2,1 bar) 0 to 30 psi (0 to 2,1 bar) ★
2 -14.7 to 150 psi (-1,01 to 10,3 bar) 0 to 150 psi (0 to 10,3 bar) ★
4 -14.7 to 4,000 psi (-1,01 to 275,8 bar) 0 to 4,000 psi (0 to 275,8 bar) ★
Code Transmitter Output
Standard Standard
S (1) 4–20 mA dc/Digital HART® Protocol ★
N(1) 1-5 Vdc Low Power/ Digital HART protocol ★
www.rosemount.com 3

Code Materials of Construction
Standard Standard
Process connection Isolating diaphragm Fill Fluid
22 (2) 316L SST 316L SST Silicone ★
★
33(2) Alloy C-276 Alloy C-276 Silicone
Expanded
2B(2) 316L SST 316L SST Inert
Code Process Connection
Standard Standard
A ½–14 NPT Female ★
B(3) DIN 16288 G ½ Male ★
D(3)(4) M20 1.5 Male ★
Expanded
C(3)(4) RC ½ Female
Code Conduit Entry
Standard Standard
1 ½–14 NPT ★
2(3) M20 1.5 ★
Expanded
4(3) G½
Options (Include with selected model number)

Diaphragm Seal Assemblies
Standard Standard
S1(5) (6) Assemble to one Rosemount 1199 diaphragm seal ★
Display and Interface

Standard Standard
M4 LCD Display with Local Operator Interface ★
M5 LCD Display, configured for Engineering Units ★
Configuration Buttons
Standard Standard
D4 Analog Zero and Span ★
DZ Digital Zero Trim ★
Mounting Brackets
Standard Standard
B4 SST mounting bracket with SST Bolts ★
4 www.rosemount.com

Product Certifications
Standard Standard
C6 CSA Explosion-Proof, Intrinsically Safe, and non-Incendive ★
E2 INMETRO Flameproof ★
E3 China Flameproof ★
E4(3)(7) TIIS Flameproof ★
E5 FM Explosion-Proof, Dust Ignition-proof ★

E7 IECEx Flameproof ★
ED ATEX Flameproof ★
(3) ATEX Intrinsic Safety ★
I1
I2 INMETRO Intrinsic Safety ★
I3 China Intrinsic Safety ★
I5 FM Intrinsically safe, Division 2 ★
I7 IECEx Intrinsic Safety ★
K1 ATEX Flameproof, Intrinsic Safety, Type n, Dust ★
K2 INMETRO Flameproof, Intrinsic Safety ★
K5 FM Explosion-Proof, Dust Ignition-proof, Intrinsically Safe, Division 2 ★
(3) ATEX and CSA Explosion-Proof, Dust Ignition-proof, Intrinsically Safe, Division 2 ★
K6
K7 IECEx Flameproof, Intrinsic Safety, Type n, Dust ★
KB FM and CSA Explosion-Proof, Dust Ignition-proof, Intrinsically Safe, Division 2 ★
KH(3) FM Approvals and ATEX Explosion-Proof and Intrinsically Safe ★

★
N1(3) ATEX Type n
N3 China Type n ★
N7 IECEx Type n ★
ND(3) ATEX Dust ★
NK IECEx Dust ★
Shipboard Approvals
Standard Standard
SBS American Bureau of Shipping (ABS) Type Approval ★
SBV Bureau Veritas (BV) Type Approval ★
SDN Det Norske Veritas (DNV) Type Approval ★
SLL Lloyd's Register (LR) Type Approval ★
Pressure Testing
Expanded
P1 Hydrostatic testing
Terminal Blocks
Standard Standard
T1 Transient protection ★
Special Cleaning
Expanded
P2 Cleaning for special service
Calibration Certificate
Standard Standard
Q4 Calibration certificate ★
www.rosemount.com 5

Quality Calibration Certificate Traceability Certification
Standard Standard
Q8 Material Traceability Certification per EN 10204 3.1 ★
Q15 Certificate of Compliance to NACE MR0175/ISO 15156 for wetted materials ★
Q25 Certificate of Compliance to NACE MR0103 for wetted materials ★
Digital Signal
Standard Standard
★
C4(3) NAMUR alarm and saturation levels, high alarm
CN(3) NAMUR alarm and saturation levels, low alarm ★
C5 (8)(9) Custom alarm and saturation levels, high alarm, (Requires C9 and Configuration Data Sheet) ★
★
C7(8)(9) Custom alarm and saturation levels, low alarm (Requires C9 and Configuration Data Sheet)
C8(9) Low alarm (Standard Rosemount Alarm and Saturation Levels) ★
Configuration
Standard Standard
C9 Software configuration ★
Manifold Assemblies
Standard Standard
(5)(6) Assemble to Rosemount 306 integral manifold ★
S5
Calibration Accuracy
Standard Standard
P8(10) 0.065% accuracy to 10:1 turndown ★
Water Approval
Standard Standard
DW(11) NSF drinking water approval ★
Surface Finish
Standard Standard
Q16 Surface finish certification for sanitary remote seals ★
Toolkit Total System Performance Reports
Standard Standard
QZ Remote Seal System Performance Calculation Report ★
HART Revision Configuration
Standard Standard
(9)(12) Configured for HART Revision 5 ★
HR 5
★
HR7 (9)(13) Configured for HART Revision 7
Typical Model Number: 2088 G 2 S 22 A 1 B4 M5
(1) HART Revision 5 is the default HART output. The 2088 with selectable HART can be factory or field configured to HART Revision 7. To order HART Revision 7 factory
configured, add option code HR7.
6 www.rosemount.com
(2) Materials of Construction comply with recommendations per NACE MR0175/ISO 15156 for sour oil field production environments. Environmental limits apply to
certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(3) Not available with low-power Transmitter Output code N.
(4) Not available with Alloy C-276, Material of Construction code 33.
(5) Use 1/2 - 14 NPT Female Process Connection code A.
(6) “Assemble-to” items are specified separately and require a completed model number.
(7) Only available with Conduit Thread code 4.
(8) Only available with 4-20 mA HART Output (Output Code A).
(9) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(10) Requires Transmitter Output code S with either Materials of Construction code 22 or 23.
(11) Requires Materials of Construction code 22 with Process Connection code A.
(12) Configures the HART output to HART Revision 5. The device can be field configured to HART Revision 7 if needed.
www.rosemount.com 7
Specifications
Performance Specifications Functional Specifications
For zero-based spans, reference conditions, silicone oil fill, 316L
Table 2. 2088 Range Values
SST isolating diaphragm.
Minimum Upper Lower Lower(1)
Reference Accuracy Range
Span (URL) (LRL) (LRL) (Gage)
±0.075% of calibrated span. Includes combined effects of
0.60 psi 30.00 psi 0 psia –14.70 psig
linearity, hysteresis, and repeatability 1
(41,37 mbar) (2,07 bar) (0 bar) (–1,01 bar)
±0.065% of calibrated span (high accuracy option - P8)
3.00 psi 150.00 psi 0 psia –14.70 psig
For spans less than 10:1, accuracy = 2
(206,85 mbar) (10,34 bar) (0 bar) (–1,01 bar)
16.00 psi 800.00 psi 0 psia –14.70 psig
± 0.009  ------------- % of Span
URL 3
 Span (1,11 bar) (55,16 bar) (0 bar) (–1,01 bar)
80.00 psi 4000.00 psi 0 psia –14.70 psig
4
Ambient Temperature Effect (5,52 bar) (275,79 bar) (0 bar) (–1,01 bar)
Expressed as a total effect per 50 °F (28 °C)
(1) Assumes atmospheric pressure of 14.70 psia (1,01 bar-a).
Total effect includes zero and span effects.
± (0.15% URL + 0.15% of span)
Output
Stability Code S: 4–20 mA
Ranges 2-4: ±0.10% of URL for 3 years Code N: 1-5 Vdc, low power
Range 1: ±0.10% of URL for 1 year (Outputs are directly proportional to the input pressure)
Vibration Effect Selectable HART

Digital communications based on HART Revision 5 (default)
Less than ±0.1% of URL when tested per the requirements of
or Revision 7 (option code HR7) protocol can be selected.
IEC60770-1 field or pipeline with high vibration level (10 - 60 Hz
The HART revision can be switched in the field using any
0.21 mm displacement peak amplitude / 60 - 2000 Hz 3g). HART based configuration tool or the optional local operator
Power Supply Effect interface (LOI).
Less than ±0.005% of calibrated span per volt change in voltage Service
at the transmitter terminals. Liquid, gas, and vapor applications
Mounting Position Effect Power Supply

Zero shifts to ±2.5 inH2O (6,22 mbar), which can be zeroed External power supply required. Transmitter operates on
Span: no effect 10.5–42.4 Vdc with no load (5.8-28 V for Low Power). Reverse
polarity protection is standard.
Transient Protection
Tested in accordance with IEEE C62.41.2-2002,
Location Category B
6 kV crest (0.5 s - 100 kHz)
3 kA crest (8 x 20 microseconds)
6 kV crest (1.2 x 50 microseconds)
General Specifications
Tested to IEC 801-3
8 www.rosemount.com
Load Limitations Temperature Limits

Reverse polarity protection is standard. Maximum loop Ambient:
resistance is determined by the power supply voltage as -40 to 185 °F (–40 to 85 °C)
described by the following equations: With LCD display(1): -40 to 176 °F (–40 to 80 °C)
Figure 1. Maximum loop resistance Storage(1):

Max. Loop Resistance = 43.5 (Power Supply Voltage – 10.5) -50 to 230 °F (-46 to 110 °C)
1387 With LCD display: –40 to 185 °F (–40 to 85 °C)
Process
Load (ohms)
1000
Silicone fill sensor: –40 to 250 °F (–40 to 121 °C)(2)
Inert fill sensor: –22 to 250 °F (–30 to 121 °C)(2)
500 Operating
Region Process temperatures above 185 °F (85 °C) require derating the
ambient limits by a 1.5:1 ratio. For example, for process
0
temperature of 195 °F (91 °C), new ambient temperature limit is
10.5 20 30 42.4 equal to 170 °F (77 °C). This can be determined as follows: (195
Voltage (Vdc) °F - 185 °F) x 1.5 = 15 °F, 185 °F - 15 °F = 170 °F
The Field communicator requires a minimum loop resistance of
250W for communication. Humidity Limits
0–100% relative humidity
Indication Volumetric Displacement
Optional two line LCD/LOI Display. Less than 0.0005 in3 (0,008 cm3)
Zero and Span Adjustment Requirements Damping
Zero and span values can be set anywhere within the range
Analog output response time to a step change is user-selectable
limits stated in Table 2 on page 8. Span must be greater than
from 0 to 60 seconds for one time constant. Software damping
or equal to the minimum span stated in Table 2 on page 8.
is in addition to sensor module response time.
Turn-on Time
The LOI utilizes a 2 button menu with internal and external
2.0 seconds, no warm-up required
configuration buttons. Internal buttons are always configured
for Local Operator Interface. External Buttons can be configured Transmitter Security
for either LOI, (option code M4), Analog Zero and Span (option Activating the transmitter security function prevents changes to
code D4) or Digital Zero Trim (option code DZ) for LOI the transmitter configuration, including local zero and span
configuration menu. adjustments. Security is activated by an internal switch.
Current Draw Failure Mode Alarm
Output Code N:  3 mA. If self-diagnostics detect a sensor or microprocessor failure, the
Overpressure Limits analog signal will be driven either high or low to alert the user.
High or low failure mode is user-selectable with a jumper on the
Range 1: 120 psig max
transmitter. The values to which the transmitter drives its
All other ranges: two times the URL
output in failure mode depend on whether it is
Burst Pressure factory-configured to standard or NAMUR-compliant operation.
11,000 psi for all ranges The values for each are as follows:
Standard Operation
Zero Elevation and Suppression
Zero can be suppressed between atmosphere for gage Output Code Linear Output Fail High Fail Low
transmitters or 0 psia for absolute transmitters and upper range S 3.9  I  20.8 I  21.75 mA I  3.75 mA
limit, provided the calibrated span is equal to or greater than the N 0.97  V  5.2 V  5.4 V V  0.95 V
minimum span, and the upper range value does not exceed the
NAMUR-Compliant Operation
upper range limit.
Output Code Linear Output Fail High Fail Low
Dynamic Performance
S 3.8  I  20.5 I  22.5 mA I  3.6 mA
Total Response Time: 145 milliseconds
Update rate: 20 times per second minimum
(1) If storage temperature is above 85 °C, perform a sensor trim prior to

installation.
(2) 220 °F (104 °C) limit in vacuum service; 130 °F (54 °C) for pressures
below 0.5 psia.
www.rosemount.com 9
Physical Specifications
Electrical Connections
/ –14 NPT, M20 1.5 (CM20), or
1 2
G 1/2 female (PF 1/2 female) conduit entry
Process Connections
1
/2–14 NPT female, DIN 16288 G 1/2 male, RC 1/2 female
(PT 1/2 female), M20 1.5 (CM20) male
Process-Wetted Parts
Isolating Diaphragm
316L SST (UNS S31603), Alloy C-276 (UNS N10276)
Process Connector
316L stainless steel CF-3M (Cast version of 316L SST, material
per ASTM_A743) or Alloy C-276
Non-Wetted Parts
Electronics Housing
Low-copper aluminum, NEMA 4X, IP65, IP67,
CSA enclosure Type 4X
Paint for Aluminum Housing
Polyurethane
Cover O-rings
Buna-N
Fill Fluid
Silicone or inert fill
Weight
Output Code S and N: Approximately 2.44 lb (1, 11 kg)
10 www.rosemount.com
Approved Manufacturing Locations Canadian Standards Association (CSA)
Rosemount Inc. — Chanhassen, Minnesota, USA All CSA hazardous approved transmitters are certified per
Emerson Process Management GmbH & Co. — Wessling, ANSI/ISA 12.27.01-2003.
Germany
C6 Explosion-Proof, Intrinsically Safe, Dust Ignition-Proof and
Emerson Process Management Asia Pacific
Class I Division 2
Private Limited — Singapore
Applicable Standards: CAN/CSA Std. C22.2 No. 0-M91, CSA
Beijing Rosemount Far East Instrument Co., LTD — Beijing, China
Std. C22.2 No. 25 - 1966, CSA Std. C22.2 No. 30 - M1986,
European Directive Information CAN/CSA Std. C22.2 No. 94 - M91, CSA Std. C22.2 No. 142
- M1987, CAN/CSA Std. C22.2 No. 157-92, CSA Std. C22.2
The EC declaration of conformity for all applicable European
No. 213 - M1987, ANSI/ISA 12.27.01-2003.
directives for this product can be found at
Markings: Explosion-proof for Class I, Division 1, Groups B,
www.rosemount.com. A hard copy may be obtained by
C, and D.
contacting an Emerson Process Management representative.
Dust-Ignition-Proof for Class II, Division 1, Groups E, F, G,
ATEX Directive (94/9/EC) Class III.
Emerson Process Management complies with the ATEX Suitable for Class I, Division 2, Groups A, B, C, and D.
Directive. Intrinsically Safe for Class I, Division 1, Groups A, B, C, and
D. Temperature Code: T3C.
European Pressure Equipment Directive (PED) (97/23/EC) Enclosure Type 4X. Factory sealed. Single Seal. See control
2088/2090 Pressure Transmitters drawing 02088-1024.
— Sound Engineering Practice European Certifications
Electro Magnetic Compatibility (EMC) (2004/108/EC) ED ATEX Flameproof
EN 61326-1:2006 Certification No.: KEMA97ATEX2378X
Applicable Standards: EN60079-0:2006, EN60079-1:2007,
EN60079-26:2007
Hazardous Locations Certifications
Markings: II 1/2 G
North American Certifications Ex d IIC T6 (-40 °C Tamb 40 °C); T4 (-40 °C Tamb 80 °C)
FM Approvals 1180
Vmax = 36 (with Output Code S)
E5 Explosion-proof and Dust Ignition Proof Vmax = 14 (with Output Code N)
Certificate No.: 1V2A8.AE
Special Conditions for Safe Use (x):
Applicable Standards: FM Class 3600 - 1998,
FM Class 3615 - 1989, FM Class 3810 - 1989 1. The cable and conduit entry devices shall be of a certified
Markings: Explosion-proof for Class I, Division 1, Groups B, flameproof type Ex d, suitable for the conditions of use and
C, and D. Dust Ignition-Proof for Class II/III, Division 1, correctly installed.
Groups E, F and G. 2. With the use of conduit entries a sealing device shall be
Temperature Code: T5 (Ta = -40 °C to + 85 °C) Factory provided immediately on the entrance thereto.
Sealed, Enclosure Type 4X. 3. Unused apertures shall be closed with suitable Ex d
For input parameters see control drawing 02088-1018. certified blanking elements.
4. Suitable heat-resisting cables shall be used when the
I5 Intrinsically Safe and Non-Incendive ambient temperature at the cable or conduit entries
Certificate No.: 0V9A7.AX exceed 65 °C.
Applicable Standards: FM Class 3600 - 1998, FM Class 3610 5. This device contains a thin wall diaphragm. Installation,
- 2010, FM Class 3811 - 2004, FM Class 3810 - 1989. maintenance, and use shall take into account the
Markings: Intrinsically safe for use in Class I, Division 1, environmental conditions to which the diaphragm will be
Groups A, B, C, D; Class II, Division 1, Groups E, F, and G; subjected. The manufacturer's instructions for installation
and Class III, Division 1 and maintenance shall be followed in detail to assure
Temperature Code: T4 (Ta = 70 °C) in accordance with safety during its expected lifetime.
Rosemount drawing 02088-1018. 6. For information on the dimensions of the flameproof joints
Non-incendive for Class I, Division 2, Groups A, B, C, and D. the manufacturer shall be contacted.
Temperature Code: T4 (Ta = 85 °C), Enclosure Type 4X.
For input parameters see control drawing 02088-1018.
www.rosemount.com 11
I1 ATEX Intrinsic Safety

Certificate No.: BAS00ATEX1166X
Applicable Standards: EN60079-0:2012, EN60079-11: IECEx Certifications
2012 E7 IECEx Flameproof
Markings: II 1 G Certificate No.: IECEx KEM 06.0021X
Ex ia IIC T5 Ga (–55 °C  Tamb  40 °C) Applicable Standards: IEC60079-0:2004,
IEC60079-1:2003, IEC60079-26:2004
Ex ia IIC T4 Ga (–55 °C  Tamb  70 °C) Markings: Ex d IIC T4 (-20 °C Tamb  80 °C)
1180 Ex d IIC T6 (–20 °C  Tamb  40 °C)
Table 3. Input Parameters
I7 IECEx Intrinsic Safety
Ui = 30 V Certificate No.: IECEx BAS 12.0071X
Ii = 200 mA Applicable Standards: IEC60079-0:2011,
Pi = 0.9 W IEC60079-11:2011
Ci = 0.012 F Markings: Ex ia IIC T5 Ga(-55 °C Tamb  +40 °C)
Ex ia IIC T4 Ga (–55 °C  Tamb  +70 °C)
Special Conditions For Safe Use (x):
1. The apparatus is not capable of withstanding the 500V Table 4. Input Parameter
insulation test required by EN60079-11. This must be Ui = 30 V
taken into account when installing the apparatus. Ii = 200 mA
Pi = 0.9 W
N1 ATEX Non-incendive/Type n Ci = 0.012 F
Certification No.: BAS 00ATEX3167X
Applicable Standards: EN60079-0:2012, EN60079-15:
1. The equipment is not capable of withstanding the 500V
2010
insulation test required by EN60079-11. This must be
Markings: II 3 G taken into account when installing the equipment.
Ex nA IIC T5 Gc (–40 °C  Tamb  70 °C)
Ui = 50 Vdc max N7 IECEx Non-incendive/Type n
Certificate No.: IECEx BAS 12.0072X
1180 Applicable Standards: IEC60079-0:2011, IEC60079-15:
2010
1. Special Conditions For Safe Use (x): Markings: Ex nA IIC T5 Gc (-40 °C Tamb  +70 °C)
The apparatus is not capable of withstanding the 500V Ui =50 Vdc max
taken into account when installing the apparatus. Special Conditions for Safe Use (x):
1. When fitted with a transient suppression terminal block,
ND ATEX Dust the Model 2088 is incapable of passing the 500V isolation
Certificate No.: BAS01ATEX1427X test. This must be taking into account during installation.
2009 NK IECEx Dust
Markings: II 1 D Certificate No.: IECEx BAS12.0073X
Ex t IIIC T50 °C T 500 60 °C Da Applicable Standards: IEC60079-0:2011, IEC60079-31:
Vmax = 36 Vdc; Ii = 24 mA 2008
Markings: Ex t IIIC T50 °C T 500 60 °C Da
1180
Special Conditions For Safe Use (x): Vmax = 36 Vdc; Ii = 24 mA
1. The user must ensure that the maximum rated voltage and Special Conditions For Safe Use (x):
current (36 volts, 24 mA, D.C.) are not exceeded. All
connections to other apparatus or associated apparatus 1. Cable entries must be used which maintain the ingress
shall have control over this voltage and current equivalent protection of the enclosure to at least IP66.
to a category “ib” circuit according to EN50020. 2. Unused cable entries must be filled with suitable blanking
2. Cable entries must be used which maintain the ingress plugs which maintain the ingress protection of the
protection of the enclosure to at least IP66. enclosure to at least IP66.
3. Unused cable entries must be filled with suitable blanking 3. Cable entries and blanking plugs must be suitable for the
plugs which maintain the ingress protection of the ambient range of the apparatus and capable of
enclosure to at least IP66. withstanding a 7J impact.
4. Cable entries and blanking plugs must be suitable for the
ambient range of the apparatus and capable of
withstanding a 7J impact test.
5. The 2088/2090 sensor module must be securely screwed
in place to maintain the ingress protection of the
enclosure.
Japanese Certifications N3 China Type n Non-Sparking

E4 TIIS Flameproof Certification No.: GYJ101126X (2088 Series)
Ex d IIC T6 (Tamb = 85 °C) Applicable Standards: GB3836.1-2000, GB3836. 8-2000
Markings: Ex nA nL IIC T5 (-40 °C Tamb  +70 °C)
Certificate Description
TC15874 2088 with Alloy C-276 wetted parts (with display) Refer to Appendix B of the 2088/2090 Reference Manual
TC15873 2088 with Alloy C-276 wetted parts (no display) (document number 00809-0100-4690) for Special
TC15872 2088 with SST wetted parts (with display) Conditions for Safe Use.
TC15871 2088 with SST wetted parts (no display)
Combinations of Certifications
Brazil Certifications
Stainless steel certification tag is provided when optional approval is
I2 INMETRO Intrinsic Safety specified. Once a device labeled with multiple approval types is
Certification No.: UL-BR 13.0246 installed, it should not be reinstalled using any other approval types.
Markings: Ex ia IIC T5/T4 Ga Permanently mark the approval label to distinguish it from unused
T5 (-55 °C  Tamb  +40 °C); T4 (-55 °C Tamb  +70 °C) approval types.
Special Conditions For Safe Use (x): K1 I1, N1, ED, and ND combination
1. When fitted with a transient suppression terminal block, K2 I2 and E2 combination
the model 2088 is incapable of passing the 500V isolation
test. This must be taken into account during installation. K5 E5 and I5 combination
2. The enclosure may be made of aluminum alloy and given a K6 C6, I1, and ED combination
protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in K7 I7, N7, E7, and NK combination
a zone 0 environment.
KB K5 and C6 combination
E2 INMETRO Flameproof (2088 Series only)
Certification No.: CEPEL 97.0076 KH K5, ED, and I1 combination
Markings: Ex d IIC T6/T5 Gb
T6 (-20 °C  Tamb  +40 °C); T5 (-20 °C Tamb  +60 °C)
China Certifications
I3 China Intrinsic Safety
Certification No.: GYJ111063X (2088 Series); GYJ111065X
(2090 Series)
Applicable Standards: GB3836.1-2000, GB3836.4-2000
Markings: Ex ia IIC T4/T5
T4 (-55 °C  Tamb  +70 °C);T5 (-55 °C Tamb  +40 °C)
Ui = 30 V
Ii= 200 mA
Pi= 0.9 W
Ci = 0.012 F
Refer to Appendix B of the 2088/2090 Reference Manual

(document number 00809-0100-4690) for Special
Conditions for Safe Use
E3 China Flameproof
Certificate No.: GYJ111062 (2088 Series); GYJ111064
(2090 Series)
Markings: Ex d IIC T4/T6
T4 (-20 °C  Tamb  +40 °C); T6 (-20 °C  Tamb +80 °C)

Conditions for Safe Use.
Dimensional Drawings
Rosemount 2088
0.75 (20)
5.13 (130) Certifications
Clearance for
Cover 4.29 (109) Optional Tag
Display Cover 3.85 (98)
Removal
2 ½–14 NPT(1)
Conduit
Connection
Transmitter 4.68
Terminal Circuitry (118)
Connections
5.87
(149)
2 ¼–20 UNC-2B
Mounting Holes
(1)
M20 1.5 Female (CM20), PG 13.5, and G 1/2 Female (PF 1/2 Female)
also available as options.
½–14 NPT Female
Process Connection
(See Ordering Table for other options.)
Mounting Configurations with Optional Mounting Brackets

Pipe Mounting Panel Mounting
5.13 (130)
3.85 (98) 4.29 (109)
3.95 (100)
6.15
(156)
2.81
(71)
5.97 (152) 2.97 (75)
2-inch U-Bolt 4.78 (121)

for pipe mounting 6.90 (175)
(clamp shown)
2.81 (71) 5
/16× 1½ Bolts
for panel mounting
(not supplied)
1/ × 11/ Bolts 1/4× 11/4 Bolts
4 4
for transmitter mounting for transmitter mounting
(not supplied) (not supplied)
1.42 (36)
1.42 (36)
Dimensions are in inches (millimeters).
Options Output Information

Output range points must be the same unit of measure.
Standard Configuration Available units of measure include:
Unless otherwise specified, transmitter is shipped as follows:
ENGINEERING UNITS psi (all ranges) Pressure Units(1)
4 mA (1 Vdc): 0 (engineering units) (1) (1)
torr psf cmH2O@4°C
20 mA (5 Vdc): Upper range limit (1)
atm inH2O mH2O@4°C
Output: Linear
Flange type: Pa inH2O@4°C(1) inHg
Specified model code option
(1)
Flange material: Specified model code option kPa inH2O@60°F mmHg
O-ring material: Specified model code option (1) (1)
MPa ftH2O cmHG@0°C
Drain/vent: Specified model code option (1)
hPa ftH2O@4°C(1) mHG@0°C (1)
LCD Display: Installed or none (1)
Alarm: High mbar ftH2O@60°F g/cm2
(1)
Software tag: (Blank) bar mmH2O kg/m2
psi mmH2O@4°C(1) kg/cm2
Custom Configuration
If Option Code C9 is ordered, the customer may specify the
following data in addition to the standard configuration (1) Field configurable only, not available for factory
parameters. calibration or custom configuration (option code C9
“Software configuration”).
• Output Information
• Transmitter Information Display and Interface Options
• LCD display Configuration M4 Digital Display with Local Operator Interface (LOI)
• Hardware Selectable Information • Available for 4-20 mA HART, 4-20 mA HART Low Power
• Signal Selection M5 Digital Meter
Refer to the “Rosemount 2088 Configuration Data Sheet”
• 2-Line, 5-Digit LCD for 4-20 mA HART
document number 00806-0100-4690.
• 2-Line, 5-Digit LCD for 1-5 Vdc HART Low Power
Tagging (3 options available) • Direct reading of digital data for higher accuracy
• Standard SST hardware tag is permanently affixed on transmitter. • Displays user-defined flow, level, volume, or pressure units
Tag character height is 0.125 in. (3,18 mm), 84 characters • Displays diagnostic messages for local troubleshooting
maximum. • 90-degree rotation capability for easy viewing
• Tag may be wired to the transmitter nameplate upon request, 85
characters maximum. Configuration Buttons
• For HART protocols, the tag may be stored in transmitter memory Rosemount 2088 now offers optional internal and external
(eight characters maximum). Software tag is left blank unless configuration buttons.
specified. • Choosing option D4 will add external Analog Zero and Span
• HART Revision 5: 8 characters configuration buttons
• HART Revision 7: 32 characters • Choosing option DZ will add an external Digital Zero Trim
configuration button
Optional Rosemount 306 Integral Manifold • Choosing option M4 (LOI) adds both internal and external local
Factory assembled to 2088 transmitters. Refer to Product Data configuration buttons.
Sheet (document number 00813-0100-4733 for Rosemount
306) for additional information. Certain button options can also be combined as shown below:
Other Seals Button Configuration
Refer to Product Data Sheet (document number Option Codes Internal External
00813-0100-4016 or 00813-0201-4016) for additional DZ N/A Digital Zero Trim
information. D4 N/A Analog Zero & Trim
M4 LOI LOI
M4 + DZ LOI Digital Zero Trim
M4 + D4 LOI Analog Zero & Trim
Rosemount 2088 Bracket Option

B4 Bracket for 2-in. Pipe or Panel Mounting
• Bracket for mounting of transmitter on 2-in. pipe or panel
• Stainless steel construction with stainless steel bolts
Rosemount 2088 Product Data Sheet
00813-0100-4690, Rev NB October 2013
Emerson Process Management Emerson Process Management

Rosemount Inc. Blegistrasse 23
8200 Market Boulevard P.O. Box 1046
Chanhassen, MN 55317 USA CH 6341 Baar
T (U.S.) 1-800-999-9307 Switzerland
T (International) (952) 906-8888 T +41 (0) 41 768 6111
F (952) 906-8889 F +41 (0) 41 768 6300
www.rosemount.com www.rosemount.com

Asia Pacific Pte Ltd Latin America
1 Pandan Crescent 1300 Concord Terrace, Suite 400
Singapore 128461 Sunrise Florida 33323 USA
T +65 6777 8211 Tel + 1 954 846 5030
F +65 6777 0947 www.rosemount.com
Service Support Hotline: +65 6770 8711
Email: Enquiries@AP.EmersonProcess.com
www.rosemount.com
Standard Terms and Conditions of Sale can be found at www.rosemount.com\terms_of_sale

The Emerson logo is a trade mark and service mark of Emerson Electric Co.
Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc.
PlantWeb is a registered trademark of one of the Emerson Process Management group of companies.
HART and WirelessHART are registered trademarks of the HART Communication Foundation
Modbus is a trademark of Modicon, Inc.
All other marks are the property of their respective owners.
© 2013 Rosemount Inc. All rights reserved.
CMP PRODUCTS CABLE GLAND CATALOGUE CMP
CMP INDUSTRIAL CABLE GLAND PRODUCTS

A2 TECHNICAL DATA
Design Specification BS 6121:Part 1:1989, IEC 62444, EN 62444
A2 Single Seal Industrial Cable Gland Mechanical Classifications* Impact = Level 8, Retention = Class D
For all types of Unarmoured & Braid Armoured Enclosure Protection IK10 to IEC 62262 (20 joules) Brass & Stainless Steel only
Cables
CSA Certificate 1211841
• High quality durable materials

Code of Protection Enclosure Type 4X
• Robust, heavy duty design
• Displacement type seal GOST R Certificate POCC GB. 05.H00187
• Designed to prevent Coldflow

GOST K Certificate KZ 7500361.01.01.25266
• Deluge protected
• -60˚C to +130˚C (standard), -20˚C to 200˚C (ThermIn option page 91) RoK Permit For Use 19-02-UL-1957
Marine Approvals LRS: 01/00171 (E1), ABS: 01-LD234401-2-PDA
Ingress Protection Rating IP66, IP67 & IP68**
Deluge Protection Compliance DTS01 : 91
Cable Gland Material Brass, Electroless Nickel Plated Brass, Stainless Steel, Aluminium
Seal Material CMP Thermoset Rubber
Cable Type Unarmoured
Sealing Technique CMP Unique Displacement Seal Concept
Sealing Area(s) Cable Outer Sheath
Note : * Mechanical & Electrical Classifications applied as per IEC 62444 & EN 62444
Note : ** Refer to page 7 or www.cmp-products.com for further information on Ingress Protection Ratings
Cable Gland Selection Table

Refer to illustration at the top of the page
Available Entry Threads “C” Across Combined Ordering
(Alternate Metric Thread Lengths Available) Overall Cable Across
Corners Reference Cable
Diameter “A” Flats “D”
Cable Gland Standard Option “D” Protrusion (*Brass Metric) Gland
Shroud
Size Thread Length Thread Length “F” Weight
Ordering (Kgs)
Metric (Metric) NPT Length (NPT) NPT Min Max Max Max Size Type
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800
*For material options add the following suffix to the Ordering Reference; Brass (no suffix required); Nickel Plated Brass ‘5’; 316 Grade Stainless Steel ‘4’; Copper Free Aluminium ‘1’
For NPT options add the following digits to the material suffix; 1/2” = 31; 3/4” = 32; 1” = 33; 1 1/4” = 34; 1 1/2” = 35; 2” = 36; 2 1/2” = 37; 3” = 38; 3 1/2” = 39; 4” = 310 (Brass requires prefix ‘0’)
Examples: 32A21RA534 = Nickel Plated Brass 1-1/4” NPT, 50SA21RA035 = Brass 1-1/2” NPT, 25A21RA432 = Stainless Steel 3/4” NPT, 20A21RA5 = Nickel Plated Brass M20
Dimensions are displayed in millimetres unless otherwise stated
www.cmp-products.com TDS509 ISSUE7 08/15

Cable Glands, Connectors and Accessories Exd/Exe For Worldwide Ap... http://www.cmp-products.com/Shrouds
Cable Gland Protective Shrouds

CMP manufactures a range of push on shrouds which are used to minimise the risk of dirt or foreign substances gathering on the Cable
Gland body, and/or point of cable to cable gland interface.
• CMP Standard shrouds are produced in Black PVC.

• CMP Blue/Grey SOLO Low Smoke & Fume (LSF) Halogen Free shrouds are also available.
It should be noted that although the addition of a shroud may aid the process of keeping the surface of the cable gland free from the build up
of dust or dirt, this does not necessarily improve the Ingress Protection rating of the installed cable gland. Generally cable glands are tested
for ingress protection without a shroud being present. In certain conditions the addition of a shroud or other form of external covering may
retain unwanted moisture creating a greater threat of penetration than that which it is intended to prevent. In such cases a CMP Deluge
Proof cable gland is recommended which negates the need for the use of a shroud and protects the critical migration paths into the interior
of the cable gland.
Colour Coded Shrouds
Alternative colours including Red, Blue and White are available to suit a wide variety of customer requirements, other colours are available
on request.
The table below details the specific CMP cable gland types and their associated groups
BW BW Group A2 Group PXSS2K PX2K Group

CW Group Includes
Group Includes Includes Group Includes
BW BWL A324 / B348 (ZEN) A2 / A2F PXSS2K PX2K
- BWL CIEL CW / CWe A2RC / A2FRC SS2K PZ2KX / PX2KW
- B2K CW CIEL 2A4F - PX2KPB
- B2KX CX / CXe A2FFC - & ALL RapidEx
- PXB2KX *E* Type A4 / A4e - -
For sizes 20 and
- - *E* Type CIEL ARRC -
above
- - T3CDS CXT - C2K
- - T3CDSPB SS2KGP - C2KGP
- - - - - C2KW
For size 20S/16 and 20S
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -
TMC2 Group Includes TC Group Includes

TMC2 TC
TMC2X -
It should be noted that some of the cable gland types shown in the table above may have been withdrawn but are included for historical
reference purposes as these may still be circulating through the supply chain.
CMP SHROUD SELECTION TABLE
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CABLE GLANDS
CABLE CLEATS
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Contattare il Centro di Consulenza e progettazione per qualsiasi informazione illuminotecnica. PAG 1 - ITA
LIBRETTO USO E MANUTENZIONE per HPU
MAINTENANCE USE HANDBOOK for HPU
REVA CODE 19.021.261

CUSTOMER CODE 2112750010
CUSTOMER DIAGRAM SLASE006
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
ENEL CILE – CERRO PABELLON
00 15/09/2016 Issued C.M. E.M.

Revision Date Description Prepared Checked
IOM_14480 Pages - 1 -/69

Sommario
INTRODUZIONE / INTRODUCTION ........................................................................... - 4 -
MANUTENZIONE / MAINTENANCE .......................................................................... - 4 -
PREMESSA / PREFACE ................................................................................................................... - 4 -
PULIZIA ESTERNA SEMESTRALE / GENERAL CLEANING (EXTERIOR) EVERY SIX MONTHS ........... - 5 -
CONTROLLO FILTRI OLIO / CHECKING THE OIL FILTERS ............................................................... - 5 -
ELETTROVALVOLE - VALVOLE DI CONTROLLO / SOLENOID VALVES - CONTROL VALVES ............. - 6 -
DISPOSITIVI DI SICUREZZA / SAFETY DEVICES .......................................................... - 7 -
PREMESSA / PREFACE................................................................................................................... - 7 -
INDICATORE DI INTASAMENTO DEI FILTRI / FILTERS BLOCKAGE INDICATOR.............................. - 7 -
RICERCA GUASTI/TROUBLE SHOOTING .................................................................... - 8 -
SCHEDE TECNICHE COMPONENTI .......................................................................... - 10 -
DATA SHEET COMPONENTS ......................................................................................... - 10 -
DISCHARGE BALL VALVE S8 / 5 ½”GAS MONOBLOCK ....................................................... - 11 -
TANK PROTECTION VALVE 19.102.830 ....................................................................................... - 13 -
MICRO SWITCH ZCKJ18H29 + ZCKE056 + ZCKY13 ....................................................................... - 14 -
DUST ESCLUDER SFEX ½” ............................................................................................................ - 19 -
NEEDLE VALVE FT 2290-14 MFQ ................................................................................................. - 20 -
NEEDLE VALVE 49.020.247 .......................................................................................................... - 22 -
HYDRAULIC FILTER FR1.02.396 ................................................................................................... - 23 -
HYDRAULIC FILTER FHB065.2.B.F.F1.A10.N.P01 ......................................................................... - 25 -
HYDRAULIC PRESSURE REGULATOR 49.020.239 (SET 97BARG↑).............................................. - 32 -
CHECK VALVE CAE30/ P ............................................................................................................... - 33 -
CHECK VALVE CAE20/P................................................................................................................ - 34 -
SHUTTLE VALVE CCI20 ................................................................................................................. - 35 -
RELIEF VALVE LPA30/D–N INOX .................................................................................................. - 36 -
RELIEF VALVE MVPX4C SET 207 BAR HAWE ............................................................................... - 37 -
HYDRAULIC PILOT/SPRING POPPET TYPE VALVE 49.020.132 ..................................................... - 44 -
3/2 HAND ACTUATED VALVE PK3-S-DN10-448A-SB57(-40°C) .................................................... - 45 -
ELECTRIC PRESSURE SWITCH PCS2-GH-40/250 .......................................................................... - 47 -
UNIDIRECTIONAL FLOW REGULATOR 49.020.245 ...................................................................... - 49 -
HAND PUMP 19.102.828 ............................................................................................................. - 50 -
HYDRAULIC ROTATING PUMP R2,5 ............................................................................................. - 51 -
ELECTRIC TEMPERATURE SWITCH TCS2-CH-40/100 ................................................................... - 57 -
LEVEL GAUGE 19.102.605/200/MFQ .......................................................................................... - 59 -
OIL POURING PLUG WITH FILTER TA70B10AAP03...................................................................... - 60 -
IOM_14480 Pages - 2 -/69

ELECTRIC LEVEL TRANSMITTER LCT.S52.05/270/350.S.50.GS.E1.L ............................................ - 61 -
PRESSURE GAUGE 233.50DN63-1/4G-RADIAL BAR/PSI SAFETY GLASS GLYCERINE ................... - 63 -
ELECTRIC MOTOR M3AA 90LD4 B5 1KW ABB ............................................................................. - 67 -
SCHEMA IDRAULICO - DISEGNO D’ASSIME ............................................................ - 69 -
OPERATING DIAGRAM – LAYOUT DRAWING ................................................................ - 69 -
IOM_14480 Pages - 3 -/69

INTRODUZIONE / INTRODUCTION
L’affida ilità di qualsiasi macchina o impianto oleoidraulico e rapportata alla qualità ed allo stato
del fluido di t as issio e ed all’asse za di i pu ità el i uito. No va di e ti ato he è lo stesso
fluido a p ovvede e alla lu ifi azio e dei o po e ti dell’i pianto.
A questo scopo i manifold sono stati sottoposti ad opportuno lavaggio con olio minerale di qualità,
con particolare attenzione alla pulizia delle cartucce filtro.
Eseguito il totale svuotamento del fluido dalle apparecchiature, le bocche di collegamento sono
state chiuse con tappi di protezione che non vanno tolti se non al momento del collegamento
all’attuato e.
The reliability of any hydraulic component or system depends to a significant degree on the quality
and condition of the fluid utilized and the exclusion of contaminants from the hydraulic circuit.
It must also be remembered that the various components of the system are also lubricated by this
same hydraulic fluid.
To this end, the manifold has been flushed with a superior quality mineral oil following works
assembly, special care being taken to ensure that the filter elements are completely clean.
With all traces of the flushing oil drained from the components, the work ports are sealed off with
protective caps that should not be removed until the moment of connection to the service.
MANUTENZIONE / MAINTENANCE
PREMESSA / PREFACE
La ausa p i ipale he p ovo a ’a esto o il guasto di un impianto oleoidraulico è il bloccaggio

dei componenti dovuto a grippaggi o rotture. Tali inconvenienti sono dovuti ad usura ed
invecchiamento del fluido che trasmette potenza, con conseguente perdita delle sue proprietà
chimico fisiche.
La presenza infatti di particelle e microparticelle che circolano continuamente nel fluido,
costituiscono motivo di usura.
Queste microparticelle, se lasciate circolare nel sistema, agiscono come una miscela abrasiva
scalfendo le superfici con cui vengono continuamente a contatto e trascinando in ciclo ulteriore
contaminante. I danni risultano ovviamente tanto più gravi quanto più sono sofisticate le
apparecchiature installate.
Dall’avvia e to dell’i pia to, la a ute zio e e fatta fo da e tal e te di pi ole ope azio i
he pe esse e ve a e te effi a i devo o o pie si o egola ità. E’ pe ta to est e a e te
IOM_14480 Pages - 4 -/69

importante che tali semplici operazioni di controllo e di verifica siano programmate e riportate su
schede che debbono corredare ogni centralina. Si consigliano le seguenti operazioni periodiche:
When a hydraulic system stops or breaks down, the cause more often than not is that components
have caused to operate as the result of seizure or mechanical failure. Trouble of this nature occurs
when a hydraulic fluid is overused and becomes spent, losing its original chemical and physical
properties. In effect, the presence of particles and microscopic particulate matter entrained in the
fluid must inevitably lead to wear. Left to circulate in the system, such particles will act ultimately
as an abrasive compound, scoring the surfaces with which the fluid is permanently in contact and
generating additional contaminants as a result; and the more sophisticated and complex the
equipment installed, needless to say, the greater the damage. Once the system has been
commissioned, maintenance will consist essentially in a series of minor operations (mainly
inspections and checks) which must be performed on a regular basis if maximum benefit is to be
gained. Accordingly, it is extremely important that such operations are scheduled and recorded on
a chart, and that a separate chart is kept for each power unit. The following schedule is
recommended.
PULIZIA ESTERNA SEMESTRALE / GENERAL CLEANING (EXTERIOR) EVERY SIX

MONTHS
Pe ette u a fa ile lo alizzazio e di eve tuali pe dite e ui di ’i ediato i te ve to.
Regular cleaning will facilitate the discovery and early repair of any leaks that may develop.
CONTROLLO FILTRI OLIO / CHECKING THE OIL FILTERS
Come già richiamato, tale operazione riveste la massima importanza.

I filtri devono essere controllati mediamente ogni 2 mesi, verificando lo stato di intasamento
della a tu ia sull’i di ato e visivo di ui i filt i so o dotati.
Efficient filtration is of maximum importance, as already intimated. Assuming average operating

conditions, the filters should be inspected every two months; an indicator associated with the
filters shows the extent to which the element is blocked.
IOM_14480 Pages - 5 -/69

ELETTROVALVOLE - VALVOLE DI CONTROLLO / SOLENOID VALVES - CONTROL
VALVES
E' difficile stabilire a priori la durata media di tali componenti, oltre la quale ritenere economica
la loro sostituzione.
Non potendo programmare dei collaudi a scadenze prestabilite, per ovvie ragioni di operatività
degli attuatori, si dovranno registrare le eventuali variazioni nel tempo delle caratteristiche
tecniche di progetto e/o di collaudo. Queste variazioni possono consistere nell'allungamento dei
tempi di apertura/chiusura delle valvole e di diminuzione della pressione di esercizio.
La loro sostituzione diventa quindi programmabile nel momento in cui si presentano le prime
variazioni.
It is difficult to forecast the average lifetime of these components, in terms of a balance between
economy and the need for replacement.
As tests obviously cannot be conducted to a predetermined schedule, given the dissimilar
conditions under which different actuators operate, a record should be kept of any departures
from nominal design and/or test parameters observed over time, typically slower opening/closing
movements in the case of the valves, and lower operating pressure.
The initial appearance of a drift from nominal parameters will provide an indicator to the
appropriate time of replacement.
IOM_14480 Pages - 6 -/69

DISPOSITIVI DI SICUREZZA / SAFETY DEVICES
PREMESSA / PREFACE
I dispositivi di si u ezza dell’i pia to so o app ese tati, dall’i dicatore di intasamento posto sui
filtri.
E’ e essa io, o f e ue za e sile, o t olla e uesti dispositivi pe evita e da i se si ili a
tutto l’i pia to.
The safety devices incorporated into the system include, the filter blockage indicator.
These devices should be checked once a month to ensure that any faults or malfunctions are
discovered early, thereby preventing extensive and costly damage to the system as a whole.
INDICATORE DI INTASAMENTO DEI FILTRI / FILTERS BLOCKAGE INDICATOR
Controllare il valore di pressione indicato sull’i di ato e del filtro.
A indicator associated with the filters indicates the degree to which impurities have accumulated
in the element.
IOM_14480 Pages - 7 -/69

RICERCA GUASTI/TROUBLE SHOOTING
INCONVENIENTI CAUSE PROBABILI IPOTESI PER L'INTERVENTO
PRESSIONE INSUFFICIENTE a -Tenute usurate nei cilindri

o caduta della pressione rispetto 1) Fughe interne eccessive b -Usura delle valvole e delle elettrovalvole
al livello previsto nel circuito c -Viscosità dell'olio troppo bassa
a -Viscosità dell'olio troppo alta

b -Insufficiente dimensionamento dei passaggi
dell'olio
2) Eccessive perdite di carico

cioè innalzamento della
temperatura dell'olio oltre il limite 4) Eccessive perdite di carico - Vedi punto 2
prudenziale di 50°C - 60°C
degli organi azionati b -Eliminare le entrate d'aria.
idraulicamente rispetto al ciclo
stabilito 7) Bloccaggio delle valvole -Valvole semi aperte per interposizione di
impurità
8) Eccessive perdite di carico -Vedi punto 2
cioè eccessivamente rapida in b -Filtri inefficienti
rapporto al tempo di effettivo
esercizio al servizio 10) Insufficiente lubrificazione a -Olio di qualità scadente
IOM_14480 Pages - 8 -/69

TROUBLE LIKELY CAUSE SUGGESTED REASON
PRESSURE TO LOW 1) Excessive internal leakages a -worn cylinder seals
or drop in pressure below the b -worn valves and/or solenoid valve
level prescribed for the circuit c -oil of insufficient viscosity
a -oil viscosity too high

2) Excessive pressure losses b -oil flow paths too narrow
c -oil flow paths partly blocked
OVERHEATING 3) Excessive internal leakages - See point 1
oil temperature rising above
nominal safety limit of 50-60°C 4) Excessive pressure losses - See point 2
5) Insufficient oil in the system - Tank requires topping up

ERRATIC OPERATION OF SYSTEM 6) Air in the circuit a -system requires bleeding from top
hydraulic service do not respond b -delete infiltration
as expected
7) Sticking valves - Valves held half-open by foreign matter
8) Excessive pressure losses - See point 2

EXCESSIVE WEAR 9) Oil containing abrasive matter a -oil change overdue
wear much havier than effective b -inefficient filtration
hours operation and type of duty
might suggest 10) Poor lubrication a -better quality oil required
b -oil too thin at operating temperature
11) High operation pressure - Abnormally high loads on shafts / rods
12) Defective mounting / coupling - Abnormally high loads on shafts / rods
IOM_14480 Pages - 9 -/69

SCHEDE TECNICHE
COMPONENTI
DATA SHEET COMPONENTS
IOM_14480 Pages - 10 -/69
DISCHARGE BALL VALVE S800/ 1500 ½”GAS MONOBLOCK
IOM_14480 Pages - 11 -/69
IOM_14480 Pages - 12 -/69
TANK PROTECTION VALVE 19.102.830
IOM_14480 Pages - 13 -/69
MICRO SWITCH ZCKJ18H29 + ZCKE056 + ZCKY13
IOM_14480 Pages - 14 -/69
IOM_14480 Pages - 15 -/69
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IOM_14480 Pages - 17 -/69
IOM_14480 Pages - 18 -/69
DUST ESCLUDER SFEX ½”
IOM_14480 Pages - 19 -/69
NEEDLE VALVE FT 2290-14 MFQ
IOM_14480 Pages - 20 -/69
IOM_14480 Pages - 21 -/69
NEEDLE VALVE 49.020.247
IOM_14480 Pages - 22 -/69
HYDRAULIC FILTER FR1.02.396
IOM_14480 Pages - 23 -/69
IOM_14480 Pages - 24 -/69
HYDRAULIC FILTER FHB065.2.B.F.F1.A10.N.P01
IOM_14480 Pages - 25 -/69
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IOM_14480 Pages - 29 -/69
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HYDRAULIC PRESSURE REGULATOR 49.020.239 (SET 97BARG↑)
IOM_14480 Pages - 32 -/69
CHECK VALVE CAE30/ P
IOM_14480 Pages - 33 -/69
CHECK VALVE CAE20/P
IOM_14480 Pages - 34 -/69
SHUTTLE VALVE CCI20
IOM_14480 Pages - 35 -/69
RELIEF VALVE LPA30/D–N INOX
IOM_14480 Pages - 36 -/69
RELIEF VALVE MVPX4C SET 207 BAR HAWE
IOM_14480 Pages - 37 -/69
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HYDRAULIC PILOT/SPRING POPPET TYPE VALVE 49.020.132
IOM_14480 Pages - 44 -/69
3/2 HAND ACTUATED VALVE PK3-S-DN10-448A-SB57(-40°C)
IOM_14480 Pages - 45 -/69
IOM_14480 Pages - 46 -/69
ELECTRIC PRESSURE SWITCH PCS2-GH-40/250
IOM_14480 Pages - 47 -/69
IOM_14480 Pages - 48 -/69
UNIDIRECTIONAL FLOW REGULATOR 49.020.245
IOM_14480 Pages - 49 -/69
HAND PUMP 19.102.828
IOM_14480 Pages - 50 -/69
HYDRAULIC ROTATING PUMP R2,5
IOM_14480 Pages - 51 -/69
IOM_14480 Pages - 52 -/69
IOM_14480 Pages - 53 -/69
IOM_14480 Pages - 54 -/69
IOM_14480 Pages - 55 -/69
IOM_14480 Pages - 56 -/69
ELECTRIC TEMPERATURE SWITCH TCS2-CH-40/100
IOM_14480 Pages - 57 -/69
IOM_14480 Pages - 58 -/69
LEVEL GAUGE 19.102.605/200/MFQ
IOM_14480 Pages - 59 -/69
OIL POURING PLUG WITH FILTER TA70B10AAP03
IOM_14480 Pages - 60 -/69
ELECTRIC LEVEL TRANSMITTER LCT.S52.05/270/350.S.50.GS.E1.L
IOM_14480 Pages - 61 -/69
IOM_14480 Pages - 62 -/69
PRESSURE GAUGE 233.50DN63-1/4G-RADIAL BAR/PSI SAFETY GLASS GLYCERINE
IOM_14480 Pages - 63 -/69
IOM_14480 Pages - 64 -/69
IOM_14480 Pages - 65 -/69
IOM_14480 Pages - 66 -/69
ELECTRIC MOTOR M3AA 90LD4 B5 1KW ABB
IOM_14480 Pages - 67 -/69
IOM_14480 Pages - 68 -/69
SCHEMA IDRAULICO - DISEGNO D’ASSIME
OPERATING DIAGRAM – LAYOUT DRAWING
IOM_14480 Pages - 69 -/69
(REVA DWG. 19.021.261)
286A BOLT EYES M16 FOR LIFTING 519B 519C OUTLET MANIFOLD
ECU 395C 352F

286B
542 267
23
22
12 424A
379C 379B 356C
B 11 379D
383
A
956 401A 401B
424B
562 621C
379F
1880,5
558
424C
352C
19 428
M8 33A
528
985
540 413
39B
561 460 39A 352E 379A
559
6
ELECTRIC CABLE ENTRY 1390 MANIFOLD PUMP/ACCUMULATOR
N 2 HOLES 41
195 1000 195 519A
N 1 HOLE 33 621A
N 1 HOLE 21 800 33B
N 4 HOLES 26 352A 621B
395A
395D
21
195
352B
HYDRAULIC CONNECTION: 379E
A,B=3/4"NPT 352D
371
MASS (WITHOUT OIL)= ~520Kg 359 395B
750
850
1140
MAX OIL LEVEL
3 REVISED CAD ONLY
(WITH EMPTY ACCUMULATOR)=56lt
2 MODIFICARE SOLO CON CAD
MIN OIL LEVEL=26lt
1 20.05.16 NV REVISED POS. 19 AND OIL TANK
Drawing Number
SPRING TO OPEN
195
2112750010
ELECTRO HYDRAULIC scale date
ACTUATOR 1:15 04.03.16
N 4 SLOTS 18x35 ATTUATORI E SISTEMI DI CONTROLLO
drm chkd
HI-BAR MJ18
96 Boss Mount Safety Screen
PERFORMANCE
LEE LOHM BURST / COLLAPSE
ROB
PART RATE PRESSURE
NUMBER
NUMBER (nom.) bar (min.)
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208
SPECIFICATIONS (nom.)
LEE HOLE HOLE OPEN TOTAL NUMBER
PART SIZE SIZE AREA AREA OF

NUMBER in µm mm2 mm2 HOLES
FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
PART MATERIAL SPECIFICATION FINISH
Screen 15-5PH CRES AMS 5659 Passivate
HI-BAR MJ20
Boss Mount Safety Screen 97
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
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PI 1.110
OLAER INDUSTRIES GmbH Zum Gunterstal 4 D-66440 Blieskastel

Tel.: 06842 / 92 04-0 Fax: 06842 / 92 04-15 E-Mail: info@olaer.de Web: www.olaer.de
Blasenspeicher Serie EHV Standard-Baureihe, 330 - 350 bar

Bladder accumulator range EHV standard range, 330 - 350 bar
Abnahme / Approval
Die Speicher dieser Serie sind grundsätzlich nach der Europäischen
Druckgeräterichtlinie 97/23/EG hergestellt, geprüft und dokumentiert.
Andere Abnahmen auf Anfrage.
All accumulators of this range are manufactured, approved and certified according Directive
97/23/EC of the European Parliament. Other approvals on request.
Temperaturbereich / Temperature range

Standardausführung: -15 °C bis +80 °C
Standard: -15 °C to +80 °C
Weitere Details der Standard-Baureihe sind in der Dokumentation

doc.1-100 zusammengefasst.
Further details of the standard range are summarized in the documentation doc.1-100.
max. Betriebs- Abmessungen

Gasvolumen Gewicht
Typ druck Q max. Dimensions
Gas volume Weight
Type MWP l/min
V0 (L) (kg) A B C øD ød E F øG øH SW1
(bar)
EHV 0,2 - 350 /… 0,17 350 1,7 150 265,5 39 26 56 16 200,5 G ½" 27 38 24
EHV 0,5 - 350 /… 0,6 350 2,5 240 257 54 26 90 16 177 G ¾" 36 50 32
EHV 1 - 350 /… 1 350 5 240 329,5 54 68 114 22 207,5 G ¾" 36 50 32
EHV 1,6 - 350 /... 1,6 350 7 240 395 54 26 114 16 315 G ¾" 36 50 32
EHV 2,5 - 350 /… 2,4 350 10 450 549 66 68 114 22 415 G 1 ¼" 53 67 50
EHV 4 - 350 /… 3,7 350 16 450 435,5 66 68 168 22 301,5 G 1 ¼" 53 67 50
EHV 5 - 350 /… 5 350 17 450 898 66 68 114 22 764 G 1 ¼" 53 67 50
EHV 6 - 350 /… 6 350 20 450 561,5 66 68 168 22 427,5 G 1 ¼" 53 67 50
EHV 10 - 350 /... L 10 350 28 450 826,5 66 68 168 22 692,5 G 1 ¼" 53 67 50
EHV 10 - 330 /... K 9,2 330 32 900 585,5 101 68 226,5 22 416,5 G 2" 76 101 70
EHV 12 - 330 /… 11,2 330 35 900 685,5 101 68 226,5 22 516,5 G 2" 76 101 70
EHV 20 - 330 /... 18,1 330 53 900 895,5 101 68 226,5 22 726,5 G 2" 76 101 70
EHV 24 - 330 /... 22,5 330 61 900 1030,5 101 68 226,5 22 861,5 G 2" 76 101 70
EHV 32 - 330 /... 33,4 330 85 900 1419 101 68 226,5 22 1250 G 2" 76 101 70
EHV 50 - 330 /... 48,7 330 123 900 1927 101 68 226,5 22 1766 G 2" 76 101 70
PI 1.110
EHV 330 - 350 bar
Position
3 Körper Shell
4 Blase komplett ød* Bladder assembly
5 Blase Bladder
13 Haltemutter Lock nut
14 Gasfüllventil komplett Gas valve assembly
15 Körper Gasfüllventil Gas valve body
16 Gasventileinsatz Gas valve core
17 O-Ring O-ring
18 O-Ring O-ring
19 Hutmutter Cap
24 Schutzkappe Protective cap
25 Ölventil komplett Oil port assembly
Ölventilkörper m. Oil port body with poppet
26
Ventilteller valve
33 Geteilter Ring Anti extrusion ring
37 O-Ring O-ring
38 Stützring Back-up-ring
39 Distanzring Washer
40 Nutmutter Locking ring
46 Firmenschild Name plate
50 O-Ring O-ring
Bei Ersatzteilbestellung sind folgende Angaben wichtig:

For spare part order the following informations are important:
Körper nicht als Ersatz lieferbar

Shell not available as spare part
Firmenschilddaten sind anzugeben

Name plate datas must be indicated
* ød ist bei der Bestellung anzugeben

* ød has to be indicated
Beispiel Example
d = ø16 mm EHV 0.5
d = ø22 mm EHV 2.5
Product Data Sheet
October 2013
00813-0100-4690, Rev NB
Rosemount 2088 Absolute and Gage Pressure

Transmitter
 Performance of 0.065% with High Accuracy option

 Lightweight, compact design for cost-effective installation
 Protocols available include 4-20 mA HART® and 1-5 Vdc HART Low Power
 Absolute and gage pressure ranges up to 4,000 psi (276 bar)

 Rangeability of 50:1
Rosemount 2088 Pressure Transmitter Product Offering

Proven Reliability for Gage and Absolute
Applications
 Available protocols include 4-20 mA HART® and 1-5 Vdc

HART Low Power
 Fully Configurable LCD to display process variable, percent

of range, and diagnostic messages
 Lightweight, compact design enables easy installation
 Choice of Stainless Steel or Alloy C-276 wetted materials
Unlock the Value of Devices with the Smart

Wireless THUM™ Adapter
 Gain access to field intelligence and improve quality, safety,

availability, operations, and maintenance costs
 Remotely manage devices and monitor health
 Enable new wireless measurement points
 Utilize existing loop power
Proven, Reliable, and Innovative DP Level

Technologies
 Connect to virtually any process with a comprehensive

offering of process connections, fill fluids, direct mount or
capillary connections and materials
 Quantify and optimize total system performance with QZ

option
Instrument Manifolds – Quality, Convenient,

and Easy
 Designed and engineered for optimal performance with

Rosemount transmitters
 Save installation time and money with factory assembly
 Offers a variety of styles, materials, and configurations
Contents
Rosemount 2088 In-line Pressure Transmitter . . . page 3 Product Certifications . . . . . . . . . . . . . . . . . . . . . . .page 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . .page 14
2 www.rosemount.com
Rosemount 2088 In-line Pressure Transmitter
Configuration Transmitter Output Code

S
4-20 mA HART®

N
1-5 Vdc Low Power
Additional Information
Specifications : page 8
Product Certifications : page 11
Dimensional Drawings : page 14
Model Product description
Standard Standard
2088 Pressure Transmitter ★
Code Measurement Type
Standard Standard
A Absolute ★
G Gage ★
Code Pressure Ranges
Standard Standard
2088G 2088A
1 -14.7 to 30 psi /(-1,01 to 2,1 bar) 0 to 30 psi (0 to 2,1 bar) ★
4 -14.7 to 4,000 psi (-1,01 to 275,8 bar) 0 to 4,000 psi (0 to 275,8 bar) ★
Code Transmitter Output
Standard Standard
S (1) 4–20 mA dc/Digital HART® Protocol ★
N(1) 1-5 Vdc Low Power/ Digital HART protocol ★
www.rosemount.com 3

Code Materials of Construction
Standard Standard
Process connection Isolating diaphragm Fill Fluid
22 (2) 316L SST 316L SST Silicone ★
★
33(2) Alloy C-276 Alloy C-276 Silicone
Expanded
2B(2) 316L SST 316L SST Inert
Code Process Connection
Standard Standard
A ½–14 NPT Female ★
B(3) DIN 16288 G ½ Male ★
D(3)(4) M20 1.5 Male ★
Expanded
C(3)(4) RC ½ Female
Code Conduit Entry
Standard Standard
1 ½–14 NPT ★
2(3) M20 1.5 ★
Expanded
4(3) G½
Options (Include with selected model number)

Diaphragm Seal Assemblies
Standard Standard
S1(5) (6) Assemble to one Rosemount 1199 diaphragm seal ★
Display and Interface

Standard Standard
M4 LCD Display with Local Operator Interface ★
M5 LCD Display, configured for Engineering Units ★
Configuration Buttons
Standard Standard
D4 Analog Zero and Span ★
DZ Digital Zero Trim ★
Mounting Brackets
Standard Standard
B4 SST mounting bracket with SST Bolts ★
4 www.rosemount.com

Standard Standard
C6 CSA Explosion-Proof, Intrinsically Safe, and non-Incendive ★
E2 INMETRO Flameproof ★
E3 China Flameproof ★
E4(3)(7) TIIS Flameproof ★
E5 FM Explosion-Proof, Dust Ignition-proof ★

E7 IECEx Flameproof ★
ED ATEX Flameproof ★
(3) ATEX Intrinsic Safety ★
I1
I2 INMETRO Intrinsic Safety ★
I3 China Intrinsic Safety ★
I5 FM Intrinsically safe, Division 2 ★
I7 IECEx Intrinsic Safety ★
K1 ATEX Flameproof, Intrinsic Safety, Type n, Dust ★
K2 INMETRO Flameproof, Intrinsic Safety ★
K5 FM Explosion-Proof, Dust Ignition-proof, Intrinsically Safe, Division 2 ★
(3) ATEX and CSA Explosion-Proof, Dust Ignition-proof, Intrinsically Safe, Division 2 ★
K6
K7 IECEx Flameproof, Intrinsic Safety, Type n, Dust ★
KB FM and CSA Explosion-Proof, Dust Ignition-proof, Intrinsically Safe, Division 2 ★
KH(3) FM Approvals and ATEX Explosion-Proof and Intrinsically Safe ★

★
N1(3) ATEX Type n
N3 China Type n ★
N7 IECEx Type n ★
ND(3) ATEX Dust ★
NK IECEx Dust ★
Shipboard Approvals
Standard Standard
SBS American Bureau of Shipping (ABS) Type Approval ★
SBV Bureau Veritas (BV) Type Approval ★
SDN Det Norske Veritas (DNV) Type Approval ★
SLL Lloyd's Register (LR) Type Approval ★
Pressure Testing
Expanded
P1 Hydrostatic testing
Terminal Blocks
Standard Standard
T1 Transient protection ★
Special Cleaning
Expanded
P2 Cleaning for special service
Calibration Certificate
Standard Standard
Q4 Calibration certificate ★
www.rosemount.com 5

Quality Calibration Certificate Traceability Certification
Standard Standard
Q8 Material Traceability Certification per EN 10204 3.1 ★
Q15 Certificate of Compliance to NACE MR0175/ISO 15156 for wetted materials ★
Q25 Certificate of Compliance to NACE MR0103 for wetted materials ★
Digital Signal
Standard Standard
★
C4(3) NAMUR alarm and saturation levels, high alarm
CN(3) NAMUR alarm and saturation levels, low alarm ★
C5 (8)(9) Custom alarm and saturation levels, high alarm, (Requires C9 and Configuration Data Sheet) ★
★
C7(8)(9) Custom alarm and saturation levels, low alarm (Requires C9 and Configuration Data Sheet)
C8(9) Low alarm (Standard Rosemount Alarm and Saturation Levels) ★
Configuration
Standard Standard
C9 Software configuration ★
Manifold Assemblies
Standard Standard
(5)(6) Assemble to Rosemount 306 integral manifold ★
S5
Calibration Accuracy
Standard Standard
P8(10) 0.065% accuracy to 10:1 turndown ★
Water Approval
Standard Standard
DW(11) NSF drinking water approval ★
Surface Finish
Standard Standard
Q16 Surface finish certification for sanitary remote seals ★
Toolkit Total System Performance Reports
Standard Standard
QZ Remote Seal System Performance Calculation Report ★
HART Revision Configuration
Standard Standard
(9)(12) Configured for HART Revision 5 ★
HR 5
★
HR7 (9)(13) Configured for HART Revision 7
Typical Model Number: 2088 G 2 S 22 A 1 B4 M5
(1) HART Revision 5 is the default HART output. The 2088 with selectable HART can be factory or field configured to HART Revision 7. To order HART Revision 7 factory
configured, add option code HR7.
6 www.rosemount.com
(2) Materials of Construction comply with recommendations per NACE MR0175/ISO 15156 for sour oil field production environments. Environmental limits apply to
certain materials. Consult latest standard for details. Selected materials also conform to NACE MR0103 for sour refining environments.
(3) Not available with low-power Transmitter Output code N.
(4) Not available with Alloy C-276, Material of Construction code 33.
(5) Use 1/2 - 14 NPT Female Process Connection code A.
(6) “Assemble-to” items are specified separately and require a completed model number.
(7) Only available with Conduit Thread code 4.
(8) Only available with 4-20 mA HART Output (Output Code A).
(9) Select Configuration Buttons (option code D4 or DZ) or Local Operator Interface (option code M4) if local configuration buttons are required.
(10) Requires Transmitter Output code S with either Materials of Construction code 22 or 23.
(11) Requires Materials of Construction code 22 with Process Connection code A.
www.rosemount.com 7
Specifications
Performance Specifications Functional Specifications
For zero-based spans, reference conditions, silicone oil fill, 316L
Table 2. 2088 Range Values
SST isolating diaphragm.
Minimum Upper Lower Lower(1)
Reference Accuracy Range
Span (URL) (LRL) (LRL) (Gage)
±0.075% of calibrated span. Includes combined effects of
0.60 psi 30.00 psi 0 psia –14.70 psig
linearity, hysteresis, and repeatability 1
(41,37 mbar) (2,07 bar) (0 bar) (–1,01 bar)
±0.065% of calibrated span (high accuracy option - P8)
3.00 psi 150.00 psi 0 psia –14.70 psig
For spans less than 10:1, accuracy = 2
(206,85 mbar) (10,34 bar) (0 bar) (–1,01 bar)
16.00 psi 800.00 psi 0 psia –14.70 psig
± 0.009  ------------- % of Span
URL 3
 Span (1,11 bar) (55,16 bar) (0 bar) (–1,01 bar)
80.00 psi 4000.00 psi 0 psia –14.70 psig
4
Ambient Temperature Effect (5,52 bar) (275,79 bar) (0 bar) (–1,01 bar)
Expressed as a total effect per 50 °F (28 °C)
(1) Assumes atmospheric pressure of 14.70 psia (1,01 bar-a).
Total effect includes zero and span effects.
± (0.15% URL + 0.15% of span)
Output
Stability Code S: 4–20 mA
Ranges 2-4: ±0.10% of URL for 3 years Code N: 1-5 Vdc, low power
Range 1: ±0.10% of URL for 1 year (Outputs are directly proportional to the input pressure)
Vibration Effect Selectable HART

Digital communications based on HART Revision 5 (default)
Less than ±0.1% of URL when tested per the requirements of
or Revision 7 (option code HR7) protocol can be selected.
IEC60770-1 field or pipeline with high vibration level (10 - 60 Hz
The HART revision can be switched in the field using any
0.21 mm displacement peak amplitude / 60 - 2000 Hz 3g). HART based configuration tool or the optional local operator
Power Supply Effect interface (LOI).
Less than ±0.005% of calibrated span per volt change in voltage Service
at the transmitter terminals. Liquid, gas, and vapor applications
Mounting Position Effect Power Supply

Zero shifts to ±2.5 inH2O (6,22 mbar), which can be zeroed External power supply required. Transmitter operates on
Span: no effect 10.5–42.4 Vdc with no load (5.8-28 V for Low Power). Reverse
polarity protection is standard.
Transient Protection
Tested in accordance with IEEE C62.41.2-2002,
Location Category B
6 kV crest (0.5 s - 100 kHz)
3 kA crest (8 x 20 microseconds)
6 kV crest (1.2 x 50 microseconds)
General Specifications
Tested to IEC 801-3
8 www.rosemount.com
Load Limitations Temperature Limits

Reverse polarity protection is standard. Maximum loop Ambient:
resistance is determined by the power supply voltage as -40 to 185 °F (–40 to 85 °C)
described by the following equations: With LCD display(1): -40 to 176 °F (–40 to 80 °C)
Figure 1. Maximum loop resistance Storage(1):

Max. Loop Resistance = 43.5 (Power Supply Voltage – 10.5) -50 to 230 °F (-46 to 110 °C)
1387 With LCD display: –40 to 185 °F (–40 to 85 °C)
Process
Load (ohms)
1000
Silicone fill sensor: –40 to 250 °F (–40 to 121 °C)(2)
Inert fill sensor: –22 to 250 °F (–30 to 121 °C)(2)
500 Operating
Region Process temperatures above 185 °F (85 °C) require derating the
ambient limits by a 1.5:1 ratio. For example, for process
0
temperature of 195 °F (91 °C), new ambient temperature limit is
10.5 20 30 42.4 equal to 170 °F (77 °C). This can be determined as follows: (195
Voltage (Vdc) °F - 185 °F) x 1.5 = 15 °F, 185 °F - 15 °F = 170 °F
The Field communicator requires a minimum loop resistance of
250W for communication. Humidity Limits
0–100% relative humidity
Indication Volumetric Displacement
Optional two line LCD/LOI Display. Less than 0.0005 in3 (0,008 cm3)
Zero and Span Adjustment Requirements Damping
Zero and span values can be set anywhere within the range
Analog output response time to a step change is user-selectable
limits stated in Table 2 on page 8. Span must be greater than
from 0 to 60 seconds for one time constant. Software damping
or equal to the minimum span stated in Table 2 on page 8.
is in addition to sensor module response time.
Turn-on Time
The LOI utilizes a 2 button menu with internal and external
2.0 seconds, no warm-up required
configuration buttons. Internal buttons are always configured
for Local Operator Interface. External Buttons can be configured Transmitter Security
for either LOI, (option code M4), Analog Zero and Span (option Activating the transmitter security function prevents changes to
code D4) or Digital Zero Trim (option code DZ) for LOI the transmitter configuration, including local zero and span
configuration menu. adjustments. Security is activated by an internal switch.
Current Draw Failure Mode Alarm
Output Code N:  3 mA. If self-diagnostics detect a sensor or microprocessor failure, the
Overpressure Limits analog signal will be driven either high or low to alert the user.
High or low failure mode is user-selectable with a jumper on the
Range 1: 120 psig max
transmitter. The values to which the transmitter drives its
All other ranges: two times the URL
output in failure mode depend on whether it is
Burst Pressure factory-configured to standard or NAMUR-compliant operation.
11,000 psi for all ranges The values for each are as follows:
Standard Operation
Zero Elevation and Suppression
Zero can be suppressed between atmosphere for gage Output Code Linear Output Fail High Fail Low
transmitters or 0 psia for absolute transmitters and upper range S 3.9  I  20.8 I  21.75 mA I  3.75 mA
limit, provided the calibrated span is equal to or greater than the N 0.97  V  5.2 V  5.4 V V  0.95 V
minimum span, and the upper range value does not exceed the
NAMUR-Compliant Operation
upper range limit.
Output Code Linear Output Fail High Fail Low
Dynamic Performance
S 3.8  I  20.5 I  22.5 mA I  3.6 mA
Total Response Time: 145 milliseconds
Update rate: 20 times per second minimum
(1) If storage temperature is above 85 °C, perform a sensor trim prior to

installation.
(2) 220 °F (104 °C) limit in vacuum service; 130 °F (54 °C) for pressures
below 0.5 psia.
www.rosemount.com 9
Physical Specifications
Electrical Connections
/ –14 NPT, M20 1.5 (CM20), or
1 2
G 1/2 female (PF 1/2 female) conduit entry
Process Connections
1
/2–14 NPT female, DIN 16288 G 1/2 male, RC 1/2 female
(PT 1/2 female), M20 1.5 (CM20) male
Process-Wetted Parts
Isolating Diaphragm
316L SST (UNS S31603), Alloy C-276 (UNS N10276)
Process Connector
316L stainless steel CF-3M (Cast version of 316L SST, material
per ASTM_A743) or Alloy C-276
Non-Wetted Parts
Electronics Housing
Low-copper aluminum, NEMA 4X, IP65, IP67,
CSA enclosure Type 4X
Paint for Aluminum Housing
Polyurethane
Cover O-rings
Buna-N
Fill Fluid
Silicone or inert fill
Weight
Output Code S and N: Approximately 2.44 lb (1, 11 kg)
Approved Manufacturing Locations Canadian Standards Association (CSA)
Rosemount Inc. — Chanhassen, Minnesota, USA All CSA hazardous approved transmitters are certified per
Emerson Process Management GmbH & Co. — Wessling, ANSI/ISA 12.27.01-2003.
Germany
C6 Explosion-Proof, Intrinsically Safe, Dust Ignition-Proof and
Emerson Process Management Asia Pacific
Class I Division 2
Private Limited — Singapore
Applicable Standards: CAN/CSA Std. C22.2 No. 0-M91, CSA
Beijing Rosemount Far East Instrument Co., LTD — Beijing, China
Std. C22.2 No. 25 - 1966, CSA Std. C22.2 No. 30 - M1986,
European Directive Information CAN/CSA Std. C22.2 No. 94 - M91, CSA Std. C22.2 No. 142
- M1987, CAN/CSA Std. C22.2 No. 157-92, CSA Std. C22.2
The EC declaration of conformity for all applicable European
No. 213 - M1987, ANSI/ISA 12.27.01-2003.
directives for this product can be found at
Markings: Explosion-proof for Class I, Division 1, Groups B,
www.rosemount.com. A hard copy may be obtained by
C, and D.
contacting an Emerson Process Management representative.
Dust-Ignition-Proof for Class II, Division 1, Groups E, F, G,
ATEX Directive (94/9/EC) Class III.
Emerson Process Management complies with the ATEX Suitable for Class I, Division 2, Groups A, B, C, and D.
Directive. Intrinsically Safe for Class I, Division 1, Groups A, B, C, and
D. Temperature Code: T3C.
European Pressure Equipment Directive (PED) (97/23/EC) Enclosure Type 4X. Factory sealed. Single Seal. See control
2088/2090 Pressure Transmitters drawing 02088-1024.
— Sound Engineering Practice European Certifications
Electro Magnetic Compatibility (EMC) (2004/108/EC) ED ATEX Flameproof
EN 61326-1:2006 Certification No.: KEMA97ATEX2378X
Applicable Standards: EN60079-0:2006, EN60079-1:2007,
EN60079-26:2007
Hazardous Locations Certifications
Markings: II 1/2 G
North American Certifications Ex d IIC T6 (-40 °C Tamb 40 °C); T4 (-40 °C Tamb 80 °C)
FM Approvals 1180
Vmax = 36 (with Output Code S)
E5 Explosion-proof and Dust Ignition Proof Vmax = 14 (with Output Code N)
Certificate No.: 1V2A8.AE
Applicable Standards: FM Class 3600 - 1998,
FM Class 3615 - 1989, FM Class 3810 - 1989 1. The cable and conduit entry devices shall be of a certified
Markings: Explosion-proof for Class I, Division 1, Groups B, flameproof type Ex d, suitable for the conditions of use and
C, and D. Dust Ignition-Proof for Class II/III, Division 1, correctly installed.
Groups E, F and G. 2. With the use of conduit entries a sealing device shall be
Temperature Code: T5 (Ta = -40 °C to + 85 °C) Factory provided immediately on the entrance thereto.
Sealed, Enclosure Type 4X. 3. Unused apertures shall be closed with suitable Ex d
For input parameters see control drawing 02088-1018. certified blanking elements.
4. Suitable heat-resisting cables shall be used when the
I5 Intrinsically Safe and Non-Incendive ambient temperature at the cable or conduit entries
Certificate No.: 0V9A7.AX exceed 65 °C.
Applicable Standards: FM Class 3600 - 1998, FM Class 3610 5. This device contains a thin wall diaphragm. Installation,
- 2010, FM Class 3811 - 2004, FM Class 3810 - 1989. maintenance, and use shall take into account the
Markings: Intrinsically safe for use in Class I, Division 1, environmental conditions to which the diaphragm will be
Groups A, B, C, D; Class II, Division 1, Groups E, F, and G; subjected. The manufacturer's instructions for installation
and Class III, Division 1 and maintenance shall be followed in detail to assure
Temperature Code: T4 (Ta = 70 °C) in accordance with safety during its expected lifetime.
Rosemount drawing 02088-1018. 6. For information on the dimensions of the flameproof joints
Non-incendive for Class I, Division 2, Groups A, B, C, and D. the manufacturer shall be contacted.
Temperature Code: T4 (Ta = 85 °C), Enclosure Type 4X.
For input parameters see control drawing 02088-1018.
I1 ATEX Intrinsic Safety

Certificate No.: BAS00ATEX1166X
Applicable Standards: EN60079-0:2012, EN60079-11: IECEx Certifications
2012 E7 IECEx Flameproof
Markings: II 1 G Certificate No.: IECEx KEM 06.0021X
Ex ia IIC T5 Ga (–55 °C  Tamb  40 °C) Applicable Standards: IEC60079-0:2004,
IEC60079-1:2003, IEC60079-26:2004
Ex ia IIC T4 Ga (–55 °C  Tamb  70 °C) Markings: Ex d IIC T4 (-20 °C Tamb  80 °C)
1180 Ex d IIC T6 (–20 °C  Tamb  40 °C)
I7 IECEx Intrinsic Safety
Ui = 30 V Certificate No.: IECEx BAS 12.0071X
Ii = 200 mA Applicable Standards: IEC60079-0:2011,
Pi = 0.9 W IEC60079-11:2011
Ci = 0.012 F Markings: Ex ia IIC T5 Ga(-55 °C Tamb  +40 °C)
Ex ia IIC T4 Ga (–55 °C  Tamb  +70 °C)
Special Conditions For Safe Use (x):
1. The apparatus is not capable of withstanding the 500V Table 4. Input Parameter
insulation test required by EN60079-11. This must be Ui = 30 V
taken into account when installing the apparatus. Ii = 200 mA
Pi = 0.9 W
N1 ATEX Non-incendive/Type n Ci = 0.012 F
Certification No.: BAS 00ATEX3167X
1. The equipment is not capable of withstanding the 500V
2010
Markings: II 3 G taken into account when installing the equipment.
Ex nA IIC T5 Gc (–40 °C  Tamb  70 °C)
Ui = 50 Vdc max N7 IECEx Non-incendive/Type n
Certificate No.: IECEx BAS 12.0072X
1180 Applicable Standards: IEC60079-0:2011, IEC60079-15:
2010
1. Special Conditions For Safe Use (x): Markings: Ex nA IIC T5 Gc (-40 °C Tamb  +70 °C)
The apparatus is not capable of withstanding the 500V Ui =50 Vdc max
taken into account when installing the apparatus. Special Conditions for Safe Use (x):
1. When fitted with a transient suppression terminal block,
ND ATEX Dust the Model 2088 is incapable of passing the 500V isolation
Certificate No.: BAS01ATEX1427X test. This must be taking into account during installation.
2009 NK IECEx Dust
Markings: II 1 D Certificate No.: IECEx BAS12.0073X
Ex t IIIC T50 °C T 500 60 °C Da Applicable Standards: IEC60079-0:2011, IEC60079-31:
Vmax = 36 Vdc; Ii = 24 mA 2008
Markings: Ex t IIIC T50 °C T 500 60 °C Da
1180
Special Conditions For Safe Use (x): Vmax = 36 Vdc; Ii = 24 mA
1. The user must ensure that the maximum rated voltage and Special Conditions For Safe Use (x):
current (36 volts, 24 mA, D.C.) are not exceeded. All
connections to other apparatus or associated apparatus 1. Cable entries must be used which maintain the ingress
shall have control over this voltage and current equivalent protection of the enclosure to at least IP66.
to a category “ib” circuit according to EN50020. 2. Unused cable entries must be filled with suitable blanking
2. Cable entries must be used which maintain the ingress plugs which maintain the ingress protection of the
protection of the enclosure to at least IP66. enclosure to at least IP66.
3. Unused cable entries must be filled with suitable blanking 3. Cable entries and blanking plugs must be suitable for the
plugs which maintain the ingress protection of the ambient range of the apparatus and capable of
enclosure to at least IP66. withstanding a 7J impact.
4. Cable entries and blanking plugs must be suitable for the
ambient range of the apparatus and capable of
withstanding a 7J impact test.
5. The 2088/2090 sensor module must be securely screwed
in place to maintain the ingress protection of the
enclosure.
Japanese Certifications N3 China Type n Non-Sparking

E4 TIIS Flameproof Certification No.: GYJ101126X (2088 Series)
Ex d IIC T6 (Tamb = 85 °C) Applicable Standards: GB3836.1-2000, GB3836. 8-2000
Markings: Ex nA nL IIC T5 (-40 °C Tamb  +70 °C)
Certificate Description
TC15874 2088 with Alloy C-276 wetted parts (with display) Refer to Appendix B of the 2088/2090 Reference Manual
TC15873 2088 with Alloy C-276 wetted parts (no display) (document number 00809-0100-4690) for Special
TC15872 2088 with SST wetted parts (with display) Conditions for Safe Use.
TC15871 2088 with SST wetted parts (no display)
Combinations of Certifications
Brazil Certifications
Stainless steel certification tag is provided when optional approval is
I2 INMETRO Intrinsic Safety specified. Once a device labeled with multiple approval types is
Certification No.: UL-BR 13.0246 installed, it should not be reinstalled using any other approval types.
Markings: Ex ia IIC T5/T4 Ga Permanently mark the approval label to distinguish it from unused
T5 (-55 °C  Tamb  +40 °C); T4 (-55 °C Tamb  +70 °C) approval types.
Special Conditions For Safe Use (x): K1 I1, N1, ED, and ND combination
1. When fitted with a transient suppression terminal block, K2 I2 and E2 combination
the model 2088 is incapable of passing the 500V isolation
test. This must be taken into account during installation. K5 E5 and I5 combination
2. The enclosure may be made of aluminum alloy and given a K6 C6, I1, and ED combination
protective polyurethane paint finish; however, care should
be taken to protect it from impact or abrasion if located in K7 I7, N7, E7, and NK combination
a zone 0 environment.
KB K5 and C6 combination
E2 INMETRO Flameproof (2088 Series only)
Certification No.: CEPEL 97.0076 KH K5, ED, and I1 combination
Markings: Ex d IIC T6/T5 Gb
T6 (-20 °C  Tamb  +40 °C); T5 (-20 °C Tamb  +60 °C)
China Certifications
I3 China Intrinsic Safety
Certification No.: GYJ111063X (2088 Series); GYJ111065X
(2090 Series)
Markings: Ex ia IIC T4/T5
T4 (-55 °C  Tamb  +70 °C);T5 (-55 °C Tamb  +40 °C)
Ui = 30 V
Ii= 200 mA
Pi= 0.9 W
Ci = 0.012 F

Conditions for Safe Use
E3 China Flameproof
Certificate No.: GYJ111062 (2088 Series); GYJ111064
(2090 Series)
Markings: Ex d IIC T4/T6
T4 (-20 °C  Tamb  +40 °C); T6 (-20 °C  Tamb +80 °C)

Conditions for Safe Use.
Dimensional Drawings
Rosemount 2088
0.75 (20)
5.13 (130) Certifications
Clearance for
Cover 4.29 (109) Optional Tag
Display Cover 3.85 (98)
Removal
2 ½–14 NPT(1)
Conduit
Connection
Transmitter 4.68
Terminal Circuitry (118)
Connections
5.87
(149)
2 ¼–20 UNC-2B
Mounting Holes
(1)
M20 1.5 Female (CM20), PG 13.5, and G 1/2 Female (PF 1/2 Female)
also available as options.
½–14 NPT Female
Process Connection
(See Ordering Table for other options.)
Mounting Configurations with Optional Mounting Brackets

Pipe Mounting Panel Mounting
5.13 (130)
3.85 (98) 4.29 (109)
3.95 (100)
6.15
(156)
2.81
(71)
5.97 (152) 2.97 (75)
2-inch U-Bolt 4.78 (121)

for pipe mounting 6.90 (175)
(clamp shown)
2.81 (71) 5
/16× 1½ Bolts
for panel mounting
(not supplied)
1/ × 11/ Bolts 1/4× 11/4 Bolts
4 4
for transmitter mounting for transmitter mounting
(not supplied) (not supplied)
1.42 (36)
1.42 (36)
Dimensions are in inches (millimeters).
Options Output Information

Output range points must be the same unit of measure.
Standard Configuration Available units of measure include:
Unless otherwise specified, transmitter is shipped as follows:
ENGINEERING UNITS psi (all ranges) Pressure Units(1)
4 mA (1 Vdc): 0 (engineering units) (1) (1)
torr psf cmH2O@4°C
20 mA (5 Vdc): Upper range limit (1)
atm inH2O mH2O@4°C
Output: Linear
Flange type: Pa inH2O@4°C(1) inHg
Specified model code option
(1)
Flange material: Specified model code option kPa inH2O@60°F mmHg
O-ring material: Specified model code option (1) (1)
MPa ftH2O cmHG@0°C
Drain/vent: Specified model code option (1)
hPa ftH2O@4°C(1) mHG@0°C (1)
LCD Display: Installed or none (1)
Alarm: High mbar ftH2O@60°F g/cm2
(1)
Software tag: (Blank) bar mmH2O kg/m2
psi mmH2O@4°C(1) kg/cm2
Custom Configuration
If Option Code C9 is ordered, the customer may specify the
following data in addition to the standard configuration (1) Field configurable only, not available for factory
parameters. calibration or custom configuration (option code C9
“Software configuration”).
• Output Information
• Transmitter Information Display and Interface Options
• LCD display Configuration M4 Digital Display with Local Operator Interface (LOI)
• Hardware Selectable Information • Available for 4-20 mA HART, 4-20 mA HART Low Power
• Signal Selection M5 Digital Meter
Refer to the “Rosemount 2088 Configuration Data Sheet”
• 2-Line, 5-Digit LCD for 4-20 mA HART
document number 00806-0100-4690.
• 2-Line, 5-Digit LCD for 1-5 Vdc HART Low Power
Tagging (3 options available) • Direct reading of digital data for higher accuracy
• Standard SST hardware tag is permanently affixed on transmitter. • Displays user-defined flow, level, volume, or pressure units
Tag character height is 0.125 in. (3,18 mm), 84 characters • Displays diagnostic messages for local troubleshooting
maximum. • 90-degree rotation capability for easy viewing
• Tag may be wired to the transmitter nameplate upon request, 85
characters maximum. Configuration Buttons
• For HART protocols, the tag may be stored in transmitter memory Rosemount 2088 now offers optional internal and external
(eight characters maximum). Software tag is left blank unless configuration buttons.
specified. • Choosing option D4 will add external Analog Zero and Span
• HART Revision 5: 8 characters configuration buttons
• HART Revision 7: 32 characters • Choosing option DZ will add an external Digital Zero Trim
configuration button
Optional Rosemount 306 Integral Manifold • Choosing option M4 (LOI) adds both internal and external local
Factory assembled to 2088 transmitters. Refer to Product Data configuration buttons.
Sheet (document number 00813-0100-4733 for Rosemount
306) for additional information. Certain button options can also be combined as shown below:
Other Seals Button Configuration
Refer to Product Data Sheet (document number Option Codes Internal External
00813-0100-4016 or 00813-0201-4016) for additional DZ N/A Digital Zero Trim
information. D4 N/A Analog Zero & Trim
M4 LOI LOI
M4 + DZ LOI Digital Zero Trim
M4 + D4 LOI Analog Zero & Trim
Rosemount 2088 Bracket Option

B4 Bracket for 2-in. Pipe or Panel Mounting
• Bracket for mounting of transmitter on 2-in. pipe or panel
• Stainless steel construction with stainless steel bolts
Rosemount 2088 Product Data Sheet
00813-0100-4690, Rev NB October 2013

Rosemount Inc. Blegistrasse 23
8200 Market Boulevard P.O. Box 1046
Chanhassen, MN 55317 USA CH 6341 Baar
T (U.S.) 1-800-999-9307 Switzerland
T (International) (952) 906-8888 T +41 (0) 41 768 6111
F (952) 906-8889 F +41 (0) 41 768 6300
www.rosemount.com www.rosemount.com

Asia Pacific Pte Ltd Latin America
1 Pandan Crescent 1300 Concord Terrace, Suite 400
Singapore 128461 Sunrise Florida 33323 USA
T +65 6777 8211 Tel + 1 954 846 5030
F +65 6777 0947 www.rosemount.com
Service Support Hotline: +65 6770 8711
Email: Enquiries@AP.EmersonProcess.com
www.rosemount.com
Standard Terms and Conditions of Sale can be found at www.rosemount.com\terms_of_sale

The Emerson logo is a trade mark and service mark of Emerson Electric Co.
Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc.
PlantWeb is a registered trademark of one of the Emerson Process Management group of companies.
HART and WirelessHART are registered trademarks of the HART Communication Foundation
Modbus is a trademark of Modicon, Inc.
All other marks are the property of their respective owners.
© 2013 Rosemount Inc. All rights reserved.

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29
LIBRETTO USO E MANUTENZIONE per CABINE
MAINTENANCE USE HANDBOOK for CABINET

CUSTOMER DIAGRAM SLAHE002
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
00 15/09/2016 Issued C.M. E.M.

IOM_14481 _19021255 Pages - 1 -/55

Sommario
SCHEDE TECNICHE COMPONENTI ............................................................................ - 9 -
DATA SHEET COMPONENTS ........................................................................................... - 9 -
STOP VALVE PKH-DN10-442A ..................................................................................................... - 16 -
NEEDLE VALVE FT 2290-14/MFQ ................................................................................................ - 18 -
HYDRAULIC FILTER FHB065.2.B.F.F1.A10.N ................................................................................ - 20 -
HYDRAULIC PRESSURE REGULATOR HG031/210/BT .................................................................. - 27 -
CHECK VALVE CAE20/P................................................................................................................ - 31 -
3/2NC POPPET TYPE SOLENOID VALVE DLEH–3A–X125DC/BT................................................... - 35 -
ELECTRIC PRESSURE SWITH PCS2–GH–40/250 ........................................................................... - 39 -
BIDIRECTIONAL FLOW REGULATOR 49.020.244 ......................................................................... - 41 -
SOL.VALVE WITH INTEGRAL ELECTRONICS DHZO–TEB–SN-NP–071 –L5/F/BT ........................... - 43 -
PRESSURE GAUGE 233.50 DN63 1/ 4G RADIAL 0/160BARG/PSI SAF. GLASS GLYCERINE........... - 51 -
IOM_14481 _19021255 Pages - 2 -/55

L’affida ilità di ualsiasi a hi a o i pia to oleoid auli o e appo tata alla ualità ed allo stato
del fluido di t as issio e ed all’asse za di i pu ità nel circuito. Non va dimenticato che è lo stesso
fluido a p ovvede e alla lu ifi azio e dei o po e ti dell’i pia to.
all’attuato e.
PREMESSA / PREFACE
La ausa p i ipale he p ovo a 1’a esto o il guasto di un impianto oleoidraulico è il bloccaggio

chimico fisiche.
Dall’avvia e to dell’i pia to, la a ute zio e e fatta fo da e tal e te di piccole operazioni
he pe esse e ve a e te effi a i devo o o pie si o egola ità. E’ pe ta to est e a e te
IOM_14481 _19021255 Pages - 3 -/55

recommended.

MONTHS
Pe ette u a fa ile lo alizzazio e di eve tuali pe dite e ui di 1’i ediato i te ve to.


IOM_14481 _19021255 Pages - 4 -/55

VALVES
variazioni.
IOM_14481 _19021255 Pages - 5 -/55

PREMESSA / PREFACE
I dispositivi di si u ezza dell’i pia to so o app ese tati, dall’i di ato e di i tasa e to posto sui
filtri.
tutto l’i pia to.
in the element.
IOM_14481 _19021255 Pages - 6 -/55



dell'olio

impurità
IOM_14481 _19021255 Pages - 7 -/55



as expected

IOM_14481 _19021255 Pages - 8 -/55

SCHEDE TECNICHE
COMPONENTI
IOM_14481 _19021255 Pages - 9 -/55
IOM_14481 _19021255 Pages - 10 -/55
IOM_14481 _19021255 Pages - 11 -/55
IOM_14481 _19021255 Pages - 12 -/55
IOM_14481 _19021255 Pages - 13 -/55
IOM_14481 _19021255 Pages - 14 -/55
IOM_14481 _19021255 Pages - 15 -/55
STOP VALVE PKH-DN10-442A
IOM_14481 _19021255 Pages - 16 -/55
IOM_14481 _19021255 Pages - 17 -/55
NEEDLE VALVE FT 2290-14/MFQ
IOM_14481 _19021255 Pages - 18 -/55
IOM_14481 _19021255 Pages - 19 -/55
HYDRAULIC FILTER FHB065.2.B.F.F1.A10.N
IOM_14481 _19021255 Pages - 20 -/55
IOM_14481 _19021255 Pages - 21 -/55
IOM_14481 _19021255 Pages - 22 -/55
IOM_14481 _19021255 Pages - 23 -/55
IOM_14481 _19021255 Pages - 24 -/55
IOM_14481 _19021255 Pages - 25 -/55
IOM_14481 _19021255 Pages - 26 -/55
HYDRAULIC PRESSURE REGULATOR HG031/210/BT
IOM_14481 _19021255 Pages - 27 -/55
IOM_14481 _19021255 Pages - 28 -/55
IOM_14481 _19021255 Pages - 29 -/55
IOM_14481 _19021255 Pages - 30 -/55
CHECK VALVE CAE20/P
IOM_14481 _19021255 Pages - 31 -/55
SHUTTLE VALVE CCI20
IOM_14481 _19021255 Pages - 32 -/55
IOM_14481 _19021255 Pages - 33 -/55
IOM_14481 _19021255 Pages - 34 -/55
3/2NC POPPET TYPE SOLENOID VALVE DLEH–3A–X125DC/BT
IOM_14481 _19021255 Pages - 35 -/55
IOM_14481 _19021255 Pages - 36 -/55
IOM_14481 _19021255 Pages - 37 -/55
IOM_14481 _19021255 Pages - 38 -/55
ELECTRIC PRESSURE SWITH PCS2–GH–40/250
IOM_14481 _19021255 Pages - 39 -/55
IOM_14481 _19021255 Pages - 40 -/55
BIDIRECTIONAL FLOW REGULATOR 49.020.244
IOM_14481 _19021255 Pages - 41 -/55
IOM_14481 _19021255 Pages - 42 -/55
SOL.VALVE WITH INTEGRAL ELECTRONICS DHZO–TEB–SN-NP–071 –L5/F/BT
IOM_14481 _19021255 Pages - 43 -/55
IOM_14481 _19021255 Pages - 44 -/55
IOM_14481 _19021255 Pages - 45 -/55
IOM_14481 _19021255 Pages - 46 -/55
IOM_14481 _19021255 Pages - 47 -/55
IOM_14481 _19021255 Pages - 48 -/55
IOM_14481 _19021255 Pages - 49 -/55
IOM_14481 _19021255 Pages - 50 -/55
PRESSURE GAUGE 233.50 DN63 1/ 4G RADIAL 0/160BARG/PSI SAF. GLASS GLYCERINE
IOM_14481 _19021255 Pages - 51 -/55
IOM_14481 _19021255 Pages - 52 -/55
IOM_14481 _19021255 Pages - 53 -/55
IOM_14481 _19021255 Pages - 54 -/55
IOM_14481 _19021255 Pages - 55 -/55
(REVA DWG. 19.021.255) SEZ:A-A
OIL RETURN LINE 1"SAE3000
B 3/4"NPT
ELECTRIC CABLE ENTRY
M8
N 2 HOLES 41
N 3 HOLES 26
N 1 HOLE 33 286
N 1 HOLE 21 A 3/4"NPT
OIL SUPPLY LINE 1"SAE3000
BOLT-EYES M10 FOR LIFTING
B SEZ:B-B
ECU
22 519A 519B
621A
383
970
379
39A
424B 424A
352A
1718
621B 424C
359 352B 23
351B
748
351A
A A
8
400 B 770
(N 4 HOLE 15)
460
820
528 MASS: 240Kg
1140
413
395
3 REVISED CAD ONLY
850
356
1
428 Rev. Date Drm Chkd Description
Drawing Number
SINGLE ACTING HYDR AULICACTUATOR
FOR REGULATING SERVICE
2112750020
scale date
+OPENING FAIL SAFE ACTION 1:17 04.03.16
585 24 372 526A 526B drm chkd
VALVE ACTUATORS AND CONTROL SYSTEM -OVERAL DIMENSION- NV
HI-BAR MJ18
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208

FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
HI-BAR MJ20
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
MATERIAL

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29

CUSTOMER DIAGRAM SLAHB005/SLAHE002
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
00 15/09/2016 Issued C.M. E.M.

IOM_14481 _19021256 Pages - 1 -/55

Sommario
STOP VALVE PKH-DN10-442A (-40°C) ......................................................................................... - 16 -
HYDRAULIC PRESSURE REGULATOR KG031/210/BT ................................................................... - 27 -
CHECK VALVE CAE20/P................................................................................................................ - 31 -
RELIEF VALVE 49.020.238 ............................................................................................................ - 33 -
SOL.VALVE WITH INTEGRAL ELECTRONICS DKZOR–TEB–SN-NP–171 –L5/F/BT ......................... - 43 -
PRESSURE GAUGE 233.50 DN63 1/4G RADIAL 0/160BARG/PSI SAF. GLASS GLYCERINE ........... - 51 -
IOM_14481 _19021256 Pages - 2 -/55

fluido a provvedere alla lubrificazione dei compone ti dell’i pia to.
all’attuato e.
PREMESSA / PREFACE

chimico fisiche.
he pe esse e ve a e te effi a i devo o o pie si o egola ità. E’ pe ta to estremamente
IOM_14481 _19021256 Pages - 3 -/55

recommended.

MONTHS


IOM_14481 _19021256 Pages - 4 -/55

VALVES
variazioni.
IOM_14481 _19021256 Pages - 5 -/55

PREMESSA / PREFACE
filtri.
tutto l’i pia to.
in the element.
IOM_14481 _19021256 Pages - 6 -/55



dell'olio

impurità
IOM_14481 _19021256 Pages - 7 -/55



as expected

IOM_14481 _19021256 Pages - 8 -/55

SCHEDE TECNICHE
COMPONENTI
IOM_14481 _19021256 Pages - 9 -/55
IOM_14481 _19021256 Pages - 10 -/55
IOM_14481 _19021256 Pages - 11 -/55
IOM_14481 _19021256 Pages - 12 -/55
IOM_14481 _19021256 Pages - 13 -/55
IOM_14481 _19021256 Pages - 14 -/55
IOM_14481 _19021256 Pages - 15 -/55
STOP VALVE PKH-DN10-442A (-40°C)
IOM_14481 _19021256 Pages - 16 -/55
IOM_14481 _19021256 Pages - 17 -/55
IOM_14481 _19021256 Pages - 18 -/55
IOM_14481 _19021256 Pages - 19 -/55
IOM_14481 _19021256 Pages - 20 -/55
IOM_14481 _19021256 Pages - 21 -/55
IOM_14481 _19021256 Pages - 22 -/55
IOM_14481 _19021256 Pages - 23 -/55
IOM_14481 _19021256 Pages - 24 -/55
IOM_14481 _19021256 Pages - 25 -/55
IOM_14481 _19021256 Pages - 26 -/55
HYDRAULIC PRESSURE REGULATOR KG031/210/BT
IOM_14481 _19021256 Pages - 27 -/55
IOM_14481 _19021256 Pages - 28 -/55
IOM_14481 _19021256 Pages - 29 -/55
IOM_14481 _19021256 Pages - 30 -/55
CHECK VALVE CAE20/P
IOM_14481 _19021256 Pages - 31 -/55
SHUTTLE VALVE CCI20
IOM_14481 _19021256 Pages - 32 -/55
RELIEF VALVE 49.020.238
IOM_14481 _19021256 Pages - 33 -/55
IOM_14481 _19021256 Pages - 34 -/55
IOM_14481 _19021256 Pages - 35 -/55
IOM_14481 _19021256 Pages - 36 -/55
IOM_14481 _19021256 Pages - 37 -/55
IOM_14481 _19021256 Pages - 38 -/55
IOM_14481 _19021256 Pages - 39 -/55
IOM_14481 _19021256 Pages - 40 -/55
IOM_14481 _19021256 Pages - 41 -/55
IOM_14481 _19021256 Pages - 42 -/55
SOL.VALVE WITH INTEGRAL ELECTRONICS DKZOR–TEB–SN-NP–171 –L5/F/BT
IOM_14481 _19021256 Pages - 43 -/55
IOM_14481 _19021256 Pages - 44 -/55
IOM_14481 _19021256 Pages - 45 -/55
IOM_14481 _19021256 Pages - 46 -/55
IOM_14481 _19021256 Pages - 47 -/55
IOM_14481 _19021256 Pages - 48 -/55
IOM_14481 _19021256 Pages - 49 -/55
IOM_14481 _19021256 Pages - 50 -/55
PRESSURE GAUGE 233.50 DN63 1/4G RADIAL 0/160BARG/PSI SAF. GLASS GLYCERINE
IOM_14481 _19021256 Pages - 51 -/55
IOM_14481 _19021256 Pages - 52 -/55
IOM_14481 _19021256 Pages - 53 -/55
IOM_14481 _19021256 Pages - 54 -/55
IOM_14481 _19021256 Pages - 55 -/55
OIL RETURN LINE 1 1/4"SAE3000
B 1"NPT
M8
N 2 HOLES 41
N 3 HOLES 26
N 1 HOLE 33 286
N 1 HOLE 21 A 1"NPT
OIL SUPPLY LINE 1 1/4"SAE3000
B SEZ:B-B
ECU
22 519A 519B
621A
383
970
379
39A
424B 424A
352A
1718
621B 424C
359 352B
23
748
351A 351B
A A
8
400 770
(N 4 HOLE 15)
460
820
1140 MASS: 240Kg
528
413
395
3 REVISED CAD ONLY
850
356 1
SINGLE ACTING HYDR AULICACTUATOR Drawing Number
428 2112750030
scale date
+OPENING/CLOSING FAIL SAFE ACTION 1:17 04.03.16
585 24 372 526B 526A drm chkd
HI-BAR MJ18
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208

FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
HI-BAR MJ20
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
MATERIAL

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29

CUSTOMER DIAGRAM SLAHB005
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
00 15/09/2016 Issued C.M. E.M.

IOM_14481 _19021257 Pages - 1 -/55

Sommario
HYDRAULIC PRESSURE REGULATOR KG031/210/BT ................................................................... - 27 -
CHECK VALVE CAE20/P................................................................................................................ - 31 -
RELIEF VALVE 49.020.238 ............................................................................................................ - 33 -
SOL.VALVE WITH INTEGRAL ELECTRONICS DKZOR–TEB–SN-NP–171 –L5/F/BT ......................... - 43 -
PRESSURE GAUGE 233.50 DN63 1/4G RADIAL 0/160BARG/PSI SAF. GLASS GLYCERINE ........... - 51 -
IOM_14481 _19021257 Pages - 2 -/55

all’attuato e.
PREMESSA / PREFACE

chimico fisiche.
IOM_14481 _19021257 Pages - 3 -/55

recommended.

MONTHS


IOM_14481 _19021257 Pages - 4 -/55

VALVES
variazioni.
IOM_14481 _19021257 Pages - 5 -/55

PREMESSA / PREFACE
filtri.
tutto l’i pia to.
in the element.
IOM_14481 _19021257 Pages - 6 -/55



dell'olio

impurità
IOM_14481 _19021257 Pages - 7 -/55



as expected

IOM_14481 _19021257 Pages - 8 -/55

SCHEDE TECNICHE
COMPONENTI
IOM_14481 _19021257 Pages - 9 -/55
IOM_14481 _19021257 Pages - 10 -/55
IOM_14481 _19021257 Pages - 11 -/55
IOM_14481 _19021257 Pages - 12 -/55
IOM_14481 _19021257 Pages - 13 -/55
IOM_14481 _19021257 Pages - 14 -/55
IOM_14481 _19021257 Pages - 15 -/55
IOM_14481 _19021257 Pages - 16 -/55
IOM_14481 _19021257 Pages - 17 -/55
IOM_14481 _19021257 Pages - 18 -/55
IOM_14481 _19021257 Pages - 19 -/55
IOM_14481 _19021257 Pages - 20 -/55
IOM_14481 _19021257 Pages - 21 -/55
IOM_14481 _19021257 Pages - 22 -/55
IOM_14481 _19021257 Pages - 23 -/55
IOM_14481 _19021257 Pages - 24 -/55
IOM_14481 _19021257 Pages - 25 -/55
IOM_14481 _19021257 Pages - 26 -/55
HYDRAULIC PRESSURE REGULATOR KG031/210/BT
IOM_14481 _19021257 Pages - 27 -/55
IOM_14481 _19021257 Pages - 28 -/55
IOM_14481 _19021257 Pages - 29 -/55
IOM_14481 _19021257 Pages - 30 -/55
CHECK VALVE CAE20/P
IOM_14481 _19021257 Pages - 31 -/55
SHUTTLE VALVE CCI20
IOM_14481 _19021257 Pages - 32 -/55
RELIEF VALVE 49.020.238
IOM_14481 _19021257 Pages - 33 -/55
IOM_14481 _19021257 Pages - 34 -/55
IOM_14481 _19021257 Pages - 35 -/55
IOM_14481 _19021257 Pages - 36 -/55
IOM_14481 _19021257 Pages - 37 -/55
IOM_14481 _19021257 Pages - 38 -/55
IOM_14481 _19021257 Pages - 39 -/55
IOM_14481 _19021257 Pages - 40 -/55
IOM_14481 _19021257 Pages - 41 -/55
IOM_14481 _19021257 Pages - 42 -/55
SOL.VALVE WITH INTEGRAL ELECTRONICS DKZOR–TEB–SN-NP–171 –L5/F/BT
IOM_14481 _19021257 Pages - 43 -/55
IOM_14481 _19021257 Pages - 44 -/55
IOM_14481 _19021257 Pages - 45 -/55
IOM_14481 _19021257 Pages - 46 -/55
IOM_14481 _19021257 Pages - 47 -/55
IOM_14481 _19021257 Pages - 48 -/55
IOM_14481 _19021257 Pages - 49 -/55
IOM_14481 _19021257 Pages - 50 -/55
PRESSURE GAUGE 233.50 DN63 1/4G RADIAL 0/160BARG/PSI SAF. GLASS GLYCERINE
IOM_14481 _19021257 Pages - 51 -/55
IOM_14481 _19021257 Pages - 52 -/55
IOM_14481 _19021257 Pages - 53 -/55
IOM_14481 _19021257 Pages - 54 -/55
IOM_14481 _19021257 Pages - 55 -/55
OIL RETURN LINE 1 1/4"SAE3000
B 1"NPT
M8
N 2 HOLES 41
N 3 HOLES 26
N 1 HOLE 33 286
N 1 HOLE 21 A 1"NPT
OIL SUPPLY LINE 1 1/4"SAE3000
B SEZ:B-B
ECU
22 519A 519B
621A
383
970
379
39A
424B 424A
352A
1718
621B 424C
359 352B
23
748
351A 351B
A A
8
400 770
(N 4 HOLE 15)
460
820
1140 MASS: 240Kg
528
413
395
3 REVISED CAD ONLY
850
356 1
Drawing Number
428 SINGLE ACTING HYDR AULICACTUATOR
2112750040
scale date
585 24 372 526B 526A drm chkd
HI-BAR MJ18
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208

FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
HI-BAR MJ20
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
MATERIAL

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29

CUSTOMER DIAGRAM SLAHB005
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
00 15/09/2016 Issued C.M. E.M.

IOM_14481 _19021258 Pages - 1 -/55

Sommario
CHECK VALVE CAE20/P................................................................................................................ - 31 -
IOM_14481 _19021258 Pages - 2 -/55

all’attuato e.
PREMESSA / PREFACE

chimico fisiche.
IOM_14481 _19021258 Pages - 3 -/55

recommended.

MONTHS


IOM_14481 _19021258 Pages - 4 -/55

VALVES
variazioni.
IOM_14481 _19021258 Pages - 5 -/55

PREMESSA / PREFACE
filtri.
tutto l’i pia to.
in the element.
IOM_14481 _19021258 Pages - 6 -/55



dell'olio

impurità
IOM_14481 _19021258 Pages - 7 -/55



as expected

IOM_14481 _19021258 Pages - 8 -/55

SCHEDE TECNICHE
COMPONENTI
IOM_14481 _19021258 Pages - 9 -/55
IOM_14481 _19021258 Pages - 10 -/55
IOM_14481 _19021258 Pages - 11 -/55
IOM_14481 _19021258 Pages - 12 -/55
IOM_14481 _19021258 Pages - 13 -/55
IOM_14481 _19021258 Pages - 14 -/55
IOM_14481 _19021258 Pages - 15 -/55
IOM_14481 _19021258 Pages - 16 -/55
IOM_14481 _19021258 Pages - 17 -/55
IOM_14481 _19021258 Pages - 18 -/55
IOM_14481 _19021258 Pages - 19 -/55
IOM_14481 _19021258 Pages - 20 -/55
IOM_14481 _19021258 Pages - 21 -/55
IOM_14481 _19021258 Pages - 22 -/55
IOM_14481 _19021258 Pages - 23 -/55
IOM_14481 _19021258 Pages - 24 -/55
IOM_14481 _19021258 Pages - 25 -/55
IOM_14481 _19021258 Pages - 26 -/55
IOM_14481 _19021258 Pages - 27 -/55
IOM_14481 _19021258 Pages - 28 -/55
IOM_14481 _19021258 Pages - 29 -/55
IOM_14481 _19021258 Pages - 30 -/55
CHECK VALVE CAE20/P
IOM_14481 _19021258 Pages - 31 -/55
SHUTTLE VALVE CCI20
IOM_14481 _19021258 Pages - 32 -/55
IOM_14481 _19021258 Pages - 33 -/55
IOM_14481 _19021258 Pages - 34 -/55
IOM_14481 _19021258 Pages - 35 -/55
IOM_14481 _19021258 Pages - 36 -/55
IOM_14481 _19021258 Pages - 37 -/55
IOM_14481 _19021258 Pages - 38 -/55
IOM_14481 _19021258 Pages - 39 -/55
IOM_14481 _19021258 Pages - 40 -/55
IOM_14481 _19021258 Pages - 41 -/55
IOM_14481 _19021258 Pages - 42 -/55
IOM_14481 _19021258 Pages - 43 -/55
IOM_14481 _19021258 Pages - 44 -/55
IOM_14481 _19021258 Pages - 45 -/55
IOM_14481 _19021258 Pages - 46 -/55
IOM_14481 _19021258 Pages - 47 -/55
IOM_14481 _19021258 Pages - 48 -/55
IOM_14481 _19021258 Pages - 49 -/55
IOM_14481 _19021258 Pages - 50 -/55
IOM_14481 _19021258 Pages - 51 -/55
IOM_14481 _19021258 Pages - 52 -/55
IOM_14481 _19021258 Pages - 53 -/55
IOM_14481 _19021258 Pages - 54 -/55
IOM_14481 _19021258 Pages - 55 -/55
B 3/4"NPT
M8
N 2 HOLES 41
N 3 HOLES 26
N 1 HOLE 33 286
B SEZ:B-B
ECU
22 519A 519B
621A
383
970
379
39A
424B 424A
352A
1718
621B 424C
359 352B
23
351B
748
351A
A A
8
400 770
(N 4 HOLE 15)
460
820
528 MASS: 240Kg
1140
413
395
3 REVISED CAD ONLY
850
356
1
Drawing Number
2112750050
scale date
+CLOSING FAIL SAFE ACTION 1:17 04.03.16
585 24 372 526A 526B drm chkd
HI-BAR MJ18
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208

FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
HI-BAR MJ20
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
MATERIAL

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29

CUSTOMER DIAGRAM SLAHB005/SLAHE002
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
00 15/09/2016 Issued C.M. E.M.

IOM_14481 _19021259 Pages - 1 -/55

Sommario
CHECK VALVE CAE20/P................................................................................................................ - 31 -
IOM_14481 _19021259 Pages - 2 -/55

all’attuato e.
PREMESSA / PREFACE

chimico fisiche.
IOM_14481 _19021259 Pages - 3 -/55

recommended.

MONTHS


IOM_14481 _19021259 Pages - 4 -/55

VALVES
variazioni.
IOM_14481 _19021259 Pages - 5 -/55

PREMESSA / PREFACE
filtri.
tutto l’i pia to.
in the element.
IOM_14481 _19021259 Pages - 6 -/55



dell'olio

impurità
IOM_14481 _19021259 Pages - 7 -/55



as expected

IOM_14481 _19021259 Pages - 8 -/55

SCHEDE TECNICHE
COMPONENTI
IOM_14481 _19021259 Pages - 9 -/55
IOM_14481 _19021259 Pages - 10 -/55
IOM_14481 _19021259 Pages - 11 -/55
IOM_14481 _19021259 Pages - 12 -/55
IOM_14481 _19021259 Pages - 13 -/55
IOM_14481 _19021259 Pages - 14 -/55
IOM_14481 _19021259 Pages - 15 -/55
IOM_14481 _19021259 Pages - 16 -/55
IOM_14481 _19021259 Pages - 17 -/55
IOM_14481 _19021259 Pages - 18 -/55
IOM_14481 _19021259 Pages - 19 -/55
IOM_14481 _19021259 Pages - 20 -/55
IOM_14481 _19021259 Pages - 21 -/55
IOM_14481 _19021259 Pages - 22 -/55
IOM_14481 _19021259 Pages - 23 -/55
IOM_14481 _19021259 Pages - 24 -/55
IOM_14481 _19021259 Pages - 25 -/55
IOM_14481 _19021259 Pages - 26 -/55
IOM_14481 _19021259 Pages - 27 -/55
IOM_14481 _19021259 Pages - 28 -/55
IOM_14481 _19021259 Pages - 29 -/55
IOM_14481 _19021259 Pages - 30 -/55
CHECK VALVE CAE20/P
IOM_14481 _19021259 Pages - 31 -/55
SHUTTLE VALVE CCI20
IOM_14481 _19021259 Pages - 32 -/55
IOM_14481 _19021259 Pages - 33 -/55
IOM_14481 _19021259 Pages - 34 -/55
IOM_14481 _19021259 Pages - 35 -/55
IOM_14481 _19021259 Pages - 36 -/55
IOM_14481 _19021259 Pages - 37 -/55
IOM_14481 _19021259 Pages - 38 -/55
IOM_14481 _19021259 Pages - 39 -/55
IOM_14481 _19021259 Pages - 40 -/55
IOM_14481 _19021259 Pages - 41 -/55
IOM_14481 _19021259 Pages - 42 -/55
IOM_14481 _19021259 Pages - 43 -/55
IOM_14481 _19021259 Pages - 44 -/55
IOM_14481 _19021259 Pages - 45 -/55
IOM_14481 _19021259 Pages - 46 -/55
IOM_14481 _19021259 Pages - 47 -/55
IOM_14481 _19021259 Pages - 48 -/55
IOM_14481 _19021259 Pages - 49 -/55
IOM_14481 _19021259 Pages - 50 -/55
IOM_14481 _19021259 Pages - 51 -/55
IOM_14481 _19021259 Pages - 52 -/55
IOM_14481 _19021259 Pages - 53 -/55
IOM_14481 _19021259 Pages - 54 -/55
IOM_14481 _19021259 Pages - 55 -/55
B 3/4"NPT
M8
N 2 HOLES 41
N 3 HOLES 26
N 1 HOLE 33 286
B SEZ:B-B
ECU
22 519A 519B
621A
383
970
379
39A
424B 424A
352A
1718
621B 424C
359 352B 23
351B
748
351A
A A
8
400 770
(N 4 HOLE 15)
460
820
528 MASS: 240Kg
1140
413
395
3 REVISED CAD ONLY
850
356
1
SINGLE ACTING HYDR AULICACTUATOR Drawing Number
FOR REGULATING SERVICE 2112750060

scale date
+OPENING/CLOSING FAIL SAFE ACTION 1:17 04.03.16
585 24 372 526A 526B drm chkd
HI-BAR MJ18
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208

FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
HI-BAR MJ20
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
MATERIAL

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29

CUSTOMER DIAGRAM SLAHE002
Cliente/Customer:
BIFFI ITALIA S.R.L.
PROGETTO/PROJECT:
00 15/09/2016 Issued C.M. E.M.

IOM_14481 _19021260 Pages - 1 -/55

Sommario
CHECK VALVE CAE20/P................................................................................................................ - 31 -
IOM_14481 _19021260 Pages - 2 -/55

all’attuato e.
PREMESSA / PREFACE

chimico fisiche.
IOM_14481 _19021260 Pages - 3 -/55

recommended.

MONTHS


IOM_14481 _19021260 Pages - 4 -/55

VALVES
variazioni.
IOM_14481 _19021260 Pages - 5 -/55

PREMESSA / PREFACE
filtri.
tutto l’i pia to.
in the element.
IOM_14481 _19021260 Pages - 6 -/55



dell'olio

impurità
IOM_14481 _19021260 Pages - 7 -/55



as expected

IOM_14481 _19021260 Pages - 8 -/55

SCHEDE TECNICHE
COMPONENTI
IOM_14481 _19021260 Pages - 9 -/55
IOM_14481 _19021260 Pages - 10 -/55
IOM_14481 _19021260 Pages - 11 -/55
IOM_14481 _19021260 Pages - 12 -/55
IOM_14481 _19021260 Pages - 13 -/55
IOM_14481 _19021260 Pages - 14 -/55
IOM_14481 _19021260 Pages - 15 -/55
IOM_14481 _19021260 Pages - 16 -/55
IOM_14481 _19021260 Pages - 17 -/55
IOM_14481 _19021260 Pages - 18 -/55
IOM_14481 _19021260 Pages - 19 -/55
IOM_14481 _19021260 Pages - 20 -/55
IOM_14481 _19021260 Pages - 21 -/55
IOM_14481 _19021260 Pages - 22 -/55
IOM_14481 _19021260 Pages - 23 -/55
IOM_14481 _19021260 Pages - 24 -/55
IOM_14481 _19021260 Pages - 25 -/55
IOM_14481 _19021260 Pages - 26 -/55
IOM_14481 _19021260 Pages - 27 -/55
IOM_14481 _19021260 Pages - 28 -/55
IOM_14481 _19021260 Pages - 29 -/55
IOM_14481 _19021260 Pages - 30 -/55
CHECK VALVE CAE20/P
IOM_14481 _19021260 Pages - 31 -/55
SHUTTLE VALVE CCI20
IOM_14481 _19021260 Pages - 32 -/55
IOM_14481 _19021260 Pages - 33 -/55
IOM_14481 _19021260 Pages - 34 -/55
IOM_14481 _19021260 Pages - 35 -/55
IOM_14481 _19021260 Pages - 36 -/55
IOM_14481 _19021260 Pages - 37 -/55
IOM_14481 _19021260 Pages - 38 -/55
IOM_14481 _19021260 Pages - 39 -/55
IOM_14481 _19021260 Pages - 40 -/55
IOM_14481 _19021260 Pages - 41 -/55
IOM_14481 _19021260 Pages - 42 -/55
IOM_14481 _19021260 Pages - 43 -/55
IOM_14481 _19021260 Pages - 44 -/55
IOM_14481 _19021260 Pages - 45 -/55
IOM_14481 _19021260 Pages - 46 -/55
IOM_14481 _19021260 Pages - 47 -/55
IOM_14481 _19021260 Pages - 48 -/55
IOM_14481 _19021260 Pages - 49 -/55
IOM_14481 _19021260 Pages - 50 -/55
IOM_14481 _19021260 Pages - 51 -/55
IOM_14481 _19021260 Pages - 52 -/55
IOM_14481 _19021260 Pages - 53 -/55
IOM_14481 _19021260 Pages - 54 -/55
IOM_14481 _19021260 Pages - 55 -/55
B 3/4"NPT
M8
N 2 HOLES 41
N 3 HOLES 26
N 1 HOLE 33 286
B SEZ:B-B
ECU
22 519A 519B
621A
383
970
379
39A
424B 424A
352A
1718
621B 424C
359 352B 23
351B
748
351A
A A
8
400 770
(N 4 HOLE 15)
460
820
528 MASS: 240Kg
1140
413
395
3 REVISED CAD ONLY
850
356
1
Drawing Number
2112750070
scale date
585 24 372 526A 526B drm chkd
HI-BAR MJ18
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB1803110M 6 520 22
FSHB1803115M 6 520 47
H

FSHB1803120M
FSHB1803140M
6
6
520
520
88
527
FSHB1803150M 6 520 1208

FSHB1803110M 0.004 100 170 860 20 970
FSHB1803115M 0.006 150 170 860 9 320
FSHB1803120M 0.008 200 170 860 5 245
FSHB1803140M 0.015 380 206 860 1 810
FSHB1803150M 0.020 500 206 860 1 015
MATERIAL
HI-BAR MJ20
PERFORMANCE
ROB
PART RATE PRESSURE
NUMBER
FSHB2003115M 5 520 64
FSHB2003120M 5 520 120
FSHB2003140M 5 520 718 H
FSHB2003150M 5 520 1642
FSHB2003115M 0.006 150 230 1160 12 610
FSHB2003120M 0.008 200 230 1160 7 095
FSHB2003140M 0.015 380 280 1160 2 470
FSHB2003150M 0.020 500 280 1160 1 380
MATERIAL

A2 TECHNICAL DATA
Cables



Shroud
Ordering (Kgs)
Suffix
“E” “E”
20s16 M20 10.0 1/2” 19.9 3/4” 3.2 8.7 24.0 26.4 25.1 20S16 A2 1RA PVC04 0.070
20S M20 10.0 1/2” 19.9 3/4” 6.1 11.7 24.0 26.4 25.1 20S A2 1RA PVC04 0.060
20 M20 10.0 1/2” 19.9 3/4” 6.5 14.0 27.0 29.7 27.2 20 A2 1RA PVC05 0.070
25 M25 10.0 3/4” 20.2 1” 11.1 20.0 36.0 39.6 35.5 25 A2 1RA PVC09 0.130
32 M32 10.0 1” 25.0 1 1/4” 17.0 26.3 41.0 45.1 34.2 32 A2 1RA PVC10 0.150
40 M40 15.0 1 1/4” 25.6 1 1/2” 23.5 32.2 50.0 55.0 35.1 40 A2 1RA PVC13 0.200
50S M50 15.0 1 1/2” 26.1 2” 31.0 38.2 55.0 60.5 32.0 50S A2 1RA PVC15 0.260
50 M50 15.0 2” 26.9 2 1/2” 35.6 44.0 60.0 66.0 36.3 50 A2 1RA PVC18 0.270
63S M63 15.0 2” 26.9 2 1/2” 41.5 49.9 70.5 77.6 33.5 63S A2 1RA PVC21 0.430
63 M63 15.0 2 1/2” 39.9 3” 47.2 55.9 75.0 82.5 35.8 63 A2 1RA PVC23 0.460
75S M75 15.0 2 1/2” 39.9 3” 54.0 61.9 80.0 88.0 34.2 75S A2 1RA PVC24 0.520
75 M75 15.0 3” 41.5 3 1/2” 61.1 67.9 84.0 92.4 40.6 75 A2 1RA PVC26 0.500
90 M90 24.0 3 1/2” 42.8 4” 66.6 79.9 108.0 118.8 58.3 90 A2 1RA PVC31 1.600
100 M100 24.0 4” 44.0 5” 76.0 91.0 123.0 135.3 55.2 100 A2 1RA LSF33 1.780
115 M115 24.0 4” 44.0 5” 86.0 97.9 133.4 146.7 65.2 115 A2 1RA LSF34 2.670
130 M130 24.0 5” 46.8 6” 97.0 114.9 152.4 167.6 73.9 130 A2 1RA LSF35 3.800



of the cable gland.
on request.

CW Group Includes
For sizes 20 and
above
- - T3CDS CXT - C2K
- - - - - C2KW
- - - - C2KX
only
- - C2K, C2KW, C2KX - - -

TMC2 TC
TMC2X -
1 di 3 01/02/2016 16:29
CABLE GLANDS
CABLE CLEATS
2 di 3 01/02/2016 16:29
BIFFI ITALIA srl

Loc. Caselle S. Pietro n. 420, 29017 Fiorenzuola d’Arda (PC) ITALY
Società unipersonale – Direzione e coordinamento di Pentair Valves & Controls Inc.,
Stati Uniti.

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“OLGAS-H-MHP + CONTROL CABINET”

M9899 Technical documentation

Customer PENTAIR VALVES & CONTROLS

Order P.O. 4500292316

Project CERRO PABELLON

Final Customer ENEL GREEN POWER S.P.A.

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1. ACKNOWLEDGEMENT SUMMARY TABLE

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2. INSTRUCTION AND OPERATING MANUAL

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Use and maintenance manual

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UNI EN ISO 12100-1: 2005: Safety of machinery – Basic notions,

UNI EN ISO 12100-2: 2005: Safety of machinery – Basic notions,

2006/42/EC: Machine directive.

97/23/EC: Directive for pressure PED equipment (until 18 July

2006/95/EC: Directive for low voltage equipment (until 19 April

2004/108/EC: Directive for the electromagnetic compatibility

94/9/CE: Directive and safety instructions for use in hazardous

1.1.2 Terms and conditions

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were modified or repaired by unauthorized staff. In the event that a

1.2 IDENTIFICATION PLATE

Figure 1 – Data plate

1.3 INTRODUCING THE ACTUATOR

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above mentioned accessories are operated by the actuator drive

Spring cartridge Valve position indicator

1.4 DATA SHEET

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If the actuator needs storage before installation, follow these steps:

2.3 ACTUATOR ASSEMBLY ON THE VALVE

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Position 2 Position 3 Position 4

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2.3.2 ACTUATOR HANDLING (VALVE STEM WITH VERTICAL

The lifting and handling should be made by qualified staff

The fastening points are appropriate for the lifting of the

1-2 = Lifting points ( obligatory ) 3 = Balancing point

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1 = point of support - 2 = supports for lateral positioning

For the transport of OLGAS-H with hydraulic manual hand-pump, when

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