El Book Manual Repotenciamiento

A company
of ThyssenKrupp
Technologies
ThyssenKrupp Robins
Los Pelambres – Power Upgrade, Bechtel 25100-220-POA-MHCB-0001
TABLE OF CONTENTS
VOLUME 1 MECHANICAL (ENGLISH)
SECTION 1 GENERAL
1. INTRODUCTION
2. CONTROL PHILOSOPHY
SECTION 2 DRAWINGS
1. GENERAL ARRANGEMENT DRAWINGS
2. P&IDS
SECTION 3 VENDOR MANUALS

1. REDUCERS
2. OIL SUPPLY UNITS
3. BRAKES AND LOW SPEED COUPLINGS
VOLUME 2 MECHANICAL (SPANISH)
SECTION 4 MANUAL DE VENDEDOR

1. REDUCTOR
2. SISTEMA APROVISIONAMIENTO DE ACEITE
3. FRENOS Y ACOPLAMIENTO
Note: This manual is being supplied as supplemental documentation to the manuals supplied for the
original contract by Krupp Canada under Bechtel P.O. #23265-M-002-AC. In case of discrepancy
between the English and Spanish Operation and Maintenance Manuals, the English version shall
take precedence.
Page 1 of 2
ThyssenKrupp Robins
A company
of ThyssenKrupp
Technologies
Los Pelambres – Power Upgrade, Bechtel 25100-220-POA-MHCB-0001
TABLE OF CONTENTS
VOLUME 1 ELECTRICAL
SECTION 10 CONTROL DESCRIPTION

SECTION 30 PROTECTION AND CO-ORDINATION STUDY
SECTION 40 MAINTENANCE SCHEDULE
SECTION 50 SPARE PARTS
VOLUME 2 ELECTRICAL
BINARY ELEMENTS, DELAY ELEMENTS, STORING

SECTION D ELEMENTS
SECTION E MISCELLANEOUS
SECTION F PROTECTIVE EQUIPMENT
SECTION J AFD AND H.V ELEC. HOUSE
SECTION K RELAYS, CONTACTORS
VOLUME 3 ELECTRICAL
SECTION M MOTORS
SECTION P MEASURING INSTRUMENTS
SECTION Q HIGH POWER SWITCH-GEAR
SECTION R RESISTORS
SECTION T TRANSFORMERS
SECTION U MODULATORS, CONVERTERS
SECTION X TERMINALS, PLUG CONNECTORS, SOCKET OUTLETS
CONTROL PHILOSOPHY
Revision U2
LOS PELAMBRES UPGRADE PROJECT
CHILE
Submitted by:
Krupp / Siemens / Conveyor Dynamics, Inc.

December 1, 2006
- INDEX -
1 INTRODUCTION
1.1 General System Description

1.2 General Conveyor Description
1.3 General Control System Description
2 SYSTEM ARCHITECTURE
2.1 Control System Architecture

2.2 Control Modes
3 CONTROL FUNCTIONS
3.1 PLC Control
3.1.1 PLC 5 Control Functions

3.1.4 Digital I/O Points
3.1.5 Analog I/O Points
3.1.6 Structured Programming
3.2 AFD Drives control
3.2.1 General Description

3.2.2 AFD/PLC Interface
3.3 Alarm Handling
3.3.1 PLC Alarms
3.3.1.1 Alarms
3.3.1.2 Malfunctions
3.3.1.3 Emergency Malfunctions
3.3.2 AFD Alarms

3.3.3 Alarm Reset
3.3.4 Alarm Bypass
4 OPERATOR CONTROLS
4.1 Mode Selection
4.1.1 Conveyors
4.1.2 Other Equipment
4.2 Control Modes - Conveyors
4.2.1 Remote-Automatic Mode
4.2.1.1 System Commands

4.2.1.2 System Sequences
4.2.1.3 Conveyor Commands
1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 2 of 96

4.2.2 Local-Automatic Mode
4.2.3 Reduced-Speed Mode
4.2.4 Local-Manual Mode
4.2.5 Local-creep Mode
4.2.6 Locked Mode
4.3 Maintenance Workstations (OP37)

4.4 Local Operator Interface Terminals (OP7)
5 SUPERVISORY SYSTEM
5.1 Graphics Screens

5.2 Alarm Diagnostics
5.3 Historical Log
5.4 Real Time Trending
5.5 Historical Trending
5.6 Accumulated Registers
5.7 Advanced Help Feature
6 BELT FEEDERS
6.1 General Considerations

6.2 Feeders Control
6.2.1.1 Feeder Selection

6.2.1.2 Speed Control
6.2.1.3 Weight Scales
6.2.1.4 Tonnage Limitations

6.2.4 Disabled Mode
6.3 Automatic Speed setback

6.4 Conveyor Overload Interlocks
6.5 Tramp Iron Magnets
6.5.1 General Considerations

6.5.2 Magnet Control
6.5.2.1 Remote-Automatic Mode

6.5.2.2 Maintenance Mode
6.5.2.3 Disabled Mode
7 OVERLAND CONVEYORS

7.2 Tonnage Limitations
7.3 Overload Protection
7.4 Zero Torque Prevention
7.5 Hardwired Interlocks
7.5.1 PLC to PLC Interlocks

7.5.2 PLC to AFD Interlocks
7.5.3 Emergency Circuit

7.6 AFD Drives Selection/Deselection
7.7 Pre-Start Control
7.8 Starting Control
7.9 Running Control
7.10 Stopping Controls
7.10.1 AFD Stop (level 2)

7.10.2 Mechanical Brake Controlled Stop (level 3)
7.10.3 Mechanical Brake Emergency Stop (level 4)
7.10.4 Mechanical Brake Pressure Dump Stop (level 5)
7.11 Stopped State Controls
8 AFD DRIVES
8.1 Normal Operation

8.2 Chopper Braking
8.3 Drive Failure
8.4 Selection and De-selection of Drives
8.5 Mechanical Conveyor Configuration
8.6 Soft Start Ramp Generator
8.7 Conveyor Speed Correction
8.8 Closed Loop Speed Controller
8.9 Advanced Load Control
8.10 Advanced Acceleration Control
8.11 Load Sharing Closed Loop Control
8.12 Torque Closed Loop Control
8.13 Differential Speed Filtering
9 MECHANICAL BRAKE

9.1.2 Disc Temperature Monitoring
9.1.3 Maintenance Mode
9.2 General Description

9.3 Hydraulic Power Packs
9.3.1 Pressure Generation

9.3.2 Proportional Pressure Control
9.3.3 Quickset Circuit
9.3.5 Dump Circuit
9.3.6 Quick-Set Modules
9.3.7 Quick-Apply Modules
10 REDUCERS

10.2 Keller Reducers
10.3 Flender Reducers

11 TAKE-UP WINCHES

11.2 Winch Control

11.2.4 Disabled Mode
12 SHUTTLE
12.1 General Interlocks

12.2 Shuttle Control

13 AUXILIARY SYSTEMS
13.1 Dust Suppression Systems
13.1.1 Fogger Systems

13.1.2 Spray Systems
13.2 AFD Houses
13.2.1 Air Conditioning Units

13.2.2 Fire Detection System
13.2.3 Emergency Switches
13.3 Miscellaneous Equipment
14 PLC / NETWORKS
14.1 Redundant CPU

14.2 I/O diagnostics
14.3 Profibus Networks
14.4 H1 Network
14.5 OTN Network
14.6 RS-485 Networks
14.7 PCS Modbus Link
15 APPENDICES
A. General Layout Drawings

B. Control System Architecture
C. PLC Block Diagrams
D. PLC Alarm List
E. AFD Drives Fault list
F. AFD Drives Protection Levels
G. System Sequence Diagrams
H. Typical Graphic Screens
I. Advanced Help Features

J. Soft Start/Stop Ramps
K. Torque Tonnage Tables
L. Belt Tension Calculation
M. PLC-AFD Drives Interlocks Diagram
N. Emergency Circuit
O. AFD Drives Control Loop Diagrams
P. Mechanical Brake Drawings
Q. P&ID Drawings

1 INTRODUCTION
This document describes the control and operation philosophy for the overland conveying
system at the Los Pelambres mine.
The overland conveying system is designed to transport primary crushed copper ore
between two stockpiles over a total distance of 12.6 km, with a total negative elevation of
1296 meters. It is designed for a maximum tonnage of 8700 tph.
The system control is performed by several PLC’s interconnected by a system wide

network. The system is designed to be operated by a single operator from one of three
operator graphic stations located in the concentrator and crusher control rooms.
1.1 General System Description
The system consists of four belt feeders (120-FE-005, 120-FE-006, 120-FE-007

and 120-FE-008) and three large downhill conveyors (120-CV-005, 120-CV-006,
and 120-CV-007).
All the overland conveyors are of the downhill type and operate in regenerative
conditions when their tonnage exceeds 1000-1500 tph.
Conveyor 120-CV-005 is 5,905 meters long with a negative elevation of 536

meters. Conveyor 120-CV-006 is 5,281 meters long with a negative elevation of
526 meters. Conveyor 120-CV-007 is 1,467 meters long with a negative
elevation of 233 meters. Conveyor 120-CV-007 is equipped with a moveable
shuttle head.
All the overland conveyors are powered by variable speed drives (AFD) and are
equipped with mechanical brake systems located at their tail station The head
stations are not equipped with a drive.
All the belt feeders are designed for a maximum tonnage of 2900 tph. Each belt
feeder is powered by a variable speed hydraulic motor and is equipped with a
tramp iron magnet system to protect the conveying system from belt damages.
The head of conveyor CV-120-007 is equipped with a moveable shuttle. The

shuttle motion is controlled by an AFD drive. The shuttle position is continuously
variable under load, but the discharge positions are limited due to interference
with the steelwork.
The shuttle currently travels over a 62 meters span. Six discharge positions are
used to form an elongated stockpile. The shuttle travel will be extended to 94
meters in the future, with additional discharge positions added as required.
Several dust suppression systems are used to control the dust emission. A mist
(water and air mix) suppression type is used at the discharge end of each belt
feeder and at the head of conveyors 120-CV-005 and 120-CV-006. A water
controlled spray system is used at the head of conveyor 120-CV-007.
A general overview of the system, together with the belt profiles and drive
configurations for conveyors 120-CV-005, 120-CV-006 and 120-CV-007, are
provided in appendix A. Additional information about the feeders and overland
conveyors can also be found in the P&ID drawings provided in appendix Q.

1.2 General Conveyor Description
Conveyors 120-CV-005 and 120-CV-006 are equipped with four 2500 kW AFD
drives and one mechanical disk brake system. The brake system consists of a
central power pack, of six low speed disks with two calipers each, of two quick-
set modules located near the primary and secondary pulleys, and of one quick-
apply module located near the tertiary pulley.
Conveyor 120-CV-007 is of a similar design, but is only equipped with two AFD
drives, three low speed disks, and two quick-set modules located near the
primary and secondary pulleys. All three brake disks have two calipers each.
The AFD drives are equipped with braking–choppers, braking resistors, and UPS
to maintain their stopping capabilities in case of line failure or trips of the 23 kV
breaker. The AFD drives are designed to provide 130% of their nominal torque
for up to 30 minutes to accommodate short term motor overload without stopping
the conveyor (35 minutes for conveyor 120-CV-007). The braking-choppers and
braking resistors are designed to provide a maximum of 150% of the AFD drive
nominal torque for 80 seconds.
The AFD drives are used to accelerate and stop the conveyors under normal
conditions. They are also used to stop the conveyors in case of line failure or
trips of the 23 kV breaker.
The primary driving or retarding torque for the conveyors during running
conditions is provided by the electric motors. The conveyors require retarding
torque when loaded over 1000-1500 tph (regenerative conditions). All the energy
produced under these conditions is fed back to the main grid.
The mechanical brake systems include both digital and analog controls. Several
calipers on each system are controlled with simple on/off valves, while the
remaining calipers are controlled from an analog pressure control valve. This
combined design was selected to decrease the response time of the brake while
decreasing the peak tension in the belt in case of UPS power failure.
All the analog brake calipers on all conveyors and all the digital brake calipers on
conveyor 120-CV-007 are of a fail-safe design (spring applied, hydraulically
released). Conveyors 120-CV-005 and 120-CV-006 use a mix of fail-safe and
fail-open digital brake calipers. The brake hydraulic power packs are fitted with
redundant pumps, redundant proportional control valves, several solenoid valves,
and a two-level emergency circuit to be used in case of proportional valve failure.
The mechanical brakes are used as a backup to the AFD drives to bring the
conveyors to a controlled stop in case of AFD, motor, or UPS power failure. They
are also used to park the conveyors at the end of each stopping cycle.
Three of the four reducers on conveyors 120-CV-005 and 120-CV-006 and both
reducers on conveyor 120-CV-007 are splash lubricated. The new reducers
installed on drives 22 of conveyors 120-CV-005 and 120-CV-006 are forced
lubricated and require a dedicated lubrication system. The lubrication system is
controlled by an independent unit under PLC supervision.
The belt tension of each conveyor is controlled by a gravity take-up located at the
head station. All the conveyors are equipped with a take-up winch used to
position the counterweight.

1.3 General Control System Description
The control system consists of three PLC’s, of several remote I/O stations
located along the conveying system route, and of three operator graphic stations
located in the crusher control room #1, the crusher control room #2, and the
concentrator control room.
The PLC’s have redundant CPU‘s. The PLC’s and the operator graphic stations
are interconnected by a redundant fiber optic network (H1/OTN network) used for
monitoring, diagnostics and operator control. .
All conveyor to conveyor interlocks are hardwired between the PLC’s to insure
fail-safe operation under any conditions.
The system can be operated from any of the operator graphic stations. The
operator station in the crusher control room #1 is connected to the mine PCS via
a Modbus link.
Each drive station is equipped with a maintenance workstation, a small operator

interface terminal, and several push button panels for local and manual control of
the equipment.
All the system control and monitoring functions are performed by the PLC’s. The
control and monitoring of the AFD drives are performed by Simadyn D
controllers. Several functions are shared between the PLC’s and the Simadyn D
controllers.
Each PLC is interconnected to the local AFD drives by a local Profibus network.
A second Profibus is used in each substation to connect the maintenance
workstation, the local operator interface, the remote I/O stations, and the shuttle
AFD drive (PLC 7 only) to the PLC. In addition, two RS-485 links are used in
each substation to connect the PLC to the substation monitoring relays.
The PLC’s, the brake instrumentation, and all the critical field instrumentation are
powered by UPS’s to maintain control of the system in case of AC power failure.
A general overview of the control system and of the various networks is provided
in appendix B.

2 SYSTEM ARCHITECTURE
2.1 Control System Architecture
All the equipment control functions are performed by three Siemens S5-155H
programmable logic controllers (PLC) and several remote I/O stations located
along the conveying system route. The PLC’s are located in the substations at
the tail end of each conveyor.
The 155H PLC’s are equipped with redundant CPU’s and are interconnected by
an industrial network (H1 network) used for monitoring, diagnostics and operator
control.
All conveyor to conveyor interlocks are hardwired between the PLC’s to insure
fail-safe operation under any conditions.
The H1 network information is carried between the substations and the operator
control rooms over a redundant fiber optic network (OTN network). The OTN
network is transparent to the PLC’s.
The control and monitoring of the AFD drives and their related equipment are
performed by Simadyn D controllers. One Simadyn D controller is used for each
drive.
Two local Profibus networks are used at each drive station. The first network is
used to interconnect the AFD drives and the PLC. The second network is used to
connect the PLC to its remote I/O modules, the maintenance workstation, and
the local operator interface terminal.
Two local RS-485 links are also used in each substation. The first link is used to
connect the 23 kV monitoring relay to the PLC. The second link is used to
connect the 400V monitoring relay to the PLC. Both links are used for monitoring
purposes only.
Under normal conditions, the system is operated from one of the three operator
graphic stations located in the crusher control rooms #1 and #2 and in the
concentrator control room. All the graphic stations run the same supervisory
software.
The supervisory software was developed with the Siemens WIN-CC graphics
interface software running under Windows NT.
The operator graphic stations communicate with the PLC’s via the H1/OTN
network. All the operator graphic stations have monitoring and control
capabilities. The control functions of each station are protected with multi-level
passwords. In addition, the operator station in the crusher control room #1 is
connected to the mine PCS via a Modbus link.
Each drive station is equipped with a Siemens OP37 maintenance workstation

for local and manual control and status information of all local equipment. A small
Siemens OP7 operator interface is also provided at each drive station for basic
status information. The OP7 are located in the field near the tail drive stations.
Several pushbuttons are also located in the field for local, manual and
maintenance control of the equipment.

A general overview of the control system and of the various networks is provided
in appendix B.
2.2 Control Modes
Several control modes are available for the overland conveyors and each major
component. The equipment control mode is selected from the maintenance
workstation (OP37) and from several local switch panels (see section 4.1).
Access to the various modes from the maintenance workstation is passwords
protected.
The system is normally operated in remote-automatic mode. In this mode, the

complete system is operated from the central operator control room. Only fully
interlocked automatic equipment starts and stops are available in this mode. A
complete description of this mode is provided in section 4.2.1.
The local-automatic mode provides the ability to maintain system operation and
production in case of supervisory system failure. In local-automatic mode, the
complete system is operated from the maintenance workstations located at the
drive stations. Only fully interlocked automatic equipment starts and stops are
available in this mode. A complete description of this mode is provided in section
4.2.2.
The reduced-speed mode is only available for conveyors. It provides the ability
to run each conveyor at medium speed (50%). This mode is provided to allow a
fully loaded conveyor to be emptied when the downstream conveyor is limited in
tonnage by a drive failure. This mode can only be entered if the conveyor is
stopped, but can be selected from both the local-automatic and local-manual
modes. When selected from the local-automatic mode, the conveyor to conveyor
interlocks are kept active. The feeders are disabled whenever any conveyor is
operated in this mode. A complete description of this mode is provided in section
4.2.3.
The local-manual mode provides the ability to run each conveyor and major
component independently for maintenance purpose. In this mode, each conveyor
or major component is operated from push-button panels located in the field. All
internal equipment interlocks are maintained in this mode. However, most
external interlocks are disabled. The feeders are disabled whenever any
conveyor is operated in this mode. A complete description of this mode is
provided in section 4.2.4.
The local-creep mode is only available for conveyors. In this mode, each
conveyor can be operated at low speed (10%) in forward or reverse direction
from push-button panels located in the field. This mode is provided for
maintenance purpose and is otherwise similar to the local-manual mode. This
mode can only be entered if the conveyor is stopped and is only available when
the conveyor is empty. The feeders are disabled whenever any conveyor is
operated in this mode. A complete description of this mode is provided in section
4.2.5.

The maintenance modes provide manual control of various equipment for
maintenance purpose (feeders, brake systems, take-up winches, and shuttle).
When in maintenance mode, the equipment is operated from push buttons
located at the equipment panel. All external and internal interlocks are disabled in
this mode. Maintenance modes can only be entered when the corresponding
conveyor or feeder is stopped, and conveyor or feeder starts are prevented as
long as the mode is active. In addition, the brake maintenance mode can only be
entered when the conveyor is empty. Complete descriptions of the various
maintenance modes are provided within their respective equipment sections.
The locked mode is only available for the conveyors. In this mode, the conveyor
drives are prevented from starting and the brake is prevented from releasing. The
locked mode is selected from the BCS switch at the tail of each conveyor. A
complete description of this mode is provided in section 4.2.6.
The disabled mode is only available for the take-up winches, the shuttle, the
feeders and the feeder’s magnet systems. In this mode, all motors are prevented
from starting. The disabled mode is selected from the equipment mode selector
switch. A complete description of this mode is provided for each equipment in its
respective section.

3 CONTROL FUNCTIONS
Two types of controllers are used in the project:
• PLC SIEMENS Simatic S5-155H

• AFD SIEMENS Simadyn D
All the equipment control and monitoring functions are performed by these controllers.
The control and monitoring of the AFD drives are performed by the Simadyn D
controllers. In addition, the AFD controllers control and monitor all the equipment related
to the drives, including the 23 kV incoming feeders, 3.15 kV breakers, braking-choppers,
drive fans, drive auxiliaries, and motors.
The PLC’s control and monitor all the remaining equipment, including the mechanical
brakes. They also handle the AFD drives sequencing and monitor the AFD drives activity.
The closed loop speed and load sharing control of the AFD drives are shared between
the PLC’s and the Simadyn D controller.
The PLC commands and the AFD drive status and alarms are exchanged via the
Profibus networks.
3.1 PLC Control System
The PLC software has been developed to control, monitor, and report on the
equipment as follows:
A more detailed description of the control logic used for each component is
provided in sections 6 to 12.
3.1.1 Control Functions – PLC 5
PLC 5 is programmed to perform the following tasks:
• Interlock the belt feeders and conveyor 120-CV-005 to avoid plugged

chutes or material overload.
• Interlock conveyor 120-CV-005 and conveyor 120-CV-006 to avoid

plugged chutes or material overload. This interlock uses one of the
hardwired interlock links between PLC 6 and PLC 5.
• Control the belt feeders and magnets according to operator inputs,

cleaning requirements, and detected malfunctions.
• Control the speed of the belt feeders according to operator inputs.

Two modes of automatic operation are available (speed and tonnage
controls).
• Protect the conveying system from material overloads by monitoring

the weight-scales and reducing the belt feeders’ speed or stopping
them as required.

• Protect conveyor 120-CV-005 from overload and excessive belt
tension by monitoring the AFD drives torque and the conveyor
primary pulley load cells, and reducing the belt feeder’s speed or
stopping them as required.
• Control conveyor 120-CV-005 start and stop sequences according to

operator inputs and detected malfunctions.
• Interlock and sequence conveyor 120-CV-005 mechanical brake and

AFD drives during startup to avoid conflict and possible damage to
the equipment.
• Control and monitor conveyor 120-CV-005 mechanical brake and

AFD drives to provide soft belt starting and stopping cycles. All the
starting and stopping logic functions are provided for in the PLC
program according to the results of the dynamic analysis modeling.
• Generate the speed ramps used during mechanical braking of

conveyor 120-CV-005, and control the speed reference to the AFD
drives.
• Generate the reference speed ramps used to verify conveyor 120-

CV-005 AFD drives internal speed ramp generation.
• Control conveyor 120-CV-005 take-up counterweights position.
• Protect conveyor 120-CV-005 from overspeed, underspeed, belt

misalignment, belt rip, and other mechanical and electrical damages,
as applicable, by monitoring the brake, AFD drives, reducers, take-
up, and beltline inputs and stopping the equipment when required.
• Supervise and monitor conveyor 120-CV-005 reducer lubrication

systems (drive 32 only).
• Minimize the risk of drive pulley slip on conveyor 120-CV-005 by

monitoring the speed of all drive and brake pulleys and stopping the
feeders when slip is detected.
• Monitor conveyor 120-CV-005 auxiliary equipment for ready-to-start

conditions and malfunctions.
• Control conveyor 120-CV-005 horns as required to provide warning

of impeding equipment starts.
• Monitor and control the dust suppression system at conveyor 120-

CV-005 loading station.
• Monitor and control the PLC 5 substation air conditioning units.
• Monitor the PLC 5 H1, OTN, and Profibus networks for normal
operating conditions.
• Monitor the PLC 5 modules, 110 VDC power supply, and UPS for
normal operating conditions.

• Interlock conveyor 120-CV-006 and conveyor 120-CV-007 to avoid

plugged chutes or material overload. This interlock uses one of the
hardwired interlock links between PLC 7 and PLC 6.


stopping conveyor 120-CV-005 as required.

the equipment.


drives.

• Control conveyor 120-CV-006 take-up counterweights position.

• Supervise and monitor conveyor 120-CV-006 reducer lubrication

systems (drive 32 only).



• Monitor and control the dust suppression system at the transfer

station between conveyors 120-CV-005 and 120-CV-006.

• Control the shuttle positioning according to operator inputs and

detected malfunctions. Two modes of automatic operation are
available (fixed position and automatic motion between selected
positions)


stopping conveyor 120-CV-006 as required.

the equipment.


drives.






• Monitor and control the dust suppression system at the transfer
station between conveyors 120-CV-006 and 120-CV-007.
• Monitor and control the dust suppression system at the shuttle

discharge station.
3.1.4 Digital I/O Points
All the digital inputs are filtered through timers to minimize noise and
switch bouncing problems.
Upon detection of a fault, all necessary action(s) are taken according to

the equipment specifications and the malfunction information is reported
to the operator graphic stations.
3.1.5 Analog I/O Points
All the analog inputs are filtered through a first order digital filter to
minimize noise problems.
All the analog inputs are scaled to engineering units to simplify operator
monitoring of the process.
The validity of the analog signals is constantly evaluated. All analog

inputs are checked for out of range condition (4-20 mA). In addition,
redundant analog inputs are checked against each other. When a
significant difference is observed, the input with the lowest reading is
flagged as invalid (i.e. weight scales).
Readings from tachometers located on different pulleys are also

compared. A special algorithm is used to differentiate between slip and
invalid inputs.
If an analog signal is found invalid, the faulty input is disabled and the
fault reported to the operator graphic stations. Disabled inputs are
ignored by the control logic and alternate options are used if available.
Upon detection of a fault, all necessary action(s) are taken according to

the equipment criteria list and the malfunction information is reported to
the operator graphic stations.
All the analog set points and timing values used in the software are
independently adjustable by changing the constants stored in the PLC’s.

3.1.6 Structured Programming
All the control logic has been developed using structured programming
techniques.
The program structure is developed along equipment lines, with the

control task divided into several levels of control. Three hierarchical logic
levels are used, starting at the conveyor level and extending down to
single components like pumps and motors.
Each control task is composed of independent logic blocks. Each block is

responsible for the interlock, sequencing, and monitoring of the elements
at the next lower level.
The structure developed for the project is shown in the PLC block
diagrams provided in appendix C.
3.2 AFD Drives Control
3.2.1 General Description
The Simadyn D controllers software has been developed to control,

monitor, and report on the equipment as follows:
• Monitor the 23 kV incoming feeders
• Monitor the 23 kV / 3.15 kV transformer
• Monitor and control the 3.15 kV breakers
• Monitor and control the drive inverter stages
• Monitor and control the braking-chopper and associated resistors
• Monitor and control the main drive motor
• Generate the speed ramps used during the drive acceleration and
deceleration
• Control the motor torque to accelerate and decelerate the drive in a

smooth manner according to several setpoints received from the
PLC via the Profibus network
• Monitor the motor temperature sensors
• Monitor and control the drive fans
• Monitor the motor vibration sensors
• Report its operating and fault status to the PLC via the Profibus
network
A more detailed description of the control logic used for the AFD drives is
provided in section 8.

3.2.2 AFD/PLC Interface
The PLC’s are programmed to perform the following tasks:
• Sequence the AFD drive start/stop sequences via the Profibus

network according to operator inputs and detected fault conditions
• Provide each AFD drive with a speed setpoint via the Profibus
network according to the conveyor operating mode and state
• Monitor the AFD drives internal speed ramp generation using

internally generated reference speed ramps
• Provide the AFD drive with several loop modifier setpoints via the
Profibus network to control the drive load sharing and close the
integral portion of the drive speed loop
• Monitor the AFD drive status for normal operating conditions
• Monitor the AFD drive performance for normal operating conditions
• Stop the AFD drives as required via the AFD/PLC hardwired

interlocks in case of drive Profibus network fault
A more detailed description of the control logic used for the interface with
the AFD drives is provided in sections 7 and 8.
3.3 Alarm Handling
Both the PLC’s and the AFD drives perform equipment monitoring and alarm
handling functions.
The AFD drives monitor the drives and all the drive related equipment, including
the 23 kV incoming feeders, 3.15 kV breakers, braking-choppers, drive fans,
drive auxiliaries, and motors.
The PLC’s monitor all the remaining equipment, monitor the AFD drives for
reported faults, and check the overall AFD drive activity.
The AFD drives status and alarms are reported to the PLC’s via the Profibus
networks.
The health of the Profibus networks is constantly monitored by the PLC’s, but not
by the AFD drives which cannot detect a Profibus failure. Consequently, several
hard-wired interlocks are used between the PLC’s and the AFD drives to enable
safe shutdown of the conveyors in case of drive Profibus network failure.
3.3.1 PLC Alarms
In all modes of operation, the PLC’s constantly monitor all the equipment
for alarm conditions. The alarms are classified into several levels
depending on their severity. Three categories and eight levels of alarms
are used on this project.

Every critical alarm and every malfunction (trip conditions) is latched at
the time it is detected. All alarm flags remain latched until an operator
reset is performed
Only latched flags are used to initiate conveyor shutdowns
The following categories of alarms are used:
• Alarms
• Malfunctions
• Emergency malfunctions
Alarms are for indication only. Malfunctions require a conveyor

shutdown. Emergency malfunctions require a shutdown of the conveyor
using the mechanical brake.
A typical list of alarms defined for the PLC’s, together with their level, is
provided in appendix D.
3.3.1.1 Alarms
A1 Alarm level 1
This is the lowest level of alarm. The PLC does not take
any action.
The following are typical examples of level 1 alarms:
• Belt alignment alarm

• Brake tank level LO
A2 Alarm level 2
This alarm level indicates a disabling fault on a non-

critical component. The PLC stops the faulty component
but does not stop the conveyor.
This level is also used for faulty analog inputs. In this

case, the PLC disables the faulty input. Disabled inputs
are ignored by the control logic and alternate options are
used if available.
The following are typical examples of level 2 alarms:
• Belt speed invalid

• Brake pump filter plugged
• Brake pump discharge pressure LO
This level is also used for non-critical faults that result in

diminished system capacity such as:
• 120-CV-005 Belt tension HI (triggers feeder speed

setback)
• Single weight scale fault (limits number of feeders)

3.3.1.2 Malfunctions
SP Start Permissive
This alarm level indicates a problem with components

required during startup. The PLC does not shutdown a
running conveyor but would prevent a conveyor start.
The following are typical examples of start permissive

malfunctions:
• Brake disk temperature HI

• Active AFD drive fault
• Horn/Beacon breaker fault
M1 Malfunction level 1
This is the first level of malfunction. It indicates a

problem that requires emptying the conveyor. The PLC
immediately stops the upstream conveyors.
The following are typical examples of level 1

malfunctions:
• Total drive torque HIHI - regenerative

• Belt tension HIHI
This is the second level of malfunction. It indicates a

critical problem with the conveyor. The PLC initiates an
immediate shutdown of the conveyor using the AFD
drives.

malfunctions:
• General Pull cord / Belt alignment fault

• Line failure
• Reducer bearing temperature HIHI
Note that such a shutdown maintains the conveyor

stopping time and the time tolerance between
conveyors.
3.3.1.3 Emergency Malfunctions
This is the first level of emergency malfunction. It usually

indicates a problem with the AFD drives (multiple drive
or motor fault). The PLC initiates an immediate

shutdown of the conveyor using the mechanical brake
under proportional control (controlled speed ramp).

malfunctions:
• Multiple drives fault

• Overspeed (105-107% field adjustable)
• Multiple AFD cooling units fault
Note that such a shutdown also maintains the conveyor

stopping time and the time tolerance between
conveyors.
This is the second level of emergency malfunction. It

usually indicates a problem with the mechanical brake
proportional control components. The PLC initiates an
immediate shutdown of the conveyor using the
mechanical brake emergency circuit.
This level is also used automatically in case of PLC

power failure or when the emergency circuit is tripped
(see chapter 7.4). The emergency circuit is independent
of the PLC and is hardwired into the brake system and
the AFD drive.

malfunctions:
• HI overspeed from tachometers (120%)

• Proportional brake apply check fault
A level 4 shutdown does not maintain the conveyor

stopping time or the time tolerance between conveyors.
This is the last level of emergency malfunction. It can

only be set during a level 4 stop and indicates that the
conveyor is out of control and requires maximum brake
torque. The PLC initiates an immediate shutdown of the
conveyor using the mechanical brake pressure dump
circuit.
The following are the only level 5 malfunctions defined

for the system:
• Emergency brake pressure HIHI

• Stopped brake pressure HIHI
• Confirmed HIHI overspeed
• Sustained HI overspeed
• Maintenance mode motion detected fault

A level 5 shutdown does not maintain the conveyor
stopping time or the time tolerance between conveyors.
3.3.2 AFD Alarms
In all modes of operation, the AFD drives constantly monitor all drive-
related equipment for alarm conditions. The alarms are classified into
several levels depending on their severity.

the time it is detected. All fault flags remain latched until an operator
reset is performed.
All detected alarms are coded and sent to the PLC via the Profibus
networks.
The alarms are classified into three levels depending on their severity.
The following levels of alarms are used:
A1 Alarms
M2 Trips
M3 Emergency Trips
A typical list of alarms defined for the AFD drives, together with their
level and locations, is provided in appendix E. A table showing the
protection levels for the AFD drives is provided in appendix F.
3.3.3 Alarm Reset

the time it is detected in both the PLC and the AFD drives.
All alarm flags remain latched until an operator reset is performed.
Most PLC alarms can be remotely reset from the operator graphic
stations. However, selected alarms cannot be remotely cleared and
require a local reset from the field or from one of the maintenance
workstations located at the drive stations.
The following alarms and malfunctions have to be reset from one of the
maintenance workstations:
• Belt rip
• Belt alignment
• Blocked chute
• Most brake faults
• Most drive faults
The following alarms and malfunctions have to be reset from field-

mounted push buttons or from their respective equipment panel:
• Feeder magnet field failure

• Belt splice failure
• Belt rip (loop system)

All remote and local operator resets are logged by the supervisory
system.
A typical alarm list is provided in appendix D. This list indicates the

alarms that can be remotely reset and the alarms that require a local
reset.
3.3.4 Alarm Bypass
The belt alignment sensors can be temporarily bypassed from field

mounted switches. The position of all the bypass switches is shown on
the operator control screens and logged by the supervisory system.
No other alarm can be bypassed.

4 OPERATOR CONTROLS
The system is normally operated from one of the three operator graphic stations located
in the crusher control rooms #1 and #2 and in the concentrator control room. All the
operator graphic stations have monitoring and control capabilities. The control functions
of each station are protected with multi-level passwords.
The supervisory system allows remote automated control of all the conveyors and
feeders, and provides visual indication of all equipment status and alarm condition.
Furthermore, advanced help and diagnostic information is available through the use of a
separate interactive help file system working in conjunction with the supervisory system
(advanced help feature).
The supervisory system was developed using the Siemens WIN-CC graphics interface
software. The advanced help features were developed in a separate software package
and linked to WIN-CC through custom written DLL files (Window executable file).
All the equipment control functions are performed by the PLC’s. The operator graphic
stations are only used to input the operator commands, to report on the system status
and alarms, and to generate the system start and stop sequences.
Each drive station is equipped with a Siemens OP37 maintenance workstation and a
small Siemens OP7 operator interface for local control and status information. Several
push button panels are located in the field for local and manual control of the equipment.
Several control modes are available depending upon the equipment. The mode selection
for all equipment and the modes of operation for the conveyors are described in the
following paragraphs. The modes of operation for all other equipment are described in
their respective sections.
4.1 Mode Selection
The control mode is selected from the maintenance workstation (OP37) and from
several local control switches. Access to the various modes from the
maintenance workstation is passwords protected.
The status of the mode selection switches and the current operating mode for all
equipment is indicated on the operator graphic stations and the maintenance
workstations (OP37).
4.1.1 Conveyors
Each overland conveyor is equipped with two local control panels located
at the head and the tail of the conveyor, and with one lockable three-
position Belt Control Switch (BCS).
The BCS is also mounted at the tail of the conveyor and has the
following positions:
• I - Interlocked
• NI - Not Interlocked
• O - Locked out
The tail control panel is fitted with a three-position creep selector switch
(normal/tail-creep/head-creep) and a two-position direction selector

switch (forward/reverse). The head control panel is only fitted with a two-
position direction selector switch (forward/reverse).
In addition, the brake systems and take-up winches are equipped with a
three-position mode selector switch (MSS) with the following positions:
• R - Remote
• L - Local
• O - Off
All the control switches described above are used for software mode
selection only and are not hardwired to the equipment. The mode of
operation for each component is selected by the PLC according the
following combinations:
Overland Conveyors:
CREEP TAIL HEAD

CONTROL MODE BCS OP37 CONVEYOR
SELECT FWD/REV FWD/REV
REMOTE-AUTO I REMOTE - - - -
LOCAL-AUTO I LOCAL - - - -
REDUCED-SPEED I REDUCED - - - STOPPED
LOCAL-MANUAL NI - NORMAL - - -
LOCAL-CREEP FWD NI - CREEP-TAIL FWD - STOPPED-EMPTY
LOCAL-CREEP REV NI - CREEP-TAIL REV - STOPPED-EMPTY
LOCAL-CREEP FWD NI - CREEP-HEAD - FWD STOPPED-EMPTY
LOCAL-CREEP REV NI - CREEP-HEAD - REV STOPPED-EMPTY
LOCKED OFF - - - - STOPPED
In addition, the remote-automatic mode is automatically entered upon

detection by the PLC of a communication failure with the maintenance
workstations (OP37) while in local-automatic mode.
Brake Systems:
CONTROL MODE BCS OP37 MSS CONVEYOR

REMOTE-AUTO I - - -
REMOTE-AUTO NI - REMOTE -
MAINTENANCE NI - LOCAL STOPPED-EMPTY
LOCKED OFF - - STOPPED
Take-up Winches (C5 and C6 only):

REMOTE-AUTO - - REMOTE -
LOCAL-MANUAL - - LOCAL -
MAINTENANCE - - LOCAL STOPPED
DISABLED - - OFF -

4.1.2 Other Equipment
All the belt feeders, all the feeders’ magnet systems, and the shuttle are
equipped with a three or four position mode selector switch (MSS) with
the following positions:
• R - Remote
• L - Local
• O - Off
The mode of operation for each component is selected by the PLC

according the following combinations:
Shuttle:
CONTROL MODE OP37 MSS CONVEYOR

REMOTE-AUTO REMOTE REMOTE -
LOCAL-AUTO LOCAL REMOTE -
LOCAL-MANUAL - LOCAL -
MAINTENANCE - LOCAL STOPPED
DISABLED - OFF -
Belt Feeders:
CONTROL MODE OP37 MSS

REMOTE-AUTO REMOTE REMOTE
LOCAL –AUTO LOCAL REMOTE
LOCAL-MANUAL - LOCAL (2 POS)
DISABLED - OFF
Feeder Magnets:
CONTROL MODE OP37 MSS FEEDER

REMOTE-AUTO - REMOTE -
LOCAL-
MAINTENANCE - LOCAL
MANUAL/DISABLED
DISABLED - OFF -
Dust Suppression Systems:
The dust suppression systems are also equipped with a local mode
selector switch. However, this switch is hardwired and independent of
the PLC. Consequently, no local or manual modes of operation are
defined in the PLC for the dust suppression systems, and the local
selector switch is used for monitoring only.
4.2 Control Modes - Conveyors
The following 6 modes have been defined for the conveyors:
• Remote-automatic mode
• Local-automatic mode
• Reduced-speed mode

• Local-manual mode
• Local-creep mode
• Locked mode
In addition, various maintenance modes are available when the conveyor is

stopped and in the local-manual mode. These modes are described in their
respective equipment section.
The position of the various mode selection switches is constantly monitored by

the PLC. The selection of any of the modes is only enabled when safe to
perform. The active modes and the position of all the mode selector switches are
shown on the operator control screens and logged by the supervisory system.
Mode changes between the remote-automatic mode and the local-automatic

mode can be done at any time.
The local-manual mode can only be entered when the conveyor is stopped.
However, this mode can be exited with the conveyor running.
Mode changes to and from the reduced-speed mode, the local-creep mode, the
various maintenance modes, and the locked mode are only accepted when the
conveyor is stopped. Furthermore, the local-creep mode and the brake
maintenance mode can only be entered after an empty-stop sequence has been
completed, or after an empty conveyor override command has been received
from the operator. The conveyor cannot be started in the locked mode or in any
of the maintenance modes.
In addition, in order to avoid being locked into the local-automatic mode, the
remote-automatic mode is automatically entered upon detection by the PLC of a
communication failure with the maintenance workstations (OP37) while in local-
automatic mode.
The remote-automatic mode is the normal mode of operation of the

system. In this mode, a single operator controls all the conveyors and
auxiliary equipment from one of the operator graphic stations.
Only fully interlocked automatic equipment starts and stops are available
to the operator.
Full equipment status and alarm information is available to the operator

on the operator graphic stations.
This mode requires the OTN/H1 networks to be operational.
Full status and alarm information is also available on the OP37

maintenance workstations. Basic status and group alarm information is
available on the OP7 operator interface terminals located at each drive
station.

4.2.1.1 System Commands
The following operator controls are available for the conveying

system in remote-automatic mode:
• System pre-start
• System start
• System empty-stop
• System sequence-stop
• System immediate stop
• Alarms/malfunction reset
Visual feedback of all system start/stop sequences and operator

commands is provided on the operator graphic stations.
A reset command clears selected latched alarms/malfunctions

flags in the PLC’s. A reset has to be performed by the operator
prior to any start-up whenever a malfunction is latched in a PLC.
Some alarms cannot be remotely cleared and require a local

reset from the corresponding maintenance workstation or from
field-mounted push buttons or equipment panels.
All system sequences are generated from the supervisory

system. The system sequences corresponding to the above
commands are described in the next paragraph.
4.2.1.2 System Sequences
This section provides a basic description of the system start and

stop sequences defined for the system. Basic timing diagrams
for the various sequences are provided in appendix G.
• System Pre-Start
A system pre-start command initiates the pressurization of

the brake system accumulator, initiates the pre-excitation of
the AFD drive converters, and starts the AFD drive air
conditioning units on all the conveyors in the route.
When a pre-start command is issued by the operator, all the

conveyor horns are turned on for 10 seconds and all open
3.15 kV breakers are closed by the AFD drives.
• System Start
When a system start command is issued by the operator; a

pre-start command is sent to all the conveyors in the route.
As soon as conveyor 120-CV-007 is ready, the start

sequence is initiated for conveyor 120-CV-007.
The remaining conveyors are then started in sequence,

provided that they are ready, as soon as the next
downstream conveyor has reached 20% speed.

The warning horns on each conveyor are turned on at the
beginning of the conveyor own start sequence. The horns
are turned off when conveyor motion is detected.
Visual feedback is provided to the operator when a system

start sequence is in progress.
• System Empty Stop
When a system empty-stop command is received from the

operator, the belt feeders are immediately stopped and a
system-empty timing sequence is activated. All the
conveyors in the route are then stopped in sequence as
soon as they are empty.
The system-empty timing sequence is also started

automatically whenever the feeders are stopped.
Consequently, an empty-stop command results in a normal
sequence-stop if the system is already empty.
All the conveyors are stopped with their AFD drives.
A system empty-stop is required before the local-creep and

brake maintenance modes can be entered.
Visual feedback is provided to the operator when an empty-

stop sequence is in progress, and after it has been
completed. All the PLC’s are also flagged when the system
is empty.
• System Sequence-Stop
When a system sequence-stop command is received from

the operator, the belt feeders are stopped and a stop
command is sent to conveyor 120-CV-005.
The remaining conveyors in the route are then stopped in

sequence. Each conveyor is stopped as soon as the next
upstream conveyor has slowed down to 80% speed. All the
conveyors are stopped with their AFD drives.
Visual feedback is provided to the operator when a

sequence-stop sequence is in progress.
• System Immediate-Stop
When an immediate-stop command is received from the

operator, the belt feeders and all the conveyors are
immediately stopped.
All the conveyors are stopped with their AFD drives.

4.2.1.3 Conveyor Commands
The following operator controls are available for individual

conveyors:
• Conveyor pre-start
• Conveyor start
• Conveyor stop
• AFD drive disable
• AFD drive enable
Visual feedback of all conveyor start/stop sequences and

operator commands is provided on the operator graphic stations.
A conveyor pre-start command initiates the pressurization of the

brake system accumulator, initiates the pre-excitation of the AFD
drive converters, and starts the AFD drive air conditioning units
on the selected conveyor. In addition, the conveyor horns are
turned on for 10 seconds and all open 3.15 kV breakers are
closed by the AFD drives.
A conveyor start command starts the selected conveyor. This

command is only accepted if the conveyor is ready to start, and if
the downstream conveyor is running (if applicable).
A conveyor stop command immediately stops the selected

conveyor and all its upstream conveyors using the AFD drives.
An AFD drive disable command disables the corresponding

drive. An AFD drive enable command enables the corresponding
drive. All AFD drive enable and disable commands are password
protected.
The AFD drive enable/disable function is provided for

maintenance purpose only and is limited to one disabled drive
per conveyor at any time. In addition, in order to limit potential
damages to the drive reducer, a conveyor can only be operated
with a disabled AFD drive for a maximum of 30 minutes.
It is possible to disable an AFD drive on a running conveyor

provided that the load on the conveyor would not result in
overloading of the remaining drives. It is also possible to enable
a disabled AFD drive on a running conveyor.
An AFD drive can also be permanently disabled. However, this

command is not available from the operator graphic stations and
has to be entered from the local maintenance workstations
(OP37).
A description of the conveyor start and stop sequences is

provided in section 7.
The local-automatic mode provides complete control of the conveying

system from the maintenance workstations located in the drive stations.

This mode should be used to maintain system operation and production
in case of supervisory system failure and to help during commissioning
of the system.
Only fully interlocked automatic equipment starts and stops are available
in this mode. Conveyors to conveyor interlocks are maintained in this
mode through hardwired PLC to PLC interlocks (see section 7.4).
Full status and alarm information is available on the OP37 maintenance

workstations. Basic status and group alarm information is available on
the OP7 operator interface terminals located at each drive station.
Centralized status and alarm information is also available on the operator

graphic stations if the H1/OTN networks and the supervisory systems are
operational.
This mode offers the same control options as the remote-automatic

mode.
4.2.3 Reduced-Speed Mode
The reduced-speed mode provides the ability to run each conveyor at

medium speed (50%) from the maintenance workstations located in the
drive stations.
This mode is provided to allow a fully loaded conveyor to be emptied

when the downstream conveyor is limited in tonnage by a drive failure. It
can only be entered or exited if the conveyor is stopped.
This mode can be entered from both the local-automatic and local-
manual modes. When selected from the local-automatic mode, the
conveyor to conveyor interlocks are kept active.
When a conveyor is operating in this mode, the belt feeders are

automatically disabled and all upstream conveyors can only be started in
reduced-speed or local-manual mode.
If this mode is entered from the local-automatic mode, only fully

interlocked conveyor starts and stops are available and, as in all
interlocked modes, conveyors to conveyor interlocks are maintained
through hardwired PLC to PLC interlocks (see section 7.4).
This mode is otherwise similar to the local-automatic mode, but with a

reduced set of operator controls. Only the following operator controls are
available:
• Conveyor pre-start
• Conveyor start
• Conveyor stop
A conveyor start command starts the conveyor at a preset creep speed

(50%). This command is only accepted if the conveyor is ready to start,
and if the downstream conveyor is running (at full or reduced speed).
All other available commands work as in the local-automatic mode.

at the head and the tail of the conveyor. The local-manual mode provides
control of each conveyor from the local control panel located at its tail
drive station.
This mode provides the ability to run each conveyor independently and
should be used for maintenance purposes and to help during
commissioning of the conveyors.
All internal conveyor interlocks are maintained in this mode. However, all
conveyors to conveyor interlocks are disabled.
This mode can only be selected when the conveyor is stopped. However,
it can be exited at any time.
When a conveyor is operating in this mode, the belt feeders are

automatically disabled and all upstream conveyors can only be started in
local-manual mode.
Full status and alarm information is available on the OP37 maintenance

workstations. Basic status and group alarm information is available on
the OP7 operator interface terminals located at each drive station.
Centralized status and alarm information is also available on the operator

graphic stations if the H1/OTN networks and the supervisory systems are
operational.
In addition to the mode select switches, the following local switches are
available on the tail control panel.
• Sound horns
• Start conveyor
• Stop Conveyor
Pushing the Horn button turns on the conveyor horns for 10 seconds and
initiates a conveyor pre-start sequence.
Pushing the start button when the conveyor is ready initiates a start
sequence. If the conveyor is not ready, a conveyor pre-start sequence is
initiated.
Pushing the stop switch immediately stops the conveyor with the AFD
drives.
Note that in the local-manual mode the conveyor can only be started
from the tail panel, but can be stopped from both the head and the tail
panels. This is true in all modes of operation.
If any alarm or malfunction is latched in the local PLC, a reset has to be

performed by the operator prior to a conveyor start. Most alarms can be
reset from the maintenance workstation. However, some have to be
reset from field-mounted push buttons or equipment panels.

4.2.5 Local-Creep Mode
The local-creep mode provides the ability to run each conveyor at low
speed in forward or reverse direction for maintenance purpose.
at the head and the tail of the conveyor. The tail control panel is fitted
with a three-position creep selector switch with the following positions:
• Normal speed
• Creep - Tail
• Creep - Head
The creep-select switch is used to enable the local-creep mode and to

select which local control panel is enabled. Each local panel is also fitted
with a light. This light is turned on when the local-creep mode is active
and the panel is selected.
For obvious reasons, a conveyor should never be run in the negative

direction when loaded. In addition, due to thermal limitation of the
motors, a conveyor should never be operated at low speed under load
for extended periods of time. Consequently, the local-creep mode can
only be selected after an empty-stop sequence has been completed and
flagged in the PLC. For emergency cases, this interlock can be
overridden from the maintenance workstation.
The local-creep mode can only be entered from the local-manual mode,
and can only be entered or exited when the conveyor is stopped.
This mode is otherwise similar to the local-manual mode and offers the
same control options with the addition of the following controls:
• Select forward motion

• Select reverse motion
Pushing the start button when the conveyor is ready starts the conveyor
in the selected direction at a preset creep speed (10%).
All the other controls work as in the local-manual mode.
4.2.6 Locked Mode
The locked mode provides the ability to immobilize each conveyor. This
mode is selected from the BCS switch located at the conveyor tail
stations.
The BCS switch is lockable with a pad lock.
Switching the BCS switch to the locked position with the conveyor
running results in an immediate shutdown of the conveyor using the AFD
drives.
In the locked mode, the AFD drives and the conveyor are prevented from
starting, and the brake is blocked against releasing.

4.3 Maintenance Workstations (OP37)
Each drive station is equipped with a Siemens OP37 maintenance workstation

for local and manual control of the equipment.
The maintenance workstations provide the same information available on the

operator graphic stations, but limited to the equipment local to the drive station.
It also provides more detailed diagnostic information on the AFD drives, PLC
equipment, and PLC networks.
In addition, the maintenance workstation is used to enable the local-automatic

and reduced-speed modes, to control the system in local-automatic and reduced-
speed modes, to reset the AFD drive malfunctions, to reset selected alarms and
malfunctions, to permanently disable AFD drives, and to enable the local-creep
and brake maintenance modes when the system empty flag has not been set.
All local operator resets are logged by the supervisory system. The typical alarm
list provided in appendix D indicates the alarms that require a local reset from a
maintenance workstation.
4.4 Local Operator Interface Terminals (OP7)
Each conveyor drive station is equipped with a Siemens OP7 operator interface
terminal. This terminal provides basic status and group alarm information for
local indication at each drive station. The following information is shown:
• Group malfunctions (brake fault, AFD drive fault, shuttle fault, etc.)
• Basic brake and AFD drive status (applied/released, ready/fault, etc.)
• Basic analog data (drive kW, conveyor speed, belt tension, etc.)
• Selected individual alarms (belt rip, pull cord, blocked chute, etc.)
The OP7 operator interface terminals are used for monitoring only and are not
programmed with any reset or control capabilities.
The typical alarm list provided in appendix D indicates which alarms or groups of
alarms are shown on the OP7 terminals.

5 SUPERVISORY SYSTEM
5.1 Graphics Screens
Full indication of system status and alarms for each conveyor, each feeder and
the shuttle is available on the overview graphics screen. All the operator
commands required to operate the system in remote-automatic mode are also
accessible from the overview screen.
Full indication of status and alarms for each individual component is available on
subsequent graphics screens. Furthermore, the graphics screens provide visual
indication of the physical state of all critical I/O points.
The cause of any conveyor trip is available to the operator in a maximum of 4

keystrokes.
The following screens have been defined:
• System overview
• Conveyor overviews (1 per conveyor)
• Conveyor AFD drives overviews
• Conveyor AFD drives (1 per drive)
• Conveyor brake (2 per brake system)
• Conveyor miscellaneous (5 per conveyor)
• Belt feeders (2 per feeder)
• Auxiliary systems
• Substations (1 per substation)
• Alarm log
• Real Time trending (1 for the system and 1 per conveyor)
• Historical trending
Several typical screens are included in appendix H.
5.2 Alarm Diagnostics
The graphics screens provide visual indication of each equipment alarm

condition.
All defined alarms are shown with an individual graphical icon and a short
associated text.
5.3 Historical Alarm Log
The operator graphic stations maintain a historical log of all events and alarms
reported to the system in the last 48 hours. The alarms and events are logged in
the order of occurrence.
The log should be printed continuously, and is logged to the hard disk. The
historical log files are automatically saved to disk every 48 hours (48 hours
cycle).
The operator has the option to save the files for permanent storage using normal
Windows commands outside the WIN-CC environment.

The files are not automatically erased by the system, and the operator should
occasionally clean up the hard disk to avoid a disk overflow.
The following data is logged:
• Equipment start/stop
• Control mode changes
• AFD drive enabling/disabling
• Alarm resets (remote and local)
• Alarms/malfunctions
5.4 Real Time Trending
Several real time trend screens are available for the system and for each
conveyor. These screens show real time trends of the last 10 minutes of
operation for the most critical analog registers.
The real time trend screens can be setup to show any logged analog register.
They have been initially setup to show the following variables:
Overview trends:
• Belt feeders total speed

• Tonnage
• Conveyor total torque (each conveyor)
• Conveyor belt tension (each conveyor)
Conveyor trends:
• Total AFD drives power

• Conveyor speed
• Conveyor speed ramp
5.5 Historical Trending
Selected analog registers are continuously recorded to disk at a 1-second

interval. The historical trend files are automatically saved to disk every 48 hours
(48 hours cycle).
The operator has the option to save the files for permanent storage using normal
Windows commands outside the WIN-CC environment.
The files are not automatically erased by the system, and the operator should
occasionally clean up the hard disk to avoid a disk overflow.
A trend review screen provides the ability to review all recorded analog variables.
It is possible to review up to eight variables at the same time, and the screen has
zoom, pan, and print capabilities.

The following data is recorded:
• AFD drive power (each drive and total power for each conveyor)
• AFD drive speed reference (1 per conveyor)
• Conveyor speed (1 per conveyor)
• Mechanical brake pressure (1 per conveyor)
• Load cells (2 per conveyor)
• Belt tension (calculated, 1 per conveyor)
• Take-up counterweight position (1 per conveyor)
• Tonnage (2 weight scales)
• Shuttle position
• Feeder speed (1 per feeder)
• Motor RTD temperatures (all)
• Reducers RTD temperatures (all)
• Pulley bearing RTD temperatures (all)
• Drive vibration
5.6 Accumulated Registers
Several accumulated registers are used to keep track of various functions. These
registers are updated by the PLC’s and are shown on the operator screens.
The following accumulated registers are available:
• Daily run-time counter (1 per conveyor and feeder)

• Total run-time counter (1 per conveyor and feeder)
• Daily tonnage (2 weight scales)
• Total tonnage (2 weight scales)
The daily accumulated registers are automatically reset at midnight by the

supervisory system. The total accumulated registers can be individually reset by
the operator at any time. The time of the last reset is recorded and shown on the
operator screen.
5.7 Advanced Help Features
Advanced help and diagnostic information is available through the use of a

separate interactive help file system working in conjunction with the WIN-CC
graphic interface.
The advanced help features were developed in a separate software package and
linked to WIN-CC through custom written Windows executable files (DLL files).
Several levels of help are available, from simple tool-tips to advanced interactive
trouble shooting screens.
A description of the features of the advanced help system can be found in

appendix I.

6 BELT FEEDERS
Conveyor 120-CV-005 is fed by four belt feeders (120-FE-005, 120-FE-006, 120-FE-007

and 120-FE-008).
All the belt feeders are designed for a maximum tonnage of 2900 tph.
All the belt feeders are powered by a variable speed hydraulic motor and are equipped
with an oil cooler and a tramp iron magnet system to protect the conveying system from
belt damages.
The tramp iron magnets are motorized and can be moved between the feeder discharge
chutes and their tramp iron discharge bin.
Each belt feeder is fitted with a stockpile low level switch. This switch is used to
prevent feeder start when the stockpile is low to avoid damage to the feeder belt.
The feeders can only be started if conveyor 120-CV-005 is running at full speed
in remote-auto or local-auto mode.
A feeder can only be started if its magnet is located at the feeder chute position.
Each feeder is equipped with one latching emergency stop switch located next to
its hydraulic power pack. This switch is hardwired to the feeder pump contactor.
In addition, each feeder is equipped with one latching emergency stop switch
located next to its magnet carriage. This switch is only connected to the PLC (not
hardwired).
Actuation of any of these switches stops the selected feeder and its magnet
positioning motor, but not the magnet flux. The remaining feeders are not
stopped.
If an overload or negative drive pulley slip is detected on conveyor 120-CV-005,

the feeder speed setpoint is automatically reduced (automatic speed setback).
If a severe overload or negative drive pulley slip is detected on any of the

conveyors, the feeders (and all upstream conveyors) are stopped. This interlock
is hardwired between the PLC’s.
The feeders are automatically stopped when a high stockpile level is detected.
This interlock is also hardwired between the PLC’s.
The maximum number of active feeders, the feeder speed setpoints, and the
feeder system tonnage setpoint are also interlocked to the number of working
weight scales, the number of active AFD drives, and the operating mode of the
feeders.
The above interlocks are described in detail in the following paragraphs.
6.2 Feeders Control
Several control modes have been defined for the belt feeders. The control mode
is selected from the maintenance workstation (OP37) and from two selector

switches. Access to the various modes from the maintenance workstation is
passwords protected.
Each feeder is equipped with a mode selector switch (MSS) located on the
feeder panel. The MSS switch is used for software mode selection only and is
not hardwired to the equipment. It is also used as a speed selector switch to
select the source of the speed setpoint (PLC or local potentiometer).
When the mode selector switch is turned to the local-PLC position, the speed
control input from PLC 5 is enabled. When the mode selector switch is turned to
the local-panel position, the panel speed control potentiometer is enabled and
the speed control input from PLC 5 is disabled.
The operating mode for each feeder is selected by PLC 5 according the following
combinations:
CONTROL MODE OP37 MSS

REMOTE-AUTO REMOTE REMOTE
LOCAL-AUTO LOCAL REMOTE
LOCAL-MANUAL - PLC SPEED CTRL - LOCAL-PLC
LOCAL-MANUAL - POT SPEED CTRL - LOCAL-PANEL
DISABLED - OFF
The feeders are normally operated in automatic mode (remote or local).
A feeder can only be switched to the local-manual mode when it is stopped. In

order to enable maintenance work while the system is in operation, a feeder can
be switched to the local-manual mode while the other feeders remain in
automatic mode. However, only one feeder at a time can be operated in local-
manual mode. In addition, the system automatically limits the maximum number
of active feeders, sets the control to the fixed-speed mode, and limits the active
feeders speed setpoint to account for the potential material flow from the feeder
in local-manual mode.
In this mode the feeders are operated from the central operator control
room. Only fully interlocked automatic feeder starts and stops are
available in this mode.
The following controls are available to the operator in the remote-

automatic mode:
• Select number of active feeders (but not which feeder is active)

• Start/stop feeder system
• Initiate cleanup sequence on active feeder
• Select feeder speed control mode
• Enter feeder control setpoint
The number of active feeders and the operator setpoints are limited by
PLC 5 based on operating conditions as described below.

When a start command is received from the operator, all the active
feeders warning horns and beacons are turned on for 10 seconds while
the feeders pump motors are started. The active feeders are then started
in sequence starting from feeder 120-FE-005. Each feeder warning horn
and beacon is turned on again during the feeder start sequence.
If an active feeder trips on fault while running, a new active feeder is

automatically selected by PLC 5, but the new feeder is not started until a
new operator start command is received from the operator.
6.2.1.1 Feeder Selection
The number of active feeders is automatically limited to 3 under

the following conditions:
• If one feeder is switched to the local-manual mode

• If one of the weight scales on conveyor 120-CV-005 is
out of order
PLC 5 selects which feeder is active. The active feeders are

identified on the operator overview screen.
Due to the increasing material drop of the feeder chutes between

feeder 120-FE-005 and feeder 120-FE-008, PLC 5 always
selects the feeders starting from the tail end of the conveyor
(feeder 120-FE-005). All available feeders are then selected until
the number of active feeders is reached.
A feeder is considered available if it is not locked out (MCC

feedback), if it is in automatic mode, if its magnet is ready, and if
it is not in a fault condition.
6.2.1.2 Speed Control
Two speed control modes are available to the operator:
• Tonnage control
• Fixed speed control
In the tonnage mode, all the active feeders are operated at

variable speed in a closed loop tonnage control. The tonnage
setpoint is entered by the operator but is limited by PLC 5 based
on the current operating conditions (see chapter 7).
In the fixed-speed mode, all the active feeders are operated at

constant speed. The speed setpoint is entered by the operator,
but is also limited by PLC 5 based on the current operating
conditions. The maximum allowable speed is calculated from the
maximum allowable tonnage using an empirical relation
determined during commissioning (100% speed = 2700 tph).
In both control modes, all the running feeders are operated at the
same speed and the automatic speed setback is active.

The speed control mode is automatically set to the fixed-speed
mode if the tonnage signal is not available (both weight scales
out of order) or if one feeder is operated in local-manual mode.
When one feeder is operated in local-manual mode, the

maximum speed of the remaining feeders is reduced to allow for
the potential material flow from the feeder operated in local-
manual mode. The maximum allowable speed is calculated by
PLC 5 based on the number of operating feeders and the current
6.2.1.3 Weight Scales
Conveyor 120-CV-005 is equipped with two weight scales for

redundancy. The feeder tonnage control is always done using
the highest of the two weight scales readings.
The two scales are constantly compared to each other. An alarm

is latched whenever the two readings differ by more than 500 tph
for more than 10 seconds, but no other action is taken.
If one weight scale is out of order, the number of active feeders

is automatically limited. If both weight scales are out of order, the
fixed-speed speed control mode is automatically selected.
Both weight scales are fitted with a reset input to enable remote
reset of faults by the operator.
6.2.1.4 Tonnage Limitations
The overland conveying system is designed for a maximum

tonnage of 8700 tph. Consequently, the feeder tonnage setpoint
is limited to 8700 tph
In addition, the feeder tonnage setpoint is automatically limited

according to the tables provided in paragraph 7.2 when any
conveyor is operated with a disabled drive.
This mode is exactly similar to the remote-automatic mode except that

the operator controls and setpoints are entered from the maintenance
workstation located at the drive station of conveyor 120-CV-005.

The local-manual mode provides control of each feeder from push

buttons located on the feeder panels. All internal feeder interlocks are
maintained in this mode. However, most external interlocks are disabled.
Only the interlocks to conveyor 120-CV-005 and to the feeder magnet
remain active. This mode can only be entered when the feeder is
stopped.
This mode provides the ability to run each feeder independently and
commissioning of the feeders.
The following local operator controls are available:
• Start hydraulic pump

• Stop hydraulic pump
• Increase feeder speed
• Decrease feeder speed
• Jog Cooler fan
A pump start command also turns on the warning horns and beacons for
10 seconds.
Depending upon the position of the mode selector switch, the feeder
speed can be adjusted from the speed-increase/speed-decrease
switches (PLC) or the potentiometer (Pot) located on the feeder panel.
Note that the cooler fans can be jogged in all modes of operation.
6.2.4 Disabled Mode
The disabled mode is selected by turning the feeder mode selection

switch to the OFF position. In this mode, the feeder hydraulic motor is
blocked against starting.
This mode provides the ability to disable a feeder for operational or

maintenance purposes.
This mode only applies to the feeder itself. The feeder magnet system is
not disabled when the feeder is set to the disabled mode, the automatic
magnet cleaning sequence is still enabled, and the magnet system can
still be switched to the maintenance mode.
6.3 Automatic Speed setback
An automatic speed setback is incorporated in the feeder control logic to protect

the conveyors against temporary overload conditions.
The automatic speed setback is triggered by the following conditions on conveyor

120-CV-005:
• High belt tension (over 260 tons for 10 seconds)

• High negative AFD drive torque (over 100% of nominal regenerative
torque for 10 seconds)

• High negative belt slip on any drive pulley (over 1.5% for 5 seconds)
• High tonnage (over 100% of allowable tonnage for 10 seconds)
When the automatic setback is activated in speed control mode, the total feeder
speed (accumulated for all operating feeders) is instantly decreased by 70%. In
tonnage control mode, the tonnage setpoint is instantly decreased by 2000 tph.
The setback remains active as long as the overload condition is detected, and for
5 minutes after the condition has returned to normal.
6.4 Conveyors Overload Interlocks
An overload interlock is incorporated in the feeder control logic to protect the

conveyors against severe overload conditions.
The overload interlock is triggered by the following conditions:
• Very high belt tension (over 110% of nominal tension for 10 seconds,
150 tons on conveyor 120-CV-007, 290 tons on conveyors 120-CV-005
and 120-CV-006)
• Very high negative AFD drive torque (over 130% of nominal regenerative
• High sustained negative AFD drive torque (over 100% of nominal
regenerative torque for 30 minutes)
• Very high negative belt slip on any drive pulley (over 10% for 5 seconds)
• Very high tonnage (over 110% of allowable tonnage for 10 seconds,
conveyor 120-CV-005 only)
When an overload condition is detected on any conveyor, the belt feeders and all
the upstream conveyors are automatically stopped. The overloaded conveyor is
not stopped. This interlock is hardwired between the PLC’s.
6.5 Tramp Iron Magnets
All the belt feeders are equipped with a tramp iron magnet system to protect the
conveying system from belt damages.
The magnet is installed in a reversible motorized carriage and can be moved

between the feeder discharge chute and a tramp iron discharge bin.
Each magnet is equipped with a warning horn/beacon, a local control panel, a

latching emergency stop switch, and several control and over-travel position
switches.
6.5.1 General Considerations
Each magnet needs to be cleaned every 8 hours by moving the magnet

to the bin position and turning off the magnet field for a minimum of 90
seconds.
Each magnet is automatically cleaned after a feeder shutdown.
A feeder can only be started if its magnet is located at the feeder chute
position, is in the automatic mode, and is not in a fault condition.

Each feeder magnet system is equipped with one latching emergency
stop switch located next to the magnet carriage. This switch is only
connected to the PLC (not hardwired). Actuation of this switch stops the
carriage motor and the corresponding feeder, but not the magnet flux.
Conveyor 120-CV-005 is automatically stopped in case of magnet power

failure while the feeder is running. This fault has to be reset from a switch
located at the discharge end of the feeder.
6.5.2 Magnet Control
The following control modes have been defined for the magnet systems.
CONTROL MODE OP37 MSS FEEDER

REMOTE-AUTO - REMOTE -
LOCAL-
MAINTENANCE - LOCAL
MANUAL/DISABLED
DISABLED - OFF -
The magnet system mode is independent of the feeder mode, except

that the magnet maintenance mode can only be selected if the feeder is
in local-manual or disabled mode and is stopped.
6.5.2.1 Remote-Automatic Mode
In remote-automatic mode, the magnets are automatically

cleaned after each feeder shutdown. They are then repositioned
over the feeder chute automatically. The magnets stay de-
magnetized until the next start of the feeder.
The automatic magnet cleaning sequence is independent of the

feeder mode of operation, and is enabled even when the feeder
is disabled.
The magnets warning horns/beacons are automatically turned on

5 second before any carriage motion is started, and remain on
until the end of the motion.
A time counter is displayed on the operator graphic stations to

indicate each feeder running time since the last cleanup. It is the
operator responsibility to initiate the cleaning sequence for each
active feeder before the maximum time is reached.
An active feeder can be cleaned at any time while the system is

operating. However, only one active feeder can be cleaned at
any one time. If the system is operating in a tonnage mode, the
loop is temporarily disabled while the feeder is stopped for
cleaning. However, the speed setpoint of the remaining
operating feeders is automatically increased to compensate for
the loss of material flow.
If a feeder magnet has not been cleaned for more than the
maximum time, an alarm is displayed on the screen. If the
operator does not stop the feeders within the next 1 hour, the
feeder is automatically stopped and a fault is latched.

The time limit is adjustable by the operator, but is limited to 8
hours.
6.5.2.2 Maintenance Mode
The maintenance mode provides control of each magnet from

push buttons located in the field. The maintenance mode can
only be entered if the corresponding feeder is in local-manual or
disabled mode and is stopped.
In this mode, the magnet carriage can be moved to any location

between the feeder chute and the discharge bin. The magnet
flux can also be turned on and off as long as that the magnet is
positioned over the discharge bin.
If a feeder magnet is switched to the local-manual mode before

its automatic cleaning sequence has been completed, the
sequence will automatically resume when the magnet is
switched back to the remote-automatic mode.
Similarly, if a feeder magnet is moved away from the feeder

chute location while in maintenance mode, it is automatically
returned to the feeder chute location upon exiting the
maintenance mode.
6.5.2.3 Disabled Mode
The disabled mode is selected by turning the magnet mode

selection switch to the OFF position. In this mode, the carriage
motor is blocked against starting.
This mode can be entered at any time, even when the feeder is
operating. Switching a feeder magnet to the disabled mode will
not stop the corresponding feeder until an automatic cleaning
sequence is required.
This mode provides the ability to disable a feeder for operational

or maintenance purposes.

7 OVERLAND CONVEYORS
This section provides a description of the control algorithm presently defined for the
overland conveyors.
A detailed description of the final algorithms is provided in the PLC technical

documentation. The control logic and the control algorithms are subject to change during
the system commissioning.
All the overland conveyors are fitted with variable speed drives (AFD). The AFD
drives are fitted with braking-choppers, resistor banks, and UPS to maintain their
regenerative capabilities in case of 23 kV line failure or trips of the 23 kV breaker.
The AFD drives are designed to provide 130% of their nominal torque for up to
30 minutes to accommodate short term motor overload without stopping the
conveyor (35 minutes for conveyor 120-CV-007). The braking-choppers and
resistors are designed to provide a maximum of 150% of the AFD drive nominal
torque for 80 seconds.
The AFD drives are used to accelerate and stop the conveyors under normal
conditions. They are also used to stop the conveyors in case of line failure or trip
of the 23 kV breaker.
The primary driving or retarding torque for the conveyors during running
conditions is provided by the electric motors. The conveyors require retarding
torque when loaded over 1000-1500 tph (regenerative conditions). All the energy
produced under these conditions is fed back to the main grid.
The overland conveyors are also fitted with low speed, mechanical disk brake
systems mounted on their two drive pulleys and on one bend pulley at their tail
station. The disks are installed on the low speed side of the motor reducers (drive
pulleys) or directly on the pulley shaft (bend pulleys).
The mechanical brake systems include both digital and analog controls. Several
calipers on each system are controlled with simple on/off valves, while the
remaining calipers are controlled from an analog pressure control valve. This
combined design was selected to decrease the response time of the brake while
All the analog brake calipers on all conveyors and all the digital brake calipers on
conveyor 120-CV-007 are of a fail-safe design (spring applied, hydraulically
released). Conveyors 120-CV-005 and 120-CV-006 use a mix of fail-safe and
fail-open digital brake calipers. This was done to decrease the peak tension in
the belt in case of UPS power failure while providing back-up braking capacity
under PLC control.
The brake working pressure is provided by redundant hydraulic pumps. Each

conveyor is equipped with one central hydraulic power pack and with several
quick-set and quick-apply modules located next to the brake pulleys. The central
hydraulic power packs are fitted with redundant proportional control valves to
modulate the brake torque of the proportional calipers, and with a two-level
emergency circuit used in case of proportional control valve failure. The quick-set
modules are fitted with several solenoid valves to control the fail-safe digital
calipers. The quick-apply modules are fitted with several solenoid valves to
control the fail-open digital calipers.

The mechanical brakes are used as a backup to the AFD drives to bring the
conveyors to a controlled stop in case of multiple AFD or motor failure, of UPS
power failure, or whenever a malfunction of level 3, 4 or 5 is detected. They are
also used to park the conveyors at the end of each stopping cycle.
Each drive station is equipped with one latching stop switch at each motor
location. These switches are not hardwired to the motor contactors. Actuation of
any of these switches results in an immediate shutdown of the conveyor using
the AFD drives (level 2). In addition, each drive station is equipped with one
latching emergency stop switch located at the mechanical brake hydraulic panel.
This switch is hardwired to the conveyor emergency circuit. Actuation of this
switch results in the immediate shutdown of the conveyor using the mechanical
brake emergency circuit (level 4).
Each AFD drive container and each high voltage container is equipped with two
latching emergency switches located inside and outside the container next to the
main door. Those emergency switches are hardwired to the main 23 kV breaker.
Actuating one of those switches results in an immediate shutdown of the
corresponding conveyor using the AFD drives and the braking-choppers (level 2).
Pull cords are located along the complete conveyor route. Pull cord switches are
grouped in zones and are equipped with beacons used to locate tripped pull
cords. All the pull cords on each conveyor are wired in series to a master circuit.
This circuit is monitored by the PLC at each substation. The individual status of
each zone is also monitored by the PLC on the remote I/O modules located
along each conveyor. The information from the remote modules is used for
diagnostics only. This was done to allow continuous operation in case of remote
I/O module fault.
Due to the natural acceleration of loaded downhill conveyors, disconnecting the

motor contactors while running under load would result in an increase in speed
while the mechanical brake applies. Consequently, the master pull cord circuit is
not hardwired to the motor contactors. Actuation of any pull cord switch results
in an immediate shutdown of the conveyor using the AFD drives (level 2).
Three of the four drives on conveyors 120-CV-005 and 120-CV-006 (drives 11,
22 and 21) and both drives on conveyor 120-CV-007 are fitted with Keller
reducers. These reducers are splash lubricated and do not require a dedicated
lubrication system. They were initially installed without oil cooling systems, but
were retrofitted with coolers at a later date. The reducer cooling systems are
controlled by independent controllers and are not under PLC supervision.
One drive on conveyors 120-CV-005 and 120-CV-006 (drive 22) is fitted with a
Flender reducer. These reducers are forced lubricated and require a dedicated
lubrication system. These lubrication systems are controlled by independent units
provided by Flender but are supervised and monitored by the PLC.
The belt tension of each conveyor is controlled by a gravity take-up located at the
head station. All the conveyors are equipped with a take-up winch. On the two
longer conveyors (120-CV-005 and 120-CV-006), the winch is controlled by the
PLC to position the counterweight prior to start-up and to maintain its position
within a given range while the conveyor is running. This was done to reduce the
required counterweight travel and minimize manual adjustments due to splice
stretching and temperature fluctuations.

Each conveyor is equipped with mechanical and loop type belt rip detection
systems and with a belt splice monitoring system. The splice monitoring system
works by measuring the distance between several markers embedded in the belt
before and after each splice. The measured length for each splice is compared
with the original splice length to detect abnormal splice elongation (early sign of
failure). The original length for each splice is recorded during the system startup.
One beacon and one horn are located at each substation. The horn is turned on
for 1 minute whenever a conveyor malfunction has been latched. The beacon is
turned on whenever an alarm or a malfunction has been latched.
All the conveyors are started following a 40 seconds S-shaped ramp with the
AFD drives. The mechanical brakes are used to hold the conveyors until the full
AFD drives torque is developed.
Under normal conditions, all the conveyors are stopped on a curved ramp using
the AFD drives regenerating into the main grid (if required). In case of line failure,
all the conveyors are stopped on the same curved ramp using the AFD drives
and the braking-choppers.
In order to ensure that the conveyor discharge chutes remain clear of material,
the conveyors are stopped with increasing time ramps from the head to the tail of
the system.
The stopping time for each conveyor is shown in the following table:
Conveyor Conveyor stopping time

120-CV-005 76 seconds
In the event of multiple AFD drives or motors failure, the conveyor is stopped on
a linear ramp with the mechanical brake using proportional control (level 3).
Combined braking using the AFD drives and the mechanical brake
simultaneously is not permitted.
In the event of a mechanical brake proportional control failure, of a UPS failure,

or whenever the conveyor emergency circuit is tripped, the conveyor is stopped
with the mechanical brake using an emergency hydraulic circuit that provides a
preset torque control independent of the PLC (level 4).
In the event of failure of the mechanical brake emergency control, the conveyor
is stopped with the mechanical brake using a second emergency hydraulic circuit
that applies maximum brake torque instantly (level 5).
The normal conveyor stopping time is not maintained during emergency stops.
The control logic was developed to follow the design criteria established during
the dynamic analysis for each conveyor. The various ramps used for starting and
stopping the conveyors are shown in appendix J.

7.2 Tonnage Limitations
The overland conveyor system is designed for a maximum tonnage of 8700 tph.
Any conveyor can be operated with one AFD drive disabled. Under these
conditions, the maximum allowable tonnage is reduced as follows:
Maximum Tonnage
Number of Motors 120-CV-005 120-CV-006 120-CV-007
4 Motors 8700 8700 NA
3 Motors 7200 7200 NA
2 Motors NA NA 8700
1 Motor NA NA 5200
30 minutes to accommodate short term overloads. This margin is sufficient to
keep conveyors 120-CV-005 and 120-CV-006 running in case of single drive
failure under any load conditions until the conveyor load has been reduced by the
tonnage limit.
In the case of conveyor 120-CV-007, a total of 35 minutes is required before the

conveyor load has been reduced by the tonnage limit. Consequently, the time
limit for this conveyor has been extended to 35 minutes to enable continuous
operation in case of single drive failure at low tonnage (under 5800 tph). When
conveyor 120-CV-007 is running at 8700 tph, the required motor torque from a
single drive would be in excess of 180%. This torque is in excess of both the
AFD drive torque capability (150%) and the mechanical limit imposed by potential
pulley slip (160%). Consequently, conveyor 120-CV-007 is stopped with the
mechanical brake in case of single drive failure at full load.
The process of re-starting conveyor 120-CV-007 under these conditions may

require two successive start attempts. If the load remaining on the conveyor at
the end of the first attempt requires more than 150% torque from the drive, the
conveyor will be automatically stopped again with the mechanical brake.
Sufficient load should have been discharged by the end of the second start
attempt to decrease the required drive torque below 150%.
Furthermore, since the complete conveying route would be loaded at full tonnage
under these conditions, a special procedure is required to empty the conveying
system before the feeders could be re-started with the new tonnage limit. After
starting conveyor 120-CV-007, both conveyor 120-CV-006 and conveyor 120-
CV-005 should be switched to the reduced-speed mode, started in sequence,
and kept running at reduced speed until they are empty. Both conveyors should
then be stopped and switched back to the remote-automatic mode before
normally starting the system.
Several tables showing the torque/tonnage relation and the tonnage limitations
under various conditions are provided in appendix K.
7.3 Overload Protection

Several instruments have been installed on the conveyors, and several interlocks
are used between the conveyors and the feeders minimize the chance of
conveyor overload.
Conveyor 120-CV-005 is equipped with two weight scales located near its
loading station. The weight scales are used to control the feeder’s speed and to
prevent material overload of the conveyors. All control and tonnage detection is
done using the highest of the two weight scales readings.
In addition, each conveyor is equipped with two load cells mounted on the
primary drive pulley supports. The load cell readings are combined with the
motor torque information from the AFD drives to estimate the high side belt
tension. The details of the calculation used are provided in appendix L. Note that
the belt tension can only be calculated while the conveyor is moving and the AFD
drives actives. In order to avoid displaying inaccurate values on the operator
screen, the belt tension register is automatically reset to zero when the conveyor
is stopped, or when the mechanical brake is applied.
An automatic speed setback is incorporated in the feeder control logic to protect

the conveyors against temporary overload conditions. The automatic speed
setback is triggered by the following conditions on conveyor 120-CV-005:
• High belt tension (over 260 tons for 10 seconds)

• High negative AFD drive torque (over 100% of nominal regenerative
• High negative belt slip on any drive pulley (over 1.5% for 5 seconds)
• High tonnage (over 100% of allowable tonnage for 10 seconds)
The setback remains active as long as the overload condition is detected, and for
5 minutes after the condition has returned to normal.
Finally, an overload interlock is incorporated in each PLC to protect the

conveyors against severe overload conditions. The overload interlock is triggered
by the following conditions:
• Very high belt tension (over 110% of nominal tension for 10 seconds,
150 tons on conveyor 120-CV-007, 290 tons on conveyors 120-CV-005
and 120-CV-006)
• Very high negative AFD drive torque (over 130% of nominal regenerative
• High sustained negative AFD drive torque (over 100% of nominal
regenerative torque for 30 minutes)
• Very high negative belt slip on any drive pulley (over 10% for 5 seconds)
• Very high tonnage (over 110% of allowable tonnage for 10 seconds,
conveyor 120-CV-005 only)
When an overload condition is detected on any conveyor, the belt feeders and all
the upstream conveyors are automatically stopped. The overloaded conveyor is
not stopped. This interlock is hardwired between the PLC’s.
Due to mechanical limitation of the reducers, it is not recommended to run a drive

near zero power for extended periods of time.

This condition occurs for a few minutes during every loading and unloading of the
conveyors (transition to and from regenerative mode). It also occurs continuously
whenever the tonnage remains around 1000 to 1500 tph.
In order to prevent reducer damage during such occurrences without placing

serious limitations on operating conditions, a zero torque prevention feature has
been incorporated in the PLC drive control logic and in the AFD drives
controllers.
When a low total conveyor drive torque is detected for more than a few seconds,
the PLC automatically offsets the torque setpoint of each drive. The torque
setpoint of the drives on the primary pulley is increased, while the torque setpoint
of the drives on the secondary pulley is decreased. The drive offsets are
calculated to maintain the total conveyor drive torque, while making sure that no
drive is operated with less than 5 % torque (powering or regenerative).
The offset remains active as long as the zero torque condition is detected, and
for 1 minute after the total drive torque has increased sufficiently.
7.5 Hardwired Interlocks
Several hardwired interlocks are used to insure fail-safe operation of the overland
conveying system.
7.5.1 PLC to PLC Interlocks
All conveyor to conveyor interlocks are hardwired between the PLC’s to

insure fail-safe operation under any conditions. The H1/OTN network is
only used for monitoring, diagnostics and operator control.
Eight hardwired interlocks are used between each PLC to insure fail-safe
operation.
The interlocks consist of six digital outputs and two digital inputs on each
downstream PLC connected to corresponding I/O’s on each upstream
PLC.
The following interlocks are used:
• Run permissive interlock (downstream to upstream PLC)

• Level 4 stop interlock (downstream to upstream PLC)
• Full speed enable interlock (downstream to upstream PLC)
• Tonnage limit level 1 interlock (downstream to upstream PLC)
• Tonnage limit level 2 interlock (downstream to upstream PLC)
• Stockpile high interlock (downstream to upstream PLC)
• Run permissive interlock (upstream to downstream PLC)

• Chute clear interlock (upstream to downstream PLC)
Upstream Run Permissive Interlock
This signal is normally low and is turned on when the downstream

conveyor is in one of the interlocked modes (remote-automatic, local-
automatic, or reduced-speed mode), is either running or above 20%
speed during the starting cycle, and no belt tension fault, total motor

torque fault, or negative drive pulley slip fault has been detected. The
input is used as a run permissive on the upstream conveyor in remote-
automatic, local-automatic, and reduced-speed modes.
Level 4 stop Interlock
This signal is normally high and is turned off when the downstream
conveyor initiates a level 4 stop (mechanical brake emergency stop). The
input is used to initiate a level 4 stop on the upstream conveyor in order
to minimize the chances of plugged chute at the transfer station. The
input is used in all modes. This input is fail safe (normally high) to insure
that a level 4 stop is initiated on the upstream conveyor in case of UPS
or power failure on the downstream conveyor PLC.
Full Speed Enable Interlock
This signal is normally high and is turned off when the downstream
conveyor is in the reduced-speed mode. When this input is low, the
feeders are disabled and the upstream conveyor is only enabled to start
if it is in the reduced-speed mode.
Tonnage Limit Level 2 Interlock
This signal is normally high and is turned off if one AFD drive has been
disabled on conveyor 120-CV-006 (level 2 tonnage limit). The input is
used by PLC 5 to limit the feeder’s tonnage and speed setpoints in both
remote-automatic and local-automatic modes.
Tonnage Limit Level 1 Interlock
This signal is controlled from PLC 7 and relayed by PLC 6. It is normally

high and is turned off if one AFD drive has been disabled on conveyor
120-CV-007 (level 1 tonnage limit). The input is used by PLC 5 to limit
the feeder’s tonnage and speed setpoints in both remote-automatic and
local-automatic modes.
Stockpile High Interlock
This signal is controlled from PLC 7 and relayed by PLC 6. It is normally

high and is turned off when a stockpile high condition is detected. The
input is used by PLC 5 to stop the belt feeders in both remote-automatic
and local-automatic modes.
Downstream Run Permissive Interlock
This signal is normally high and is turned off when a system level fault is
detected in the upstream PLC. Currently, the only system level fault
defined is the harmonic filter fault in PLC 5. The input is used as a run
permissive on the downstream conveyor in all modes.
Chute Clear Interlock
This signal is normally low and is turned on when the upstream conveyor
chute is clear of material. This information is used by the downstream
conveyor to detect when the conveyor is empty. This feature was added
to enable the operator to enter the brake maintenance and the local-

creep modes without having to perform an empty stop sequence when
the conveying system is already empty.
All these interlocks are ignored in local-manual and maintenance modes.
A drawing showing the hardwired PLC to PLC interlocks is provided in

appendix M.
7.5.2 PLC to AFD Drive Interlocks
The PLC and the AFD drives are interconnected by a local Profibus
network at each substation. This network is a critical part of the AFD
drives operation because the normal drive control is performed over the
Profibus network, and because part of the closed loop speed and load-
sharing control of the drives is done in the PLC.
The Profibus networks are constantly monitored by their master PLC, but
not by the AFD drives which cannot detect a Profibus failure.
Consequently, several hardwired interlocks are used between the PLC

and the Simadyn D drive controllers to enable safe shutdown of the
conveyors in case of drive Profibus network failure.
The interlocks consist of two PLC outputs and one PLC input for each
drive, and the corresponding I/O’s on the Simadyn controller.
The following I/O’s are used:
• Drive Stop Command (from PLC to AFD drive, low to stop)
This signal initiates a normal stop of the corresponding AFD drive

using the drive internal stopping ramp. This allows a normal stop of
the conveyor in case of drive Profibus failure, but does not maintain
load sharing during the stopping sequence.
• Drive Trip Command (from PLC to AFD drive, low to trip)
This signal triggers an instantaneous shutdown of the corresponding

AFD drive
• Drive Loss of Control (from AFD drive to PLC, low on fault)
This signal indicates that the drive is no longer able to control the
motor (major drive fault). Upon detection of a loss of control fault by
any active drive, the PLC immediately initiates a disabling sequence
of the faulty drive, provided that all the other drives are operational
and that the load on the conveyor would not result in overloading of
the remaining drives.
All the hardwired interlocks between the PLC and the AFD drives are fail-
safe (normally high).
The PLC outputs are always used to stop the conveyor in case of
multiple drive Profibus failure, or when an AFD drive does not respond to
its normal stop commands. In both cases, the PLC first tries to stop the
AFD drives using the normal-stop outputs. If the conveyor speed does

not follow the expected stopping ramp, the PLC then trips the AFD drives
using the E-stop outputs and stops the conveyor with the mechanical
brake.
When a Profibus failure is detected on a single drive, the PLC trips the
faulty drive using its E-stop output but the conveyor is not stopped
provided that all the other drives are operational and that the load on the
conveyor would not result in overloading of the remaining drives.
The AFD drive E-stop inputs are also directly controlled from the
hardwired emergency circuit to insure that the AFD drives are tripped
when the emergency circuit is activated (see following paragraph).
A drawing showing the hardwired AFD drive interlocks is provided in

appendix M.
Each conveyor is equipped with a fail-safe emergency circuit. This circuit

is independent of the PLC and is hardwired into the mechanical brake
emergency circuit and the AFD drives E-stop inputs. It is automatically
triggered in case of UPS failure, overspeed detected by the electronic
overspeed switches, or PLC failure detected by the watchdog timer. The
emergency circuit is shown in appendix N.
Triggering the emergency circuit initiates a level 4 stop of the conveyor.

The AFD drives are immediately tripped and the mechanical brake is
applied with the first emergency hydraulic circuit. All the fail-safe digital
calipers are immediately applied, and the proportional calipers are
applied on a preset mechanical pressure curve independent of the PLC.
On conveyors 120-CV-005 and 120-CV-006, two of the digital calipers

are of a fail-open design and do not apply when the emergency circuit is
triggered. On these conveyors, only 83% of the available brake torque is
applied during an emergency brake stop. All the available brake torque is
applied during an emergency brake stop on conveyor 120-CV-007.
The emergency circuit includes redundant electronic overspeed

switches. These switches are preset to open at 118% speed.
The emergency circuit also includes a watchdog timer to detect failures

of the PLC CPU’s. A manual switch is also provided to bypass the
watchdog relay when doing maintenance on a PLC.
7.6 AFD Drives Selection/Deselection
All the conveyors can be operated with one AFD drive disabled. The drives can
be temporarily disabled from the operator graphic stations, or permanently
disabled from the maintenance workstation. All the AFD drive enable and disable
commands are password protected.
The AFD drive enable/disable function is provided for maintenance purpose only
and is limited to one disabled AFD drive per conveyor at any time.
It is possible to disable an AFD drive on a running conveyor, provided that all the
other drives are operational and that the load on the conveyor would not result in

overloading of the remaining drives. It is also possible to enable a disabled AFD
drive on a running conveyor.
It is not possible to disable or enable a drive during a conveyor acceleration or

deceleration sequence, or while a disable or enable sequence is active on an
other drive. If a drive fault is detected during one of these sequences, the
conveyor is immediately stopped with the mechanical brake (level 3).
The system will automatically disable any AFD drive that fails on a running
conveyor (including single drive Profibus failure) provided that all the other drives
are operational and that the load on the conveyor would not result in overloading
of the remaining drives.
When a drive needs to be disabled on a running conveyor, whether due to an

operator command or a drive fault, the corresponding drive torque is ramped to
zero while the torque on the remaining drives is increased simultaneously to take
over the load. When the drive torque reaches zero, a stop command is sent to
the drive.
30 minutes to accommodate short term motor overloads without stopping the
conveyor (35 minutes for conveyor 120-CV-007).
When an AFD drive is disabled on a running conveyor, the feeders setpoints is

automatically reduced according to the table provided in paragraph 7.2 and the
conveyor is kept running provided that the torque of the remaining AFD drives
does not exceed 130% of their nominal torque. If the torque of any drive exceeds
130% for 10 seconds, or has not been reduced below 100% within 30 minutes
(35 minutes for conveyor 120-CV-007), the feeders and upstream conveyors are
stopped.
In order to limit potential light loading damages to the drive reducer, a conveyor
can only be operated with a remotely disabled drive for a maximum of 30
minutes. Note that this is usually a more limiting constraint than the AFD torque
limits.
When an AFD drive is temporarily disabled, the PLC verifies that the drive is
inactive. Except for enable/disable and active faults, all alarms and faults
detected on a disabled AFD drive are ignored by the control logic. However, the
corresponding reducer is still monitored. All drive faults and Profibus faults are
still reported to the operator graphic stations and the maintenance workstations
(OP37).
A drive can be permanently disabled. This command cannot be remotely sent

and has to be entered from the maintenance workstations (OP37). A drive should
never be permanently disabled unless the drive low-speed coupling is
disconnected. Permanently disabled drives, including their corresponding
reducer and auxiliary equipment, are not monitored.

7.7 Pre-Start Control
Upon receipt of a pre-start command from the operator, the brake hydraulic
pump is started, the temperature of all the brake disks is checked, the AFD
drives trip command is released, a pre-start command is sent to each enabled
AFD drive, and all the conveyors warning horns are turned on for 10 seconds
The brake hydraulic pump stays on until the active accumulator on the main
hydraulic power pack is fully charged. This also charges the spring accumulator
on the quick apply module. As soon as the accumulator is charged, and provided
that the temperature of all the brake disks is below the start permissive limit, a
brake ready flag is set in the PLC. This stage can take as long as 30 seconds if
the accumulator was fully discharged. The brake pump is then controlled to
maintain the active accumulator pressure on the main brake hydraulic power
pack.
Upon receipt of the pre-start command from the PLC, each AFD drive closes its
3.15 kV circuit breaker, starts its cooling fans, and starts its DC links pre-
excitation. This stage can take as long as 90 seconds if the 3.15 kV breaker was
open. The AFD drive then sends a “ready for operation” signal back to the PLC.
On conveyor 120-CV-005 and 120-CV-006, the take-up counterweight position is

also checked. If the counterweight position is outside a preset range, the
counterweight is moved to its start position with the take-up winch.
When all the enabled AFD drives, the brake system, and the take-up are ready, a
conveyor ready indication is shown on the operator screen.
If a start command is not received within 15 minutes of receiving a pre-start

command, the brake pump is stopped and the AFD pre-start command is
removed. A new pre-start command is required to re-initiate the sequence.
If a start command is received while the conveyor is not ready, a pre-start

sequence is initiated first.
7.8 Starting Control
Upon receipt of a start command, and provided that the conveyor is ready to
start, the conveyor warning horns are turned on. If a start command is received
by a conveyor in remote-automatic, local-automatic, or reduced-speed mode
while the downstream conveyor run permissive interlock input is low, a conveyor
interlock fault is latched and the start sequence is aborted.
After a 10 seconds delay, a start command is sent to all the enabled AFD drives.
Upon receipt of the start command from the PLC, each AFD drive enables its
motor side inverter. This stage usually takes about 10 seconds. When its motor
excitation is fully built-up, the AFD drive sends a “ready for torque control” signal
back to the PLC.
When all the enabled AFD drives are ready, the PLC sends the starting torque
preset to the drives. The starting torque preset value is stored during running
conditions.

Upon receipt of the starting torque preset from the PLC, each AFD drive
increases its torque to the starting preset value. This stage usually takes about 5
seconds. The AFD drive then send a “drive engaged” signal back to the PLC.
After confirmations that all the enabled AFD drives are engaged, the fail-safe
digital calipers are immediately released and the proportional calipers are
released over 5 seconds (the fail-open calipers are normally released). When the
mechanical brake is fully released the AFD speed reference is increased to the
selected speed setpoint.
Each AFD drive then accelerates to the selected speed setpoint on an internal S-
shaped ramp. Each AFD drive generates its own speed ramp. The drives internal
speed ramps are continuously sent back to the PLC for monitoring purpose.
The ramp duration varies with the speed setpoint, with a maximum of 40 seconds
for a full speed start. The various ramps used for starting the conveyors are
shown in appendix J.
When the conveyor speed reaches 1.5%, the warning horns are turned off.
When the AFD drives speed ramp reaches the selected speed setpoint, the
running state is entered.
The conveyor velocity is constantly monitored by the PLC during the starting
sequence. The conveyor is immediately stopped if any of the following conditions
is detected:
• the velocity of the conveyor fails to reach 1.5% within 10 seconds

after releasing the brake (conveyor stall fault)
• the velocity of the conveyor differs from the PLC speed ramp by
more than 10% of nominal speed for more than 5 seconds (AFD
ramp underspeed and AFD ramp overspeed faults)
7.9 Running Control
During the starting, running, and creep states, and during part of the stopping
state, the PLC constantly monitors the total AFD drive torque. The total torque
value is delayed through a 3 seconds filter (to guaranty a valid reading in case of
drive trip) and stored.
The stored torque value is used to calculate the mechanical brake torque that
would be required to stop the conveyor. This value is used at the beginning of the
stopping cycle to preset the mechanical brake pressure in case of level 3 stop.
The last value of the running torque is also constantly stored during the running
and creep states. This value is used to preset the AFD drive torque at the
beginning of the starting cycle.
On conveyor 120-CV-005 and 120-CV-006, the take-up counterweight position is

constantly checked. If the counterweight position moves outside a preset range,
the counterweight is moved back to its start position with the take-up winch.
The conveyor velocity is constantly monitored by the PLC during running

conditions. A level 3 fault is latched and the conveyor is stopped with the

mechanical brake if the velocity of the conveyor exceeds 105-107% (field
adjustable) for more than 1 second (indicating a failure of the AFD drives).
7.10 Stopping Controls
Four different types of stopping control (levels 2 to 5) have been defined to stop
the conveyors depending on the conditions of the stop.
7.10.1 AFD Drive Stop (level 2)
This is the normal stopping mode. It is used for all shutdowns if the AFD
drives and motors are available. Note that this includes conveyor
shutdowns in case of 23 kV line failure.
Upon receipt of a conveyor stop command, or when a level 2 malfunction

has been detected, the AFD drives speed reference is decreased to
zero.
Each AFD drive then decelerates to zero speed on an internal curved

ramp. Each AFD drive generates its own speed ramp. The drives internal
speed ramps are continuously sent back to the PLC for monitoring
purpose.
When the conveyor speed approaches 0, the mechanical brake is

applied at the preset torque value calculated in the running state.
Depending upon the required torque, a preset number of digital calipers
are applied immediately, and the proportional calipers pressure is
adjusted by the pressure control valve to provide the remaining torque.
The proportional calipers pressure is then decreased to zero over 8
seconds.
When the brake is fully applied, the AFD drives start command is
released.
The brake hydraulic pump is then stopped, the brake emergency valve is
opened, the remaining fail-safe digital calipers are applied, the fail-open
digital calipers are applied for a short time to exercise them, and the
conveyor enters the stopped state.
The conveyor velocity is constantly monitored by the PLC during the

stopping sequence. A level 3 fault is immediately latched and the
conveyor is stopped with the mechanical brake if any of the following
conditions is detected:
• the velocity of the conveyor exceeds 105-107% (field adjustable)

for more than 1 second (overspeed fault)
• the velocity of the conveyor differs from the AFD speed ramp by
more than 10% of nominal speed for more than 5 seconds (AFD
ramp underspeed and AFD ramp overspeed faults)
7.10.2 Mechanical Brake Controlled Stop (level 3)
This braking mode is only entered if the AFD drives or the motors are not
available to stop the conveyor.

Upon detection of a level 3 malfunction, the mechanical brake is
immediately applied at the preset torque value calculated in the running
state. Depending upon the required torque, a preset number of digital
calipers are applied immediately, and the proportional calipers pressure
is adjusted by the pressure control valve to provide the remaining torque.
The quickset function is used whenever the preset analog pressure is

low. In this mode, the quickset valve is opened for 1 second at the
beginning of the braking cycle to speed up the pressure drop of the
proportional calipers.
After a short time delay, the AFD drives start command is released. If a
Profibus failure has been detected, or if selected AFD faults have been
latched, the hardwired AFD E-stop outputs are also turned off.
The proportional caliper pressure is then decreased and modulated with

the pressure control valve to place and maintain the conveyor on a linear
stopping ramp. Additional digital calipers are applied as required if the
proportional caliper pressure decreases below a minimum preset value
for more than 2 seconds.
When the conveyor speed reaches 0.5%, or after the nominal stopping
time has elapsed, the proportional calipers are fully applied with the
pressure control valve.
When the conveyor reaches a complete stop, the brake hydraulic pump
is stopped, the brake emergency valve is opened, the remaining fail-safe
digital calipers are applied, the fail-open digital calipers are applied for a
short time to exercise them, and the conveyor enters the stopped state.
The conveyor velocity is constantly monitored by the PLC during the

stopping sequence. A level 4 fault is immediately latched and the
conveyor is stopped with the mechanical brake using the emergency
circuit if any of the following conditions is detected:
• The brake pad do not apply within 1.5 seconds
• the velocity of the conveyor reaches 120% at any time (high

overspeed fault)
• the velocity of the conveyor differs from the PLC speed ramp by
more than 10% of nominal speed for more than 5 seconds (stop
ramp fault)
• The velocity of the conveyor remains over 105% for more than 5
seconds (sustained overspeed condition level 1)
7.10.3 Mechanical Brake Emergency Stop (level 4)
This braking mode is only entered if a level 4 malfunction has been

detected by the PLC, or if the fail-safe hardwired emergency circuit has
been triggered.
The fail-safe hardwired emergency circuit is independent of the PLC and

is automatically triggered in case of UPS failure, overspeed detected by

the electronic overspeed switches, or PLC failure detected by the
watchdog timer.
Upon detection of an emergency malfunction, the brake hydraulic pump

is stopped, all the fail-safe digital calipers are applied, the brake
emergency valve is opened, and the proportional calipers are applied
with the emergency circuit.
The brake torque is then controlled on a preset mechanical pressure

curve independent of the PLC.
On conveyors 120-CV-005 and 120-CV-006, 83% of the available brake

torque is applied during an emergency brake stop. All the available brake
torque is applied during an emergency brake stop on conveyor 120-CV-
007.
After a short time delay, the AFD drives start command is released. If a
Profibus failure has been detected, or if selected AFD faults have been
latched, the hardwired AFD E-stop outputs are also turned off.
When the conveyor reaches a complete stop, or after the nominal

stopping time has elapsed, the fail-open digital calipers are applied for a
short time to exercise them and the conveyor enters the stopped state.
The conveyor velocity and the brake pressure are constantly monitored
by the PLC during the stopping sequence. A level 5 fault is immediately
latched and the conveyor is stopped with the mechanical brake using the
pressure dump circuit if any of the following conditions is detected:
• a high brake pressure is detected (plugged emergency orifice)
• a confirmed very high overspeed condition is detected

(mechanical overspeed switch triggered and 120% overspeed
detected from the tachometers)
• The velocity of the conveyor remains over 105% for more than
10 seconds (sustained overspeed condition level 2)
7.10.4 Mechanical Brake Pressure Dump Stop (level 5)
This braking mode is entered as a final step if a level 5 malfunction has

been detected by the PLC.
Upon detection of a level 5 malfunction, all the digital calipers are

applied, including the fail-open calipers, the brake hydraulic pump is
stopped, the emergency valve is opened, and the brake dump valve is
opened.
This results in the fast application of all the available brake torque.
The AFD drives start command is immediately released. If a Profibus

failure has been detected, or if selected AFD faults have been latched,
the hardwired AFD E-stop outputs are also turned off.
When the conveyor reaches a complete stop, or after the nominal

stopping time has elapsed, the conveyor enters the stopped state.

7.11 Stopped State Controls
15 minutes after entering the stopped state, the AFD pre-start command is
removed, thus opening the 3.15 kV breakers and stopping the drive cooling fans.
This delay is reduced to 1 minute in case of UPS line voltage failure to save
battery power.
On conveyors 120-CV-005 and 120-CV-006, the fail-open brake calipers are

released 15 seconds after the conveyor enters the stopped state. Note that the
active accumulator on the main brake hydraulic power pack and the spring
accumulator on the quick-apply module remain charged in the stopped state.

8 AFD DRIVES
Please refer to the appendix O for the drive control loop diagrams.
8.1 Normal Operation
All the AFD drive closed loop controls operate simultaneously through the
individual digital SIMADYN controls. A master and slave arrangement is
therefore not necessary. The “Pre-start”, "Start" and "Release Speed" commands
are generated and transmitted from the PLC of the conveyor station.
When a pre-start command is received by a drive, the drive gets ready for
operation (auxiliary drives on and line side inverter on), When the drive is ready,
the “drive ready for operation” signal is sent back to the PLC.
The PLC then sends a start command to the drive. When the start command is
received, the drive enables the motor side inverter and builds-up the motor
excitation. When the drive is ready, the “drive ready for torque control” signal is
sent back to the PLC.
The PLC then sends the torque pre-control setpoint (“WML”) to the drive. When
the torque pre-control setpoint is received, the drive slowly increases its actual
torque on a linear ramp. When the actual torque reaches the reference value, the
“drive engaged” signal is sent back to the PLC.
The PLC then releases the brake. When the brake is fully released, the PLC
sends the “release speed” command and the speed setpoint to the drive.
The drive then accelerates along a 40 seconds S-ramp generated by its internal
ramp-function generator with jerk limiter.
This procedure takes place automatically after the start command and the speed
setpoint have been received from the PLC.
The PLC can stop further motor acceleration at any speed by sending a speed
setpoint of "0" and removing the “release speed” command. In this case, the
drive automatically reduces its speed along the new ramp generated by the
internal S-ramp-function generator.
The drives can be operated in forward and reverse direction at creep speed
(approximately 0.5 m/s).
In order to achieve the same speed at all pulleys independently of variations in

the pulley diameter, a differential speed controller is installed in each PLC. The
pulley speed value used by the differential speed controller is the average of the
actual speed of all motors operating on the pulley. Any speed deviation between
pulleys due to variation in the pulley diameter is automatically compensated by
the differential speed controller.
8.2 Chopper Braking
For dynamic braking of the conveyors in case of a power failure, a braking-

chopper and braking resistors are provided for each drive unit.
At the moment of power failure, the drive can be in one of the following operating
modes:

• Drive in generative mode
In the event of a power failure, the DC-link voltage increases due to the line
not being receptive to receive active power. When the DC-link voltage
reaches the chopper braking setpoint value, the conveyor will be stopped
dynamically via the chopper braking.
• Drive in generative mode
In the event of a power failure, the DC-link voltage decreases due to the line
not providing energy to the drive. The drive trips and the conveyor will be
stopped by the mechanical brake system.
• Drive in Zero-torque condition
In the event of a power failure, the line frequency is not maintained. The line
frequency is monitored. When this frequency drifts out of the allowable set
frequency range, the conveyor is stopped with the mechanical brake
Additionally, the line voltage is monitored as well (synchronising voltage). If the

deviation of the line voltage is larger than the set voltage tolerance allows, the
drive will be stopped.
When the chopper braking has been triggered the following steps are initiated:
• The line side inverter is blocked
• The chopper control supervises the link voltage
• The link voltage is kept constant
• Further operation of the motor side inverter continues until the maximum
operating time of the chopper has been reached (80 seconds)
• 2 sec before the maximum operating time of the chopper has been
reached, a signal “chopper operation is about at the end” is send to the
PLC. The PLC then applies the mechanical brake. After the brake has
been applied, the drive and the chopper are switched off by the PLC by
removing the start command
• the generated energy is dissipated in the braking resistors
The chopper control works as follows:
• Start level
The Chopper control is activated at a voltage level higher than 4700 Volts.
This level is only reached when the power supply is disturbed. The DC-link
voltage is controlled to a level of 4300 V.
This start level (4700 V) is called trigger level in the text that follows.
The DC-link trigger setpoint for the chopper controller is 4350 V.
• Chopper logic

When the trigger setpoint level is reached, the chopper is activated. After a
delay of approximately 100 ms, the line control is checked and automatically
acknowledged. In the event that the line power supply is healthy (detection of
synchronising voltage), the line control is reactivated, the active power from
the chopper is commutated back to the line control within 500 msec.
After the chopper control has been triggered, a memory flag is set. This
prevents the chopper being triggered for a 90 second period. The reason for
this delay is to avoid a triggered chopper dissipating braking energy into a
preheated braking resistor.
• Temperature supervision
The chopper control contains an I2 t protection for the power semiconductors

as well as an additional I2 t protection for the braking resistors.
After a chopper braking has been performed, a re-start of the conveyor
system is possible; however, depending on the actual value of the I2 t
protection, the chopper is disabled until the I2 t protection releases the
chopper control again. During this period that the chopper is disabled, the
conveyor is stopped with the mechanical brake in the event of a line power
failure.
The braking resistor is protected with two temperature switches, one above each
resistor stack. Both switches are installed to protect the resistor against high
temperature. The temperature switch is adjusted at 250°C. This is the estimated
air temperature at the sensor location when the resistor element temperature is
550°C.
8.3 Drive Failure
In the event of an inverter failure, the PLC checks whether continuing operation
is allowed. As each drive can provide 130% of the nominal torque for 30 minutes
(35 minutes for conveyor 120-CV-007), the PLC confirms continuation of
operation, if the load does not exceed this value for each motor. Otherwise the
system is automatically shut down by the mechanical braking system. In addition
to this, the defective inverter is disconnected from the supply system. The control
system memorises with which drive motors and inverters the drive is still in
operation.
The feeding of the conveyor system is reduced to a point where the torque of all
motors is reduced to nominal torque within 35 minutes.
In the event of a drive failure on conveyor CV-007, continuation of operation is

only possible if permitted by the load condition. The remaining drive can operate
for 35 minutes with 130% of nominal torque. If the drive develops a higher
torque, the AFD trips and the conveyor is stopped with the mechanical brake.
The AFD converters of the drives require forced air cooling; therefore each AFD
is equipped with 6 cooling fans (3 per inverter) on the SIMOVERT ML converter,
and one (1) on the braking chopper. The operation of the fans is monitored with
two air pressure switches per inverter and one air pressure switch per chopper.

In the event of one or more fan failures, the drive reacts as follows:
• One fan fails on one or both inverters Æ the controller sends an alarm to the
PLC; a restart is disabled.
• Two fans fail on one or both inverters Æ the drive trips, the conveyor is
stopped with the mechanical brake.
• The chopper fan fails during regenerative operation Æ the controller sends
an alarm to the PLC and the chopper braking is disabled. In the event that a
power failure follows, the AFD trips and the conveyor is stopped with the
mechanical brake. A restart is disabled.
• The chopper fan fails during chopper braking Æ the drive trips, the conveyor
is stopped with the mechanical brake.
8.4 Selection and De-selection of Drives
It is possible to select and de-select drives during operation ("on the fly"). This
can be done, if:
• the load conditions allow operation with one less drive
• An alarm is sent from the AFD, which does not require an immediate
shut down.
• The conditions for de-selecting a drive are the same as shown in the
paragraph "Drive-failure".
To reduce jerks in the conveyor belt, the switching of the torque is done smoothly
in a time of approximately 5 to 10 seconds.
8.5 Mechanical Conveyor Configuration
Conveyors 120-CV-005 and 120-CV-006 are equipped with two drive pulleys,
AT1 and AT2. Each of these drive pulleys is driven by two 2,500 kW drive
motors. As the conveyor system operates in a steep downhill mode, the drives
are located at the tail end of the conveyors. The head station is not equipped with
a drive. A relatively low, practically constant belt tension (100 kN) is applied to
the conveyor belt by a gravity tensioning weight, connected to the conveyor belt
via a series of return pulleys. The position of the gravity take-up weight changes
in vertical direction as the load on the conveyor belt changes, as well as during
acceleration and braking operation.
Contrary to most industrial drives which normally can be modeled with single
mass or dual mass loads, a drive for a conveyor belt has a closed loop control
circuit in which continuously distributed masses and springs are present. A drive
for a dual mass load has a sinusoidal characteristic with a fixed system
frequency response after an induced speed step change. This is, however, not
the case for a conveyor belt system, where initially unexpected speed step
fluctuations occur which, only after some time, gradually change to a sinusoidal
characteristic with a characteristic constant frequency. Results from simulation
models show that the duration of the period for these oscillations is
approximately 9 seconds due to the extreme length of these conveyors at 6000
meters. When this 6-km conveyor belt is loaded at full capacity, a speed or

torque step change travels along the upper belt at a speed of approximately 0.7
km/second. On the return belt, which is without load, a higher speed is reached.
8.6 Soft Start Ramp Generator
These difficult parameters in the closed loop control circuit of this system, which
can easily oscillate with low damping capability, lead to a control concept in
which torque step functions and bumps must be eliminated. The motor drive
torque, needed to accelerate the conveyor, must be applied on a linear ramp. In
addition to this, the speed setpoint value must be applied with a curve into the
linear acceleration phase as well as with a curve into the constant speed phase.
The soft – ramp generator (S-HLG) is included in the design concept for this
purpose. This ramp generator (S-HLG) converts an incoming stepped speed
setpoint change value into a speed setpoint value with curved characteristic v*.
This setpoint value v*, ensures that the acceleration, “amax,”, as well as the jerk,
“rmax”, are limited and will not exceed a predetermined maximum value. (the jerk,
“r max”, is the first derivative of the acceleration value). The jerk time, defined as
the time ramp in which the torque increases, is defined as the quotient of “amax”
and “rmax”. (“amax” / “rmax”). The acceleration can be adjusted independently for
acceleration and deceleration. (In this case 40 seconds starting time and a
braking time of 76 / 78 / 80 seconds).
The ramp generator S-HLG is equipped with two outputs, which are realized
through integrators:
• The output v*, which corresponds exactly with the input value after the
system oscillations have stabilized.
• The output for the acceleration value a*, which is required for the
generation of the acceleration torque.
An additional input serves the purpose of switching the braking retardation to a

different value.
8.7 Conveyor Speed Correction
The diameters of the drive pulleys will decrease as time passes due to wear. The
drive motor rpm therefore needs to be increased in order to maintain a constant
speed of the conveyor belt. A conveyor belt speed correction circuit serves to
meet this requirement. The output of the S-HLG is connected to a multiplier that
in turn receives an input from the conveyor belt speed correction circuit. This
signal is compiled as a set point from the output value of the S-HLG and actual
value of the conveyor speed, which is derived from an encoder driven by a non-
driven conveyor pulley. The controller for this purpose is an integrating controller
(realized in the S5 PLC) with a long integration time, in order to delay / eliminate
smaller fluctuations. This controller is designed with a limitation value set at a few
percentage points of the nominal value. In connection with the addition of the
value 1, a small adjustment range of the belt speed correction circuit is achieved.
The integrated value of this controller is stored before stopping the conveyor,
which ensures that this value will not change during braking or after the conveyor
has stopped. The integrator is released only after the conveyor rated speed is
reached again after a subsequent start.

8.8 Closed Loop Speed Controller
Each drive is equipped with a closed loop speed controller, however, the speed
controller of both drive motors on one pulley are in identical operating modes. For
example, the input (setpoint) value to the controller for the drive pulley AT1, is
“WN01” and the actual speed value “XNP1”, which is derived from the mean
average value of the actual speeds of the drive motors M11 and M12. The actual
values for the drive motor speeds are generated by digital encoders on the main
drive motors. This mean average actual value generation has the advantage of
stabilizing the closed loop control circuit in the event that the individual main drive
motors oscillate with respect to each other.
The speed controller is designed as a combination of a P-controller (proportional

controller) and a time constant module, both connected in parallel. The gain can
be adjusted individually and has a value of 10 to 20 in this parallel connection.
With this gain a static speed control in the range of 10 to 5% is achieved which
contributes to equal load sharing on both drive pulleys.
8.9 Advanced Load Control
As the speed controllers have proportional gain characteristics, load changes in

positive as well as in negative directions will cause the actual speed value to
deviate from the setpoint speed value. As these conditions are not acceptable for
the operation of these conveyors, a common Integrator gain for both speed
controllers is provided. This integrator is realized in the PLC S5 controller. The
output signals of the two speed controllers are connected to an integrator that
forms the known integrator portion of a PI controller. This integrator signal is now
connected as additional signal component to the inputs of all the torque
controllers controlling the drive motors. This input is adjusted continuously until
the output of the speed controllers is back to zero again.
Simultaneously, this integrator is utilized for advance load control. Similarly to the
conveyor speed correction control, the value of the advance load control is stored
before the conveyor stop command is released. This stored load value is now
available to the control systems before a restart command of the conveyor is
released. Contrary to other large drives in industry, the conveyor load conditions
do not change significantly during stopping of this conveyor.
8.10 Advanced Acceleration Control
Due to the sensitivity to oscillations of this conveyor system, and as a

consequence that controller gains need to be minimized, it is advantageous to
introduce an advance acceleration control in addition to the advance torque
control already described earlier. For this purpose, the acceleration setpoint a* is
used from the ramp generator S-HLG and multiplied with the mass. As the mass
of the conveyor system is a variable due to the variable loading conditions, the
mass is computed from the advance load control and the known friction of the
conveyor belt. This application is stored in a characteristic curve. The friction
value can be measured and computed from a no load test run of the conveyor.
8.11 Load Sharing Closed Loop Control
The load sharing on both drive pulleys can be different due to differences in the
diameters of the drive pulleys. The load sharing controller processes the
difference of the output values of the speed controllers in an integrating

controller, and connects the resulting inverted value as correction adjustments to
the inputs of the two speed setpoint values for the drive pulleys. The integrated
portion is also adjusted at a very slow rate and is generated in the PLC S5
controller. If, for example, the torque on pulley 1 is larger than on pulley 2, the
value to the multiplier in front of the speed controller for pulley 1 is slightly
reduced, resulting in a reduction of the torque applied to pulley 1. The same
applies for pulley 2 in inverted sense. Also in this case, the value of the
integrating controller is stored for future use before the stop / braking signal to
the drive is released.
Minimal speed differentials between the two drive pulleys can also occur due to
the elasticity slip of the belt as it wraps around the drive pulleys. Also these
differences in speed are corrected by the load sharing closed loop control circuits
8.12 Torque Closed Loop Control
The three torque set points which are derived from the speed controllers, from
the advance load control and from the advance acceleration control, are added
together and limited. The torque limitation for the drive motors is herewith
achieved in a simplified way. For this system the limitation is adjusted to 1.5
times the nominal value. From this point on the setpoint is connected to a ramp
generator with a short ramp time (approximately .5 to 1 second). This measure
will ensure that hard torque jerks / bumps on the drive motors are avoided due to
any possible irregularities in the closed loop controller circuits.
The bottom closed loop control circuit is the torque closed loop control circuit,
with which an arbitrary torque set point M* can be converted into a corresponding
motor torque independent of the motor speed. As both motors which are driving
one drive pulley, receive the same torque set point M*, both motors also apply
exactly the same torque to the pulley.
A multilevel-converter with TRANSVECTOR-control feeds the squirrel cage

induction motor at variable Voltage and Frequency, as needed for variable
speed.
8.13 Differential Speed Filtering
The danger that both drive motors will start oscillating with respect to each other
exists with the drive configuration (motors coupled to the drive pulley via angle
gear reducers, as used on this these conveyors). This is particularly the case
when the play in the gear reducers is more significant.
A differential speed filter has been included in the design to prevent these
oscillations. The difference between the two motor speed signals is connected to
the torque set points of each motor via a variable gain-inverting controller. This
insures that oscillations of this nature are filtered.
During operation of the conveyor system Los Pelambres it can occur that the
torque delivered by the motors connected to the drive pulleys, as demanded by
the control system, hovers around the value zero for extended periods of time
under certain load conditions. Operation under these “zero demand torque”
conditions can cause greasing problems as well as the tooth surfaces of the
gearwheels to knock against each other in alternate forward and reverse
directions during minor fluctuations of the demand torque. This operation can

have a detrimental effect on the gear reducers. Continuous changes between no
load to light load will cause bi-directional knocking of the gear teeth, which will
cause accelerated wear to the gear reducer.
In order to avoid this unfavorable operation, a control circuit has been developed
which ensures that the drives / gear reducers can not be operated under these
conditions.
This is achieved within the Simadyn D controller and PLC, by application of

torque’s to the two conveyor drive pulleys with opposite senses of direction.
A suitable circuit design has the feature that a relatively fast transition from a
negative to a positive torque value, and vice versa, is achieved on a unit drive
(ATR1, ATR2), during a conveyor torque demand, ( Manf ), transition. It is ensured
that a unit drive can not operate at zero torque for any extended period of time.
The realized solution, for an assumed continuously transient demand torque,

(Manf), of the conveyor drive from a negative to a positive torque value, is as
follows:
As also in the forgoing solution, the unit drive torque’s on the drive pulleys ATR1
and ATR2, have the same sense of direction for a conveyor drive demand torque,
(Manf) above a given minimum demand torque, (delta Manf).
When the conveyor demand torque, “Manf”, approaches the zero line by a value
“delta Manf”, an additional torque, delta “Mversp”, is added to the current drive
torque on ATR1 such that the resultant torque will cross the zero line.
Simultaneously, a torque “delta Mversp” of the same magnitude but with opposite
sense of direction is added to the torque on ATR2. These two torque additions, to
ATR1 and ATR2 respectively, herewith cancel each other on the current
conveyor torque ( Manf ). The application of the torque addition “delta Mversp” is not
realized as a step function, but is applied on a ramp via a ramp generator, (with a
ramp time of approximately 5 seconds), in order to avoid oscillations in the
system.
The magnitude of “delta Mversp” is 3 to 4 times the value of “delta Manf”.
It is important that the comparator circuits, which detect the conveyor demand
torque, “Manf”, approaching the zero torque line, have a hysteresis. This
hysteresis prevents frequent switching of this control during minimal demand
torque variation transients. The load torque (load integrator) is used as the
“conveyor demand torque” value “Manf”. The zero torque suppression, counter
torque control system, is released only during stationary operation. This means
that only after the conveyor has accelerated to rated speed, and after the closed
loop control system for the load sharing has stabilized, is the zero torque
suppression control released.
Should the zero torque situation occur during startup of the conveyor drive, this
zero torque condition is allowed.

9 MECHANICAL BRAKE
All the overland conveyors are fitted with low speed, mechanical, disk brake systems
The mechanical brakes are used as a backup to the AFD drives to bring the conveyors to
a controlled stop in case of AFD, motor, or UPS power failure, or whenever a malfunction
of level 3, 4 or 5 is detected. They are also used to park the conveyors at the end of each
stopping cycle.
Each brake system consists of a central power pack, of several low speed disks with two
calipers per disk, and of several hydraulic modules. The brake disks are mounted on the
conveyor drive pulleys and on one bend pulley at the conveyor tail stations.
Conveyors 120-CV-005 and 120-CV-006 are equipped with six low speed disks (two on
each drive pulley and two on the bend pulley), with two quick-set modules located near
the primary and secondary drive pulleys, and with one quick-apply module located near
the tertiary bend pulley.
Conveyor 120-CV-007 is of a similar design, but is only equipped with three low-speed
disks (one on each pulley) and with two quick-set modules located near the primary and
secondary drive pulleys.
The brake systems include both digital and analog controls. Several calipers on each
system are controlled with simple on/off valves (digital calipers), while the remaining
calipers are controlled from a proportional pressure control valve (proportional calipers).
This combined design was selected to decrease the response time of the brake while
Conveyors 120-CV-005 and 120-CV-006 are equipped with one proportional caliper and
one digital caliper on each disk. All the proportional calipers are of a fail-safe design
(spring applied, hydraulically released). All the digital calipers on the primary and
secondary drive pulleys disks are also of a fail-safe design. The digital calipers on the
tertiary bend pulley disks are of a fail-open design (pressure applied). This was done to
decrease the peak tension in the belt in case of UPS power failure while providing back-
up braking capacity under PLC control.
Conveyor 120-CV-007 is equipped with one proportional caliper and one digital caliper on
the primary and secondary drive pulleys disks, and with two proportional calipers on the
tertiary bend pulley disk. All the calipers are of a fail-safe design.
On all conveyors, the brake instrumentation is powered by a UPS to maintain control of

the system in case of AC power failure.
When a mechanical braking cycle is initiated, the mechanical brake is applied at

a preset torque calculated from the running motor torque. A number of digital
calipers are applied immediately, based on the required torque, and the
proportional calipers are applied with the proportional control circuit (level 3).
In the event of failure of the brake proportional control circuit, or whenever the
conveyor emergency circuit is tripped, the proportional calipers are applied with
an emergency circuit that provides a preset torque control independent of the
PLC (level 4).

In the event of failure of the brake emergency control circuit, the proportional
calipers are applied with a second emergency circuit that applies maximum brake
torque instantly (level 5).
A complete description of the various brake control sequences is provided in

section 7.
Each conveyor is equipped with a fail-safe emergency circuit. This circuit

is independent of the PLC and is automatically triggered in case of UPS
failure, overspeed detected by the electronic overspeed switches, or PLC
failure detected by the watchdog timer.
The emergency circuit is hardwired into the mechanical brake

emergency circuit and the AFD drives E-stop inputs. When the
emergency circuit is triggered, the AFD drives are immediately tripped
and the brake is applied with the first emergency circuit (level 4). All the
fail-safe digital calipers are immediately applied, and the proportional
calipers are applied on a preset mechanical pressure curve independent
of the PLC.
On conveyors 120-CV-005 and 120-CV-006, two of the digital calipers

are of a fail-open design and do not apply when the emergency circuit is
triggered. On these conveyors, only 83% of the available brake torque is
applied during an emergency brake stop.
All the available brake torque is applied during an emergency brake stop
on conveyor 120-CV-007.
The emergency circuit is shown in appendix N.
9.1.2 Disc Temperature Monitoring
All the energy produced by the mechanical brake during a conveyor stop
is dissipated in the brake discs. Consequently, the brake discs can
become very hot. This is especially true following emergency stops from
high overspeed.
Under normal conditions, no waiting time is required following a

mechanical brake stop before the conveyor can be started again.
However, under abnormal conditions, up to 2 hours may be required to
cool the discs before the conveyor can be started again.
To prevent a conveyor start when the discs are too hot without imposing
unnecessary restriction on the minimum time between conveyor starts,
each brake disk is equipped with an infrared temperature detector.
The temperature of all the discs is checked prior to every conveyor start,
and the start sequence is blocked if the temperature of any disc is above
the start permissive limit.
Each brake system is equipped with a three-position mode selector

switch (MSS). The MSS is used for software mode selection only and is

not hardwired to the brake system. The mode of operation for the brake
is selected by the PLC according the following combinations:

REMOTE-AUTO I - - -
REMOTE-AUTO NI - REMOTE -
MAINTENANCE NI - LOCAL STOPPED
LOCKED OFF - - STOPPED
The maintenance mode provides direct control of the mechanical brake

system from local control panels located in the field. No interlocks are
maintained in this mode. This mode is provided to help with hydraulic
system maintenance and to help with the commissioning of the system.
This mode can only be entered when the conveyor is stopped. Each
local panel is fitted with a light to indicate when the maintenance mode is
active.
For safety reasons, the mechanical brake should never be released on a

loaded conveyor. Consequently, this mode can only be selected after an
empty-stop sequence has been completed and flagged in the PLC. For
emergency cases, this interlock can be overridden from the maintenance
workstation. However, if load is detected while in the brake maintenance
mode, indicated by any belt motion while releasing the brake, the brake
is immediately reapplied and the mode aborted.
In maintenance mode, each brake system is operated from local control

panels located at the brake hydraulics cabinet and at each quick-set
module.
The following controls are provided from the hydraulic cabinet panels:
• Select main hydraulic pump

• Start/stop main hydraulic pump(s)
• Increase hydraulic pressure (proportional calipers)
• Decrease hydraulic pressure (proportional calipers)
• Fully release brake (bypass valve, proportional calipers)
• Exercise quickset function (proportional calipers)
• Apply emergency brake
The following controls are provided from each quick-set and quick-apply
module:
• Release brake (Digital calipers)

• Apply brake (Digital calipers)
The mechanical brake system used on all the conveyors consist of several low
speed steel disks fitted with two calipers each, of one central hydraulic power
pack, and of several quick-set and quick-apply modules located close to the
brake disks.
The brake disks are mounted on the conveyor drive pulleys and on one bend
pulley at the conveyor tail stations. The disks are installed on the low speed side

of the motor reducers (drive pulleys), or directly on the pulley shaft (bend
pulleys).
The brake calipers are of the clamshell design and use a dual spring/piston
assembly per caliper. Both fail-safe and fail-open calipers are used.
On fail-safe calipers, the braking force is obtained from springs that push the
brake pads against the disk. The caliper is released by applying hydraulic
pressure to the piston, therefore decreasing the clamping force. When fully
released, the pistons retract and the pads lift free of the disk.
On fail-open calipers, the braking force is obtained by applying hydraulic

pressure to a piston that pushes the brake pads against the disk. The caliper is
released by releasing the hydraulic pressure.
The hydraulic power packs provide the working pressure for all calipers, and
include the proportional control and emergency components for the proportional
calipers.
The control components for the fail-safe digital calipers are located in the quick-
set modules. One quick-set module is used for each pulley fitted with fail-safe
calipers (primary and secondary drive pulleys on all conveyors).
The control components for the fail-open digital calipers are located in the quick-
apply modules. One quick-apply module is used for each pulley fitted with fail-
open calipers (tertiary bend pulley on conveyors 120-CV-005 and 120-CV-006).
A simplified hydraulic schematic for the brake system is provided in appendix P.

This drawing is only intended to provide a functional description of the brake
system, and only shows the components used for control purpose.
The complete set of hydraulic drawings is also provided in appendix P, together

with a drawing showing the various types of caliper and their location for each
conveyor.
9.3 Hydraulic Power Packs
A single hydraulic power pack is used for each conveyor. Each power pack is
composed of one large cabinet located close to the conveyor tail station. The
electrical components are located inside a smaller electrical enclosure mounted
to the side of the hydraulic cabinet.
All the hydraulic components in each power pack are mounted on two manifolds
inside the main cabinet. The pressure generation and the proportional control
components are mounted on one hydraulic manifold. The quickset components,
the emergency components, and the dump components are mounted on a
separate manifold.
Each power pack is equipped with redundant (standby) components to allow

continuous operation in case of component failure. The switching from the main
to the standby components is controlled with manual valves located inside the
hydraulic cabinet. The valves are fitted with position switches to provide selection
status to the PLC.

The hydraulic components can be classified into six categories:
• Pressure generation (main and standby)

• Proportional pressure control (main and standby)
• Quickset pressure control
• Emergency pressure control
• Dump pressure control
• Quick-set Modules
9.3.1 Pressure Generation
This category includes the main pump/motor assembly, the standby

pump/motor assembly, pressure relief valve PRB, a filter assembly,
manual valves MVA and MVB, two accumulators, two pressure gauges,
pressure switches PS1A and PS1B, and manual bleed valves BVA and
BVB.
The active pump is selected by the PLC based on alarm conditions and
operator commands. If a pump failure is detected while the conveyor is
running, the PLC automatically switches to the remaining pump. If both
pumps are faulty, a dual pump fault is latched and the conveyor is
stopped using the AFD drives.
Pressure relief valve PRB is used to protect the pumps from excessive
pressure.
The filter assembly is equipped with two filters. The active filter is
selected with manual valve MVF.
The active accumulator and the active proportional control components

are selected with manual valves MVA and MVB. Both valves are fitted
with position switches to provide selection status to the PLC. Both valves
automatically purge the corresponding accumulator when turned off. This
was done to allow maintenance to be performed on the inactive side
while the conveyor is running. The PLC constantly checks which side is
active and keeps all inactive components turned off. Only one side can
be active while the conveyor is running. Any abnormal valve condition
results in a conveyor shutdown using the AFD drives
Pressure switches PS1A and PS1B are used to control the active pump
in order to maintain the corresponding accumulator pressure. The
accumulators are sized to minimize pump cycling and to provide enough
fluid reserve to complete a full controlled stop in case of pump or AC
power failure.
Several check valves are used to direct the flow and isolate the various
part of the circuit. Each digital caliper set and the proportional calipers
are similarly isolated from each other. Consequently, a catastrophic loss
of pressure at any caliper, or on the main accumulator, would not result
in a loss of pressure at all calipers.
9.3.2 Proportional Pressure Control
This category includes the main and the standby pressure control
components for the proportional calipers as well as several common

components. Both the main and the standby systems are equipped with
a pressure control valve.
The main components include the main pressure control valve and its
associated pressure regulator, isolation valves SV1A and SV2A, and full
release valve SV3A.
The standby components include the standby pressure control valve and
its associated pressure regulator, isolation valves SV1B and SV2B, and
full release valve SV3B.
The common components include pressure switch PS3, pressure

transducer PT1, and the shuttle valve.
The proportional pressure control components are used to control the

proportional caliper pressure during brake release and level 3 shutdown
of the conveyor. This circuit is the normal mean of controlling the
proportional caliper pressure.
Each pressure control valve, in conjunction with its electronic amplifier,

controls the pressure at its actuator port as a percentage of the pressure
at its pressure port. The valves are internally compensated to provide a
linear pressure change in response to a control signal. The control signal
is changed by the PLC according to the required brake torque.
Solenoid valve SV3A (or SV3B) is used to bypass the pressure control
valve and apply the accumulator pressure directly to the proportional
caliper line during running conditions. This insures full release of the
brake calipers and minimizes the duty on the pressure control valves.
Solenoid valves SV1A and SV2A (or SV1B/SV2B) are used to isolate the
pressure control valve from the proportional caliper line during full
release and emergency conditions.
The shuttle valve automatically connects the active (pressurized) side to

the proportional caliper line.
Pressure switch PS3 is used to detect minimum released pressure. It is

set to open on decreasing pressure. When closed, it indicates that there
is sufficient pressure at the proportional calipers to keep them fully open.
Pressure transducer PT1 is used by the PLC to confirm the action of the
pressure control valve and to check the pressure decay during
emergency braking.
9.3.3 Quickset circuit
This category includes solenoid valve SVE2 and pressure relief valve
SQV2.
The quickset pressure control is used to speed up the pressure drop on

the proportional calipers when a very fast application of the brake torque
is required (fully loaded conveyor).
The quickset function is initiated by turning solenoid valve SVE2 on

(open) for a short time at the beginning of the braking cycle.

The proportional calipers then discharge very fast into the quickset
circuit, bringing the pressure down to the relief valve preset pressure.
The relief valve is normally preset just below the brake contact pressure.
After the pressure has dropped, solenoid valve SVE2 is closed again and
the pressure control valve takes over the pressure control.
This category includes solenoid valve SVE1, pressure relief valve SQV1,
the emergency accumulator and the emergency orifices. Valve SVE1 is
normally open and is connected to the conveyor emergency circuit
The emergency pressure control components provide a preset pressure

control of the proportional calipers independent of the control system
(level 4).
The emergency control is initiated by turning solenoid valve SVE1 off

(open).
The proportional calipers then discharge very fast into the emergency
circuit, bringing the pressure down to approximately 50%. After this initial
drop in pressure, the emergency accumulator discharges slowly trough
the emergency orifices, bringing the proportional calipers pressure to
zero in about 10 seconds.
Two emergency orifices are used. The first one is a fixed orifice with a
bleed time of approximately 20 seconds. The second orifice is adjustable
and should be set for a combined bleed time of 10 seconds. This was
done to avoid the possibility of accidental closure of the adjustable
orifice, which would result in the loss of the emergency circuit.
The design preset pressure ramp for the emergency circuit is shown in
appendix N.
9.3.5 Dump Circuit
This category includes only one component, namely solenoid valve

SVE3.
The dump pressure control is used to provide a fast decrease of the

proportional caliper pressure to 0 PSI, resulting in the immediate
application of maximum torque (level 5).
The dump control is initiated by turning solenoid valves SVE3 on (open).
The proportional calipers then discharge very fast into the dump circuit,
bringing their pressure down to zero in less than 1 second.
9.3.6 Quick-Set Modules
All the control components for the fail-safe digital calipers are mounted
on manifolds located inside the quick-set modules. One quick-set module
is used for the primary drive pulley and one for the secondary drive
pulley on all conveyors. The modules are located next to the pulley.

The same quick-set modules are used on the primary and the secondary
drive pulleys. For simplicity, only the primary module component names
are used in the following description.
The control components for each quick-set module includes three

solenoid valves (SVSP1, SVSP2, and SVRP), one pressure switch
(PSP), and one spring accumulator (ADP).
Solenoid valve SVRP is used to apply the main accumulator hydraulic

pressure on the calipers and release the brake.
Solenoid valves SVSP1 and SVSP2 are used to release the hydraulic
pressure on the caliper and apply the brake. Two valves are used for
redundancy.
Solenoid valve SVSP1 is normally open and is connected to the

conveyor emergency circuit. All the other solenoid valves are normally
closed and are not connected to the conveyor emergency circuit.
The spring accumulator ADP is used to speed up the pressure drop on

the digital calipers by eliminating the return line back pressure.
The pressure switch PSP is used to detect low released pressure. It is

set to open on decreasing pressure. When closed, it indicates that there
is sufficient pressure at the calipers to keep them fully open.
9.3.7 Quick-Apply Modules
All the control components for the fail-open digital calipers are mounted
on manifolds located inside the quick-apply modules. One quick-apply
module is used on conveyors 120-CV-005 and 120-CV-006. It is located
next to the tertiary bend pulley.
The control components for each quick-apply module includes one check
valve (CVB1), one spring accumulator (ACQA), three solenoid valves
(SVB1, SVB2, and SVB3), and one pressure switch (PSQA).
When the pump is started on the main hydraulic power pack, the spring
accumulator ACQA is automatically charged through check valve CVB1.
This check valve insures that accumulator ACQA stays pressurized even
in case of UPS power or main pack pump failure.
Solenoid valve SVB3 is used to release the hydraulic pressure on the

calipers and release the brake.
Solenoid valves SVB1 and SVB2 are used to apply the hydraulic
pressure from accumulator ACQA on the calipers and apply the brake.
Two valves are used for redundancy.
Solenoid valve SVB3 is normally open. All the other solenoid valves are
normally closed. None of the solenoid valves are connected to the
conveyor emergency circuit.
The pressure switch PSQA is used to detect high released pressure. It is

set to open on increasing pressure. When closed, it indicates that the
pressure is sufficiently low to keep the calipers fully open.

10 REDUCERS
In the original system configuration, conveyors 120-CV-005 and 120-CV-006 were only
equipped with three drives each. These drives, as well as both drives on conveyor 120-
CV-007, are fitted with Keller reducers.
An additional drive was installed on conveyors 120-CV-005 and 120-CV-006 during the
system upgrade performed in 2006. The new drives are fitted with Flender reducers.
The Keller and Flender reducers differ in several ways, the most important one being the
type of lubrication used. The Keller units are splash lubricated while the Flender units are
forced lubricated.
In addition, the Keller unit has a reduction ratio of 22.423 and the Flender units have a
reduction ratio of 22.432. While the difference amounts only to 0.04%, it is large enough
to require compensation in the drive control logic to enable proper load sharing between
the drives on the same shaft. This compensation is performed in the drive control block of
the PLC.
The following paragraphs provide a basic description of the control logic required for each
type of reducer.
All the reducers are equipped with digital vibration sensors, analog oil
temperature sensors, analog bearing temperature sensors, and digital oil level
sensors. These sensors are monitored by the PLC’s.
The vibration sensors are used for monitoring only and do not result in a
conveyor shutdown when triggered.
All the temperature sensors are monitored for high and very high levels.
Detection of a very high temperature condition on any sensor results in an
immediate shutdown of the conveyor using the AFD drives (level 2).
10.2 Keller Reducers
The Keller reducers are splash lubricated and do not require a dedicated
lubrication system.
The reducers were initially installed without oil cooling systems, but were
retrofitted with coolers at a later date. The reducer cooling systems are controlled
by independent controllers and are not under PLC supervision.
10.3 Flender Reducers
The Flender reducers are forced lubricated and are equipped with dedicated
lubrication systems. Each lubrication system includes a hydraulic power pack, a
hydraulic pump, a heat exchanger, and a fan. In addition, each reducer is
equipped with an oil heater.
The lubrication systems are controlled by dedicated controllers provided by

Flender. These controllers are independent of the PLC’s but are connected to the
PLC’s via Profibus links and are supervised and monitored by the PLC’s. In
addition, several hardwired connections are used between the PLC’s and the
controllers to ensure a fail-safe operation.

The reducer oil heaters are controlled by the PLC’s and are automatically turned
on when the oil temperature falls too low.
The lubrication system is automatically enabled by the PLC when a conveyor

start command is received from the operator. If the reducer oil temperature is too
low to safely start the hydraulic pump, a start permissive alarm is latched and the
conveyor is blocked from starting until the oil temperature has reached a safe
level.
The lubrication system is automatically stopped by the PLC a short time after the
conveyor reaches a complete stop. If the reducer oil temperature is high at the
time of the shutdown, the lubrication system is kept on to enable the oil cooler to
operate. The lubrication system is automatically stopped by the PLC when the oil
temperature has returned to normal.
The reducer oil temperature is monitored by the PLC using both the temperature
sensor connected to the PLC and the feedback received from the lubrication
system controller via the Profibus link.
Any fault on a reducer lubrication system results in an immediate shutdown of the

conveyor using the AFD drives (level 2).
Each lubrication system is equipped with a local panel which includes a

maintenance mode selector for the hydraulic pump. The mode selection is
independent of the PLC.
If an operator start command is received while a lubrication system is in

maintenance mode, a mode interlock alarm is latched and the conveyor is
blocked from starting until the lubrication system has been switched out of
maintenance mode.
However, if a lubrication system is switched to maintenance mode while the

conveyor is running, an alarm is latched but the conveyor is not stopped.

11 TAKE-UP WINCHES
The belt tension of each conveyor is controlled by a gravity take-up located at the head
station. All the conveyors are equipped with a take-up winch used to position the
counterweight.
On conveyors 120-CV-005 and 120-CV-006, the winch is controlled by the PLC to

position the counterweight prior to start-up and to maintain its position within a given
range while the conveyor is running. This was done to reduce the required counterweight
travel and minimize manual adjustments due to slow belt and splice stretching and
temperature fluctuations.
Each take-up system is equipped with one electric winch. The winch motor is
fitted with an internal brake. The winch is used to position the counterweight.
The take-up carriage and the take-up counterweight are equipped with over-
travel position switches. These switches are connected to the PLC and are not
hardwired to the winch motors.
All carriage and counterweight over-travel faults result in an immediate shutdown

of the conveyor using the AFD drives.
Winch motor faults do not result in a conveyor shutdown if the counterweight is

positioned in its normal operating range.
All the take-up systems are equipped with a latching emergency stop switch. This
switch is hardwired to the winch motor contactor. Actuation of this switch stops
the winch motor and initiates a conveyor shutdown using the AFD drives.
On conveyors 120-CV-005 and 120-CV-006, the counterweights are equipped

with one analog position sensor. This sensor is used by the PLC to monitor the
counterweight position.
On conveyor 120-CV-007, the counterweight is equipped with end-of-travel

switches. These switches are used for monitoring and alarming only. End-of-
travel alarms do not result in a conveyor shutdown.
11.2 Winch Control (120-CV-005 and 120-CV-006 only)
Several control modes have been defined for the take-up winch. The control
mode is selected from a mode selector switch (MSS) located in the field.
The MSS switch is used for software mode selection only and is not hardwired to
the equipment. The operating mode for the take-up winch is selected by the PLC

REMOTE-AUTO - - REMOTE -
LOCAL-MANUAL - - LOCAL -
MAINTENANCE - - LOCAL STOPPED
DISABLED - - OFF -
The winch is normally operated in remote-automatic mode.

In this mode the winch is controlled automatically based on the

counterweight position.
When the conveyor is stopped or in the pre-starting state, the PLC

controls the winch to maintain the counterweight position within a preset
initial range. Proper position of the counterweight is a start permissive for
the conveyor.
When the conveyor is running, the PLC controls the winch to maintain
the counterweight position within a preset operating range.
The winch is not operated during conveyor startup or shutdown.
The local-manual mode provides control of the winch from push buttons
located in the field.
This mode provides the ability to position the counterweight from the field
while the conveyor is running. All interlocks are kept active.
• Move counterweight up
• Move counterweight down
The counterweight motion is limited by the PLC to keep the

counterweight within the preset operating range.
The maintenance mode also provides manual control of the winch from
push buttons located in the field.
This mode provides the ability to move the counterweight to any position
for maintenance purposes. This mode can only be entered if the
conveyor is stopped and conveyor starts are prevented in this mode.
All interlocks are disabled in this mode except the over-travel position
switches.
The counterweight is automatically moved back to its preset initial range

when exiting from the maintenance mode.

The disabled mode is selected by turning the take-up mode selection

switch to the OFF position. In this mode, the winch motor is blocked
against starting.
This mode provides the ability to disable the winch motion for operational
purposes.
The conveyor can be still operated with the winch disabled as long as the
counterweight position is within its operating range.

12 SHUTTLE
The head of conveyor 120-CV-007 is equipped with a moveable shuttle.
The shuttle motion is controlled by an AFD drive with a maximum speed of 10 meters per
minute. The shuttle position is monitored with an absolute encoder.
The shuttle position is continuously variable under load, but the discharge positions are
limited due to interference with structural beams. The shuttle can be moved over the
structural beams while material is flowing, but cannot be parked over them.
The shuttle currently travels over a 62 meters span. Six discharge positions are used to
form an elongated stockpile. The shuttle travel will be extended to 94 meters in the future,
with additional discharge positions added as required.
12.1 General Interlocks
The shuttle is equipped with end-of-travel and over-travel position switches.

These switches are connected to the PLC and are not hardwired to the
positioning motor.
Shuttle position faults (over-travel, and out of position) result in an immediate

shutdown of the overland conveyor system.
Shuttle motor faults and shuttle jam alarms do not result in a conveyor shutdown
if the shuttle is located in a valid position.
The shuttle is equipped with two digital stockpile level switches used for blocked
chute detection. A high stockpile level detected by one of these switch results in
an immediate shutdown of the overland conveyor system.
The shuttle is also equipped with two analog stockpile level sensors. These
sensors are located on the shuttle carriage. The two sensors are constantly
compared to each other and the higher of the two reading is always used for
control. An alarm is latched whenever the two readings differ by more than 10%
for more than 10 seconds, and the belt feeders are automatically stopped if both
sensors are found defective.
The stockpile level sensors are monitored in all modes of operation. The high
level setpoint is adjusted to provide enough room on the stockpile to empty the
conveyor system. When a stockpile full alarm is latched, a warning is displayed
on the operator screens and the belt feeders are automatically stopped.
The stockpile to belt feeders interlocks are done trough a hardwired interlock
between PLC 7 and PLC 5 (relayed by PLC 6).
The shuttle is equipped with several latching emergency stop switches and
several pull cord switches. These switches are hardwired to the shuttle motor
contactor. Actuation of any of these switches stops the shuttle motion and the
conveyor system.
In addition, actuation of conveyor 120-CV-007 head emergency switch or of any

of the conveyor pull cord switches in the shuttle area also stops the shuttle
motion.

Finally, the shuttle is equipped with a local control panel fitted with a stop push
button. Actuation of this switch stops the shuttle motion and disables the
automatic motion, but does not result in a conveyor shutdown if the shuttle is
located in a valid position. This push button is enabled in all modes of operation.
12.2 Shuttle Control
Several control modes have been defined for the shuttle. The control mode is
selected from the maintenance workstation (OP37) and from a mode selector
switch (MSS) located in the field. Access to the various modes from the
maintenance workstation is passwords protected.
The MSS switch is used for software mode selection only and is not hardwired to
the equipment. The operating mode for the shuttle is selected by the PLC
CONTROL MODE OP37 MSS CONVEYOR

REMOTE-AUTO REMOTE REMOTE -
LOCAL-AUTO LOCAL REMOTE -
LOCAL-MANUAL - LOCAL -
MAINTENANCE - LOCAL STOPPED
DISABLED - OFF -
The shuttle is normally operated in automatic mode (remote or local).
In this mode the shuttle is controlled automatically based on several

operator parameters. Only fully interlocked automatic motion of the
shuttle is available in this mode.
The operator can remotely select the shuttle position control mode,
enable and disable the shuttle automatic motion, and enter the position
control parameters. In addition, several local operator commands are
available from the shuttle field control panel. These commands are
described in chapter 11.2.3 (local-manual mode).
Two position control modes are available to the operator:
• Fixed position
• Automatic motion between selected positions
In the fixed position mode, the shuttle is operated in a fixed position

selected by the operator. The operator can change the selected position
at any time, but the shuttle does not move automatically in case of high
stockpile. When a high stockpile condition is detected, a warning is
displayed on the operator screens, a stockpile full alarm is latched, and
the belt feeders are stopped.
In the automatic mode, the shuttle is operated between two end positions
selected by the operator. The shuttle remains in the first position for a
preset time (initially 5 minutes). It is then automatically moved from
position to position at the same preset time interval. When the last
position has been reached, the shuttle is automatically moved back to
the first position and the cycle is started again. If a high stockpile level is

detected in any position, the feeders are automatically stopped but the
automatic cycle continues.
In both control modes, automatic shuttle motion is only active when

enabled by the operator (i.e. changing the position setpoint with the
automatic motion disabled does not result in a shuttle position change).
Disabling the automatic motion stops the automatic update of the
position setpoint, but does not the stop the shuttle motion if a move
sequence is already active. Any active move sequence will first be
completed.
Before any automatic shuttle motion, the shuttle warning horn and
beacon are turned on for 5 seconds. They are then kept on until the new
position has been reached.
This mode is almost exactly similar to the remote-automatic mode except

that the operator controls and parameters are entered from the
maintenance workstation.
The local-manual mode provides control of the shuttle from push buttons
located in the field.
This mode provides the ability to position the shuttle from the field while
keeping all interlocks active.
• Move shuttle forward one position

• Move shuttle reverse one position
• Stop shuttle motion
• Reset shuttle system alarms
The local stop push button is enabled in all modes of operation.

Actuation of this switch immediately stops the shuttle motion and
disables the automatic motion. An operator reset is required before any
automatic motion can be resumed.
Shuttle motion can be resumed by first pushing the local reset button,
then pushing the forward or the reverse push button. In both automatic
modes, only the push button pointing toward the active operator position
setpoint is enabled.
The shuttle warning horn and beacon are turned on for 5 seconds before
any shuttle motion. They are then kept on until the new position has
been reached.
If a high stockpile level is detected, or if the shuttle is moved to a full

stockpile position, a warning is displayed on the operator screen and a
stockpile full alarm is latched.

The maintenance mode provides manual control of the shuttle from push
buttons located in the field.
This mode provides the ability to move the shuttle to any location and
commissioning of the shuttle.
All internal shuttle interlocks are maintained in this mode. However, all
external interlocks are disabled.
This mode can only be selected if conveyor 120-CV-007 is stopped and

conveyor 120-CV-007 cannot be started when this mode is selected.
• Start shuttle motion forward

• Start shuttle motion reverse
• Stop shuttle motion
• Reset shuttle system alarms
In this mode, the shuttle can be positioned at any location between the
end-of-travel position switches. The shuttle warning horn and beacon are
turned on for 5 seconds before the shuttle motion is initiated. They are
then kept on as long as the shuttle is moving.
The shuttle is stopped automatically whenever one of the end-of-travel

switches is tripped. The shuttle can then be moved normally in the
direction pointing away from the corresponding end of travel switch, but
cannot be moved further toward the corresponding end of travel switch.
The shuttle is prevented from moving in any direction whenever one of

the over-travel switches has been tripped. It is possible to override this
interlock by pushing and maintaining the push button pointing away
from the corresponding over-travel switch.
Automatic motion of the shuttle is automatically disabled when entering

the maintenance mode. Automatic shuttle motion can be re-enabled
locally after exiting the maintenance mode by pushing the forward or the
reverse push button. In both automatic modes, only the push button
pointing toward the active operator position setpoint will re-enable
automatic motion. A reset may be also required if any fault was latched
while in maintenance mode.
The disabled mode is selected by turning the shuttle mode selection

switch to the OFF position. In this mode, the shuttle remains in its
position and the positioning motors are blocked against starting.
This mode provides the ability to disable the shuttle motion for
operational purposes.
The conveying system can be still operated when the shuttle is disabled
as long as the shuttle is located in a valid position.

Automatic motion of the shuttle is automatically disabled when entering
the disabled mode. Automatic shuttle motion can be re-enabled locally
after exiting the disabled mode by pushing the forward or the reverse
push button. In both automatic modes, only the push button pointing
toward the active operator position setpoint will re-enable automatic
motion. A reset may be also required if any fault was latched while in
maintenance mode.
If a high stockpile level is detected, a warning is displayed on the

operator screen and a stockpile full alarm is latched.

13 AUXILIARY SYSTEMS
13.1 Dust Suppression Systems
Two different kinds of dust suppression systems are used in the conveying
system:
• Fogger systems (mix of water and air under pressure)

• Spray Water systems (water under pressure)
One fogger system is used at each conveyor loading station (feeder area and
transfer stations), and one spray water system is used at conveyor 120-CV-007
discharge station (shuttle area).
The dust suppression systems are constantly monitored by the PLC. Abnormal
conditions are alarmed and displayed on the operator screens. Dust suppression
alarms do not result in conveyors shutdown.
13.1.1 Fogger systems
Each fogger system is composed of one common power station, one air
compressor, and several local fogger stations (one per belt feeder and
one per transfer station).
The PLC controls the air compressors. The power station controls the
flow of water and air to all the fogger stations. Each station is equipped
with several control relays (heater, water flow and airflow), and several
monitoring devices (low air pressure and low water pressure).
Each fogger station controls its own spray. Fogger stations are equipped
with several control relays (water flow, airflow, and purge control) and
one mode selector switch. The fogger mode selector switch is hardwired
and independent of the PLC.
The foggers are normally operated in remote mode. In this mode, the
PLC automatically turns on each fogger spray when the corresponding
feeder/conveyor is in operation.
13.1.2 Spray systems
The spray system is equipped with several control relays, several

solenoid valves, several monitoring devices, and one mode selector
switch. The system mode selector switch is hardwired and independent
of the PLC.
In addition, an analog level sensor is used to detect the amount of ore on

the conveyor. This sensor is located near the head station of the
conveyor.
The spray system is normally operated in remote mode. In this mode, the
PLC automatically enables the spray system when conveyor 120-CV-007
is running, and adjusts the water flow based on the amount of ore
detected on the conveyor.
A local potentiometer is used to adjust the water flow in local mode.

13.2 AFD Houses
13.2.1 Air Conditioning Units
Several air conditioning units are used at each substation to cool the
AFD drive containers. Due to the large amount of heat dissipated by the
AFD drives, these air conditioning units are critical to the operation of the
system. Consequently, several standby units are also installed.
All the air conditioning units are constantly powered. However, only the
units required for operation are enabled.
In order to maintain the AFD drives stopping capability in case of line

failure, the air conditioning units are powered by the UPS systems.
In case of UPS line voltage failure, all the air conditioning units are
disabled one minute after the conveyor has reached a complete stop.
This is done to save battery power on the UPS.
All the air conditioning units are continuously monitored by the PLC.
The following tables show the number of units available, the number of
units required, and the number of standby units at each substation:
120-CV-005 AC Units
AFD House Available Units Required Units Standby Units
House 1 3 2 1
House 2 3 2 1
120-CV-006 AC Units
House 1 1 1
1 (Shared)
House 2 1 1
120-CV-007 AC Units
House 1 2 1 1
The standby units are automatically enabled by the PLC in case of failure
of one of the normal units.
When two units fail at the same time, the corresponding conveyor is
immediately stopped with the AFD drives (level 2).
The standby unit for conveyor 120-CV-006 is shared between the two
houses. A gate is used to direct the airflow into the required house. The

gate is operated by a solenoid and is controlled by the PLC. The gate
position is also monitored by the PLC.
Gate position faults do not result in a conveyor shutdown unless the

standby unit is required and the gate is jammed in the wrong position. In
such a case, the conveyor is immediately stopped with the AFD drives
(level 2).
In order to help maintain the correct temperature in the AFD drive

containers, all the container doors are fitted with position switches. An
alarm is shown on the operator screens whenever a door is kept open for
more than a few seconds. Keeping a door open for more than a few
minutes or opening two doors simultaneously in the same container
results in a shutdown of the corresponding conveyor with the AFD drives
(level 2).
13.2.2 Fire Detection System
Each AFD drive container and each high voltage container is equipped
with a fire detection system.
When a fire is detected in one of the AFD drive containers or in the high
voltage container, the main 23 kV breaker is immediately tripped, the
AFD drives are tripped, and the corresponding conveyor is stopped with
the mechanical brake (level 3).
13.2.3 Emergency Switches
Each AFD drive container and each high voltage container is equipped
with two latching emergency switches located inside and outside the
container next to the main door.
Those emergency switches are hardwired to the main 23 kV breaker.

Actuating one of those switches results in an immediate shutdown of the
corresponding conveyor using the AFD drives and the braking-choppers.
13.3 Miscellaneous Equipment
Substation 5 is equipped with a harmonic filter on the 23 kV line. This

filter is continuously monitored by PLC 5.
In the event of a harmonic filter failure, or whenever a high level of

harmonics is detected by the monitoring equipment, the complete
conveying system is stopped. All conveyors are stopped using their AFD
drives (level 2). This interlock is hardwired between the PLC’s
(Downstream Run Permissive Interlock).
In addition, each substation is equipped with auxiliary equipment,

including air supply fans, re-circulation fans, sump pumps, and a Grinell
fire detection system.
This equipment is controlled by the PLC but is not under operator

control. The equipment operation is shown on the operator graphic
screens.

14 PLC / NETWORKS
14.1 Redundant CPU
Each 155H PLC is equipped with two 948R CPU’s in a switched configuration.
This configuration offers central controller redundancy.
The two CPU are designated master and standby. All the I/O information is under
control of the master CPU, but is available to the standby CPU through the use of
special registers. All information used, received and issued from the master CPU
is therefore the same in the standby CPU. The transfer from master to standby
CPU is synchronized with the CPU’s scans. This synchronization procedure
ensures bumpless switching from master to standby controller at all times:
• The transfer does not affect the process output signals

• There is no loss of information from the local I/O racks
• There is no loss of information from the remote I/O racks
• There is no loss of information from the communication processors
• The user program processing is not affected
The PLC automatically switches from the master to the standby controller in the
following instances:
• Failure of the master CPU (internal fault or processor stopped)

• Unsuccessful initial error search of both sub-unit CPU’s
• First failure of a master controller’s IM314R (interface card between I/O
expansion units and the central controller) when the standby controller
has access to a larger number of IM314R interface module than the
master
• First failure of a master controller’s IM304R (interface card between the
two CPU’s) when the standby controller has access to a larger number of
IM314R interface module than the master
• First failure of a master controller’s I/O bus
• First failure of a switched I/O module
• User issued software request to transfer from master to standby
controller
• When more than 30 timeouts occur in redundant I/O bytes in the sub-unit
of the master within one PLC cycle.
Full indication of the CPU’s status and alarm condition for each PLC is available
on the operator graphics screens.
14.2 I/O Diagnostics
The health of each local I/O module is constantly monitored by the PLC.
Any module failure results in an immediate shutdown of the corresponding

conveyor and of all upstream conveyors. The type of stop used (level 2, 3 or 4)
depends on the faulty module location (brake I/O, drive I/O, etc.).
Full indication of each local I/O rack alarm condition is available on the operator
graphics screens.

14.3 Profibus Networks
Two local Profibus networks are used at each drive station. The first network is
used to connect the AFD drives Simadyn controllers to the PLC. The second
network is used to connect the PLC to the maintenance workstation, the local
operator interface terminal, and the remote I/O modules located in the drive
station and along the conveyor.
The Profibus network is a high speed field bus designed for cyclic communication
where I/O modules are distant from the PLC. It operates under a master slave
protocol similar to an RS-485 network and uses differential voltage signals over
single twisted pair wiring for high transmission rates and high noise immunity.
The Profibus port’s Baud rate is selectable from 9.6 kbit/s to 12 Mbit/s. A
maximum of 32 masters and 126 slaves can be configured on each Profibus
network.
16 remote I/O modules are used for PLC 5, 15 for PLC 6, and 5 for PLC 7. In all
the Profibus networks, the PLC is configured as the master and all the other
nodes as slaves.
All the Profibus network functions are controlled by the Profibus communication
processor. All the Profibus network configuration, programming, and diagnostic is
done by this processor independently of the PLC. Several diagnostic functions
are built in the communication processor and are available to the PLC. The
overview diagnostic function is used to check the status of the slave stations. The
master diagnostic function provides the status of the master station.
The health of each Profibus network is constantly monitored by the PLC.

However, the AFD drives controllers cannot detect a Profibus failure.
Consequently, several hard-wired interlocks are used between the PLC and the
AFD drives to insure safe shutdown of the conveyors in case of Profibus failure.
A Profibus communication failure on one of the remote I/O modules located

along a conveyor does not result in a conveyor trip. This is possible because the
corresponding inputs are used for diagnostic only, and was done to allow
continuous operation in case of remote I/O module fault. However, because of
the loss of warning horns, the corresponding conveyor is blocked from starting
(start permissive alarm).
A communication failure on any of the remaining remote I/O modules results in

an immediate shutdown of the corresponding conveyor and of all upstream
conveyors. The type of stop used (level 2, 3 or 4) depends on the location of the
fault.
When a Profibus failure is detected on a single drive, the PLC trips the faulty
drive using its E-stop output but the conveyor is not stopped provided that all the
other drives are operational and that the load on the conveyor would not result in
overloading of the remaining drives.
When a Profibus failure is detected on multiple drives, or when an AFD drive

does not respond to its normal stop commands, the PLC outputs are used to stop
the conveyor. In both cases, the PLC first tries to stop the AFD drives using the
normal-stop outputs. If the conveyor speed does not follow the expected stopping
ramp, the PLC then trips the AFD drives using the E-stop outputs and stops the
conveyor with the mechanical brake.

Full indication of each Profibus node status and alarm condition is available on
the operator graphics screens.
14.4 H1 Network
All the PLC’s and operator graphic stations are interconnected by an H1 network.
The H1 network information is carried between the substations and the operator
control rooms over a redundant fiber optic network (OTN network). The OTN
network is transparent to the PLC’s.
The H1/OTN network is only used for monitoring, diagnostics and operator
control. All conveyor to conveyor interlocks are hardwired between the PLC’s to
insure fail-safe operation under any conditions.
Siemens H1 network is a high speed Industrial Ethernet network operating at 10

Mbit/s under the CSMA/CD (carrier sense multiple access with collision
detection) access method standardized in IEEE 802.3. It uses a token ring
protocol working on the principle of Flying Master. As the token is passed from
station to station, the token holding station becomes the master. This enables
continuous network operation in case of station failure and allows for easy
detection of any configured station failure by all active stations on the same
network. This diagnostic function is built in the communication processor and
available to the PLC.
Each PLC is equipped with a CP1430 Ethernet H1 communication card plugged

in the PLC rack. All the H1 network functions are controlled by the
communication processor on this card. Each card has two 15-pin ports. The first
one is used for connecting to a programming device. The second one is the
Industrial Ethernet port. All the network configuration, programming, and
diagnostic for the H1 network is done on this card independently of the PLC.
However, basic network diagnostics are available in the PLC.
Each of the operator station is equipped with a CP1413 PC communication card

for connection to the H1 network.
Six short Ethernet H1 connections are used in the network. The first three are
used to connect the PLC’s to the main OTN network. The other three are used to
connect the operator stations to the OTN network.
The H1 network is used for monitoring, diagnostics and operator control only and
does not carry critical interlocking information. All critical interlocks are hardwired
between each PLC. This was done to enable safe operation of the complete
system in case of graphic station or network failure. A failure of the H1/OTN
network does not result in a conveyor shutdown.
Full indication of each H1 link status and alarm condition is available on the
operator graphics screens.

14.5 OTN Network
The Siemens Open Transport Network (OTN) is a proprietary high speed

transport network to which various type of communication equipment can be
connected (data, voice, telephone, video, etc.). The transport network operates
at 150 Mbit/s over an optical medium and uses a dual ring topology. The same
information is transported on both rings but in opposite direction. This topology
allows for automatic network re-configuration in case of faults.
5 OTN nodes are used in this project. Each node consists of a modular card
structure mounted in a rack. Various interface cards are used at each node for
the following equipment:
H1 network
RS-485 network (Modbus)
Video connection
Telephone connection
RS-232 communication
The OTN network is independent of the PLC’s and of the H1 network, and no
direct OTN status or diagnostic information is available to the PLC’s or the
operator stations. However, critical OTN failures are brought to the operator’s
attention through the failure of the corresponding H1 station.
14.6 RS-485 Networks
Two local RS-485 links are used in each substation. The first link is used to
connect the 23 kV monitoring relays to the PLC. The second link is used to
connect the 400V monitoring relays to the PLC. Those links are used for
monitoring purposes only.
RS485 networks are basic serial communication networks operating under a

master slave protocol. They use differential voltage signals over single twisted
pair wiring. The use of differential signals allows higher transmission rates and
ensures a higher degree of noise immunity than normal serial links (V.24 or
TTY).
Each PLC is equipped with a CP544 RS-485 communication card plugged in the
PLC rack. The CP544 communication processor is used for fast point-to-point
connections to programmable controller or equipment from other manufacturer
using standard protocols. All the RS-485 network functions are controlled by the
communication processor on the CP544 card. All the network configuration,
programming, and diagnostic for the RS-485 networks is done on this card
independently of the PLC. However, basic network diagnostics are available in
the PLC.
Each card has two independent communication ports. Each port’s Baud rate is
selectable from 300 bits/s to 76,800 bits/s. The first port is connected to the 23
kV power meter. The second port is connected to the 400 V power meter. Both
ports are set up as Masters.
The following information is monitored in both power meters:
• Amps
• Volts

• kW
• Power
• KVAR
• kWh
• KVARH
• Max kW (last 15 min)
The above information is available on the operator graphics screens. In addition,

full indication of each RS-485 link status and alarm condition is available on the
operator graphics screens.
14.7 PCS Modbus Link
The operator station in the crusher control room #1 is connected to the mine PCS
via an RS-485 link using the Modbus protocol. This link is only used for alarm
and status monitoring by the PCS system.
The operator station communicates to the PCS using the station’s RS-232 port
and an RS-232 to RS-485 converter. The operator station computer is set up as
a Slave and the PCS as a Master. All information available to the operator station
is also available to the PCS. This link is not monitored by the operator stations.

03/01/06
CRUSHER CRUSHER CONCENTRATOR
DATE CONTROL ROOM No.2 CONTROL ROOM No.1 CONTROL ROOM
To PCS
REV
U1
CHK
JLC
SHEET : 1/1
MATERIAL FLOW AND CONTROL
AREA 120 LAYOUT:
DWG: LSP-OVERVIEW-R4.VSD
CRUSHER CONCENTRATOR
COMM. ROOM COMM. ROOM
B B B
A A A
P5 P6 P7
JOB: 194
FE-008
LOS PELAMBRES PROJECT
FE-007
FE-006 TAIL STATION TAIL STATION TAIL STATION
GENERAL LAYOUT
CV-005 CV-006 CV-007

KRUPP - SIEMENS
FE-005
CV-005 (5,905 m, -536 m)
PHASE 2
CV-006 (5,281 m, -526 m)
CV-007 (1,467 m, -233 m)

B
A - Redundant PLC (S5 155H) SHUTTLE
P
CONVEYOR DYNAMICS, INC
- Ethernet Hub
- AFD Drive ( Simadyn D)
- Remote I/O Units (ET200) - Open Transpor Network (OTN)
- Fiber Pair
- Power Meter 4700 (23KV, 400V)
- Inustrial Ethernet (H1)
- Supervisory Computer (Win CC)

- Profibus
- Modbus
- Maintenance Workstation (OP 37)
- RS-485
- Local Operator Panel (OP7) - Hardwire Interlocks
This drawing is the property of Conveyor Dynamics Inc. It is loaned upon the express condition that it shall not be copied or reproduced in any manner, that it shall not be submitted to others for examination without
the consent of Conveyor Dynamics Inc., that it shall not be used in any other way detrimental to the interests of Conveyor Dynamics Inc. and that it shall be returned to Conveyor Dynamics Inc. upon demand.
Coarse Ore Conveyor 120-CV-005
50
-50
-100
-150
-200
-250
-300
-350
-400
-450
-500
This drawing is the property of Conveyor Dynamics Inc. It is loaned upon the express condition that it shall not be copied or reproduced in any manner, that it shall not be submitted to others for examination without the
-550
0 1000 2000 3000 4000 5000 6000
Station (m)
consent of Conveyor Dynamics Inc., that it shall not be used in any other way detrimental to the interests of Conveyor Dynamics Inc. and that it shall be returned to Conveyor Dynamics Inc. upon demand.
120-CV-005 Profile
Primary
Head
Secondary
120-CV-005 Geometry
2500 kW 2500 kW
Reducer Motor 12 Reducer Motor 22
561 kN-m Disk 12 561 kN-m Disk 32 561 kN-m Disk 22
Tail Primary Tertiary Secondary

Pulley Pulley Pulley
561 kN-m Disk 11 561 kN-m Disk 31 561 kN-m Disk 21

2500 kW 2500 kW
120-CV-005 Drive Layout
DATE REV CHK DWG: LSP-APP-A-LAYOUT-R6.VSD KRUPP - SIEMENS CONVEYOR DYNAMICS, INC
03/01/06 U1 JLC LOS PELAMBRES PROJECT
CONVEYOR 120-CV-005 LAYOUT
PHASE 2
SHEET: 1/3 JOB: 194 GENERAL LAYOUT
To AFD Drive To AFD Drive
To PLC
To Weight Scale 2 To PLC
Disk 12 Disk 32 (120-CV-005 Only) Disk 22 To PLC To PLC
Primary Tertiary Secondary

Tail Idler Idler
Pulley Pulley Pulley
Disk 11 Disk 31 To Weight Scale 1 Disk 21
(120-CV-005 Only)
120-CV-005/120-CV-006 Speed Sensors Location
To PLC
To PLC To PLC To PLC

Tail Pulley Pulley Pulley
Idler Idler
Disk 11 Disk 31 Disk 21

120-CV-007 Speed Sensors Location
Legend
Optical Encoder Overspeed Switch
DATE REV CHK DWG: LSP-SPD-SENSORS-R4.VSD KRUPP - SIEMENS CONVEYOR DYNAMICS, INC
03/01/06 U1 JLC CONVEYOR SPEED LOS PELAMBRES PROJECT
SENSORS LOCATIONS PHASE 2
SD SP PD SP SD SP
SD SP PD SP SD SP
120-CV-005
SD SP PD SP SD SP
SD SP PD SP SD SP
120-CV-006
SD SP SP SP SD SP
120-CV-007
SPRING APPLIED CALIPER, PROPORTIONAL CONTROL

SP
SPRING APPLIED CALIPER, DIGITAL CONTROL
SD
PRESSURE APPLIED CALIPER, DIGITAL CONTROL
PD
EACH CALIPER IS 280.5 kN-m
DATE REV CHK DWG: LSP-BRK-PAD-R4.VSD KRUPP - SIEMENS CONVEYOR DYNAMICS, INC
03/01/06 U1 JLC LOS PELAMBRES PROJECT
CONVEYOR BRAKE PAD LAYOUT
PHASE 2
03/01/06
DATE
BRAKE HYDRAULICS
REV
Watchdog
U1
Relay
Emergency Valve
CHK
From PLC Output 3-12 Sec

JLC
(Main Manifold)
(1 Hz Pulse) Delay
SHEET: 1/1
EMERGENCY CIRCUIT
DWG: LSP-EM-CIRCUIT-R5.VSD
SVE1
Over-Speed E-Stop Switch PLC Outputs

Switches (Brake Panel) (dry contact) Digital Apply Valve
(Primary Quick Set Manifold)
JOB: 194
From UPS SVSP1
To PLC Input
To PLC Input Digital Apply Valve

Manual (Secondary Quick Set Manifold)
To PLC Input Bypass
From UPS SVSS1
LOS PELAMBRES PROJECT
To PLC Input AFD Drive 11

GENERAL LAYOUT
KRUPP - SIEMENS
To PLC Input E-Stop Input

PHASE 2
AFD Drive 12
(CV-005/006)
E-Stop Input
AFD Drive 21
Note:
E-Stop Input
AFD Drive 22
Solenoid valves for tertiary
digital brake calipers on CV-
CONVEYOR DYNAMICS, INC
(CV-005/006)
005 and CV-006 are not
E-Stop Input connected to the emergency
circuit and should be powered
directly from the UPS
Legend
Normally Open
Solenoid Valve
RESET O
A
F O W A P
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A
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NOTES
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M I S D
P D 7 C All alarms and malfunctions are displayed
DESCRIPTION O
M E
C R I
L E C on both the OP 37 and the WIN-CC stations
I E S
E R
N S P
V All Setpoints and Timer preset as of July 2000
T E L
E
T A
L Y
AREA INTERLOCKS
FEEDER SYSTEM INTERLOCKS

DOWNSTREAM TONNAGE LIMIT LEVEL 1 INTERLOCK A2 0.3 X X INDICATES DISABLED DRIVE ON CV-07, TRIGGERS TONNAGE LIMIT 1 (5200TPH)
DOWNSTREAM TONNAGE LIMIT LEVEL 2 INTERLOCK A2 0.3 X X INDICATES DISABLED DRIVE ON CV-05/06, TRIGGERS TONNAGE LIMIT 2 (5200TPH)
HORN BREAKER START PERMISSIVE ALARM SP 0.3 X X X HORN BREAKER OFF OR TRIPPED
CV-05 CONVEYOR INTERLOCK M2 NA X X X CV-05 NOT RUNNING OR OVERLOADED
STOCKPILE INTERLOCK M2 0.3 X X X CONCENTRATOR STOCKPILE LEVEL HIGH
INDIVIDUAL FEEDERS INTERLOCKS

LOCAL MODE RUN PERMISSIVE NTERLOCK M2 NA X X X CONVEYOR OR STOCKPILE INTERLOCK WHILE RUNNING IN LOCAL-MANUAL MODE
HORN BREAKER INTERLOCK M2 NA X X X START COMMAND RECEIVED WITH HORN BREAKER OFF OR TRIPPED
CONVEYOR INTERLOCKS
DOWNSTREAM RUN PERMISSIVE INTERLOCK M2 0.3 X X X
UPSTREAM RUN PERMISSIVE INTERLOCK M2 0.3 X X X CV-06 AND CV-07 ONLY
SHUTTLE/STOCKPILE INTERLOCK M2 NA X X X CONCENTRATOR STOCKPILE LEVEL HIHI OR SHUTTLE OUT OF POSITION, CV-07 ONLY
BRAKE DISC TEMPERATURE INTERLOCK M2 NA X X X
AFD DRIVE CHOPPER TEMPERATURE INTERLOCK M2 NA X X X
HORN BREAKER INTERLOCK M2 NA X X X
MODE INTERLOCK M2 NA X X X
BCS SWITCH INTERLOCK M2 NA X X X
FEEDER MAGNET INTERLOCK M2 NA X X CV-05 ONLY
AREA AUXILIARY INTERLOCK M2 NA X X
DOWNSTREAM STOP 4 INTERLOCK M2 0.3 X X X CV-05 AND CV-06 ONLY
9. Lsp-app-D-alarm-list-u2.xls Los Pelambres Project - Alarm List Page 1 of 20

RESET O
A
F O W A P
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NOTES
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M I S D
DESCRIPTION O
M E
C R I
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T A
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BELT FEEDERS
INTERLOCKS
CLEANING REQUIRED ALARM A1 7 HR X
CLEANING SEQUENCE INTERLOCK M2 8 HR X X X MAXIMUM TIME BETWEEN MAGNET CLEANING EXCEEDED
LOCAL STOP SWITCH SEQUENCE INTERLOCK M2 NA X X X MAGNET SYSTEM LOCAL STOP SWITCH ACTIVATED DURING CLEANING SEQUENCE
DRIVE
MODULE CONTROL MALF M2 2 X X NO ENABLED SIGNAL FROM JUPITER CARD
DRIVE - HYDRAULIC
CHARGE PRESSURE LO SWITCH ALARM A1 NO X
RETURN FILTER CLOGED SWITCH ALARM A1 2 X
DRAIN FILTER CLOGED SWITCH ALARM A1 2 X
CHARGE PRESSURE LOLO SWITCH MALF M2 4 X
SUCTION LINE OPEN SWITCH MALF M2 2 X FROM LIMIT SWITCH ON VALVE
DRIVE - PUMP
GROUND FAULT A1 NO X
CONTACTOR MALF M2 2 X X
OVERLOAD MALF M2 2 X
CIRCUIT BREAKER Q01 MALF M2 2 X
DRIVE - COOLER
CONTACTOR ALARM A2 2 X X STOPS COOLER
OVERLOAD ALARM A2 2 X STOPS COOLER

RESET O
A
F O W A P
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A
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NOTES
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M I S D
DESCRIPTION O
M E
C R I
I E S
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N S P
T E L
E
T A
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DRIVE - TANK
LEVEL LO SWITCH ALARM A1 NO X
OIL TEMPERATURE HI SWITCH ALARM A1 NO X
LEVEL LOLO SWITCH MALF M2 2 X
OIL TEMPERATURE HIHI SWITCH MALF M2 2 X
BELTLINE - MISC
ALIGNMENT ALARM A1 2 X
STOCKPILE LEVEL LOLO SWITCH MALF M2 2 X X EMPTY MINE STOCKPILE
PULLCORD MALF M2 0.3 X X
ALIGNMENT MALF M2 2 X
PLUGGED CHUTE MALF M2 2 X
FEEDER E-STOP SWITCH MALF M2 0.3 X X
MAGNET E-STOP SWITCH MALF M2 0.3 X X STOPS FEEDER AND MAGNET CARRIAGE MOTION
BELTLINE - SPEED
BELT SPEED TACHOMETER INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES BELT SPEED TACHOMETER INPUT
DRIVE SPEED TACHOMETER INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES DRIVE SPEED TACHOMETER INPUT
DRIVE SLIP ALARM A1 20% 4 X
UNDERSPEED ALARM A1 20% UNDER 4 X WITH RESPECT TO SPEED REFERENCE
OVERSPEED ALARM A1 20% OVER 4 X WITH RESPECT TO SPEED REFERENCE
DRIVE SLIP MALF M2 25% 4 X
UNDERSPEED MALF M2 25% UNDER 4 X WITH RESPECT TO SPEED REFERENCE
OVERSPEED MALF M2 25% OVER 4 X WITH RESPECT TO SPEED REFERENCE

RESET O
A
F O W A P
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DESCRIPTION O
M E
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MAGNET SYSTEM - MOTOR

CONTACTOR FORWARD ALARM A2 2 X X STOPS CARRIAGE FORWARD MOTION (TOWARD CONVEYOR POSITION)
CONTACTOR REVERSE ALARM A2 2 X X STOPS CARRIAGE REVERSE MOTION (TOWARD BIN POSITION)
OVERLOAD ALARM A2 2 X STOPS CARRIAGE MOTION
CIRCUIT BREAKERS Q11 & Q12 ALARM A2 2 X STOPS CARRIAGE MOTION
MAGNET SYSTEM - MAGNET

CONTROL VOLTAGE MALF M2 10 X
PANEL RECTIFIER LOAD BREAKER SWITCH MALF M2 10 X
CONTACTOR MALF - CV-05 CONVEYOR INTERLOCK M2 10 X X STOPS MAGNET FIELD, FEEDER AND CONVEYOR CV-05
DC RECTIFIER CURRENT MALF - CV-05 CONVEYOR INTERLOCK M2 10 X STOPS MAGNET FIELD, FEEDER AND CONVEYOR CV-05
MAGNET SYSTEM - CARRIAGE

CARRIAGE JAM ALARM A2 30 X STOPS CARRIAGE MOTION
OVERTRAVEL CONVEYOR POSITION SWITCH ALARM A2 1 X STOPS CARRIAGE FORWARD MOTION (TOWARD CONVEYOR POSITION)
OVERTRAVEL BIN POSITION SWITCH ALARM A2 1 X STOPS CARRIAGE REVERSE MOTION (TOWARD BIN POSITION)
POSITION FAULT M2 2 X

RESET O
A
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DESCRIPTION O
M E
C R I
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T A
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CONVEYORS
AFD DRIVES
E-STOP REQUEST RECEIVED MALF M3 NA X
AFD DRIVES - INTERFACE MONITORING (SYSTEM)

READY SEQUENCE MALF M2 90 X X
ENGAGED SEQUENCE MALF M2 10 X X
DISABLED DRIVE RUN TIME MALF M2 30 MIN X X 35 MIN FOR CV-07
ENABLED DRIVE MALF (EACH DRIVE) M2 10 X X
SELECTION TIMEOUT MALF M2 10 X X
MULTIPLE DRIVES FAULT M3 NA X X
AFD DRIVES - INTERFACE MONITORING (EACH DRIVE)

DRIVE ALARM A1 NA X
DRIVE FAULT A2 NA X
READY TO PRE-START ALARM A2 NA X
READY TO START ALARM A2 90 X
ENGAGED ALARM A2 10 X
DRIVE DISABLE ALARM A2 10 X
REQUEST FOR LOAD TAKEOVER ALARM A2 NA X
LOSS OF CONTROL ALARM A2 NA X
AFD DRIVES - HARDWIRED INTERLOCKS (EACH DRIVE)

HEALTHY ALARM A2 0.5 X

RESET O
A
F O W A P
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NOTES
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M I S D
DESCRIPTION O
M E
C R I
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T E L
E
T A
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AFD DRIVES - TORQUE MONITORING (SYSTEM)

TOTAL TORQUE HI ALARM A1 200% 10 X 120% FOR CV-07
TOTAL TORQUE HI REGEN ALARM A2 -300% 10 X -200% FOR CV-07, TRIGGERS BELT FEEDERS SPEED SETBACK ON CV-05
TOTAL TORQUE HIHI REGEN MALF M1 -420% 10 X X -280% FOR CV-07, TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
TOTAL TORQUE HIHI MALF M2 250% 10 X 150% FOR CV-07
AFD DRIVES - TORQUE MONITORING (EACH DRIVE)

LOAD SHARING ALARM A1 10% 10 X
TORQUE HI ALARM A1 100% 10 X
TORQUE HI REGEN MALF M1 -100% 30 MIN X X TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
TORQUE HIHI REGEN MALF M1 -130% 10 X X TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
ZERO TORQUE FAULT M2 +/- 2.5% 20 MIN X
AFD DRIVES - SUPERVISION (SYSTEM)

FEEDER MONITORING FAULT A1 NO X
AFD DRIVES - SUPERVISION (EACH DRIVE)

FEEDER GROUND FAULT A1 NO X
CHOPPER TEMP HI ALARM SP 0.5 X
CHOPPER TEMP HIHI ALARM A2 0.5 X
CABINET HUMIDITY HI MALF M2 2 X
CABINET HUMIDITY HIHI MALF M3 2 X
CONVEYOR SPEED RAMP MONITORING

BRAKE RAMP UNDERSPEED ALARM A1 10% UNDER 5 X X RAMP UNDERSPEED DURING LEVEL 3 STOP (NORMAL FOR EMPTY CONVEYOR)
AFD RAMP UNDERSPEED MALF M3 10% UNDER 5 X X RAMP UNDERSPEED DURING START OR LEVEL 2 STOP
AFD RAMP OVERSPEED MALF M3 10% OVER 5 X X RAMP OVERSPEED DURING START OR LEVEL 2 STOP
BRAKE RAMP OVERSPEED MALF M4 10% OVER 5 X X RAMP OVERSPEED DURING LEVEL 3 STOP

RESET O
A
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NOTES
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DESCRIPTION O
M E
C R I
I E S
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T A
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BRAKE SYSTEM
PANEL E-STOP SWITCH MALF M4 0.3 X X ON BRAKE PANEL
BRAKE - HYDRAULIC
FILTER CLOGED ALARM (EACH FILTER) A1 2 X FROM DIFFERENTIAL PRESSURE SWITCH
MANIFOLD SELECTOR FAULT (EACH MANIFOLD) M2 0.5 X
DUAL PUMP MALF M2 NA X
BRAKE - HYDRAULIC - PUMP (EACH PUMP)

CONTACTOR ALARM A2 2 X X STOPS PUMP MOTOR AND TRIGGER PUMP SWITCHOVER
OVERLOAD / CONTROL VOLTAGE ALARM A2 2 X STOPS PUMP MOTOR AND TRIGGER PUMP SWITCHOVER
DISCHARGE PRESSURE LO ALARM A2 30 X STOPS PUMP MOTOR AND TRIGGER PUMP SWITCHOVER
BRAKE - HYDRAULIC - TANK

LEVEL LO SWITCH ALARM A1 NO X
OIL TEMPERATURE HI SWITCH ALARM A1 NO X
LEVEL LOLO SWITCH MALF M2 2 X
OIL TEMPERATURE HIHI SWITCH MALF M2 2 X
BRAKE - PROPORTIONAL CALIPERS - CONTROL

BRAKE PRESSURE SIGNAL INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES BRAKE PRESSURE INPUT
RELEASED CHECK FAULT M2 1.5 X
RELEASED PRESSURE LOLO SWITCH MALF M2 4 X
RELEASED PRESSURE LOLO MALF M2 1800 PSI 4 X
CONTROL PRESSURE LOLO MALF M2 400 PSI UNDER 3 X WITH RESPECT TO TARGET PRESSURE
CONTROL PRESSURE HIHI MALF M2 400 PSI OVER 3 X WITH RESPECT TO TARGET PRESSURE
APPLY CHECK FAULT M4 1.5 X
STOPPED PRESSURE HIHI MALF M5 300 PSI 4 X
EMERGENCY PRESSURE HIHI MALF M5 400 PSI OVER 4 X WITH RESPECT TO DESIGN PRESET RAMP

RESET O
A
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A
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NOTES
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M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
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BRAKE - PROPORTIONAL CALIPERS - DISCS (EACH DISC)

PAD WEAR SWITCH ALARM A1 NO X
PAD TEMPERATURE HIHI SWITCH MALF M2 4 X
PAD RELEASED SWITCH MALF M2 4 X
BRAKE - DIGITAL CALIPERS - CONTROL (EACH MANIFOLD)

RELEASED PRESSURE LOLO SWITCH MALF M2 4 X
RELEASED CHECK FAULT M2 1 X
APPLY CHECK FAULT M2 1 X
BRAKE - DIGITAL CALIPERS - DISCS (EACH DISC)

PAD WEAR SWITCH ALARM A1 NO X
PAD TEMPERATURE HIHI SWITCH MALF M2 4 X
PAD RELEASED SWITCH MALF M2 4 X
BRAKE - DISC TEMP (EACH DISC)

TEMPERATURE HI ALARM SP 170 DEG C 3 X
TEMPERATURE SIGNAL INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES BRAKE DISC TEMPERATURE INPUT
TEMPERATURE HIHI MALF M2 500 DEG C 3 X
REDUCERS (KELLER, EACH REDUCER)

VIBRATION HI SWITCH ALARM A1 5 X
OIL TEMPERATURE HI ALARM A1 95 DEG C NO X
BEARING TEMPERATURE HI ALARM (EACH SENSOR) A1 95 DEG C NO X
OIL TEMPERATURE SIGNAL INVALID ALARM A2 -25 / 250 DEG C 0.5 X DISABLES OIL TEMPERATURE INPUT
BEARING TEMPERATURE SIGNAL INVALID ALARM (EACH SENSOR) A2 -25 / 250 DEG C 0.5 X DISABLES BEARING TEMPERATURE INPUT
LOWER RESERVOIR LEVEL LOLO SWITCH MALF M2 5 X
UPPER RESERVOIR LEVEL LOLO SWITCH MALF M2 5 X
OIL TEMPERATURE HIHI MALF M2 100 DEG C 10 X

RESET O
A
F O W A P
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NOTES
R T
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M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
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BEARING TEMPERATURE HIHI MALF (EACH SENSOR) M2 105 DEG C 10 X
REDUCERS (FLENDER, EACH REDUCER)

VIBRATION HI SWITCH ALARM A1 5 X
OIL TEMPERATURE HI ALARM A1 75 DEG C NO X
BEARING TEMPERATURE HI ALARM (EACH SENSOR) A1 95 DEG C NO X
LUBRICATION SYSTEM WARNING A1 1 X
OIL TEMPERATURE SIGNAL INVALID ALARM A2 -25 / 250 DEG C 0.5 X DISABLES OIL TEMPERATURE INPUT
BEARING TEMPERATURE SIGNAL INVALID ALARM (EACH SENSOR) A2 -25 / 250 DEG C 0.5 X DISABLES BEARING TEMPERATURE INPUT
OIL LEVEL LOLO SWITCH MALF M2 5 X
OIL TEMPERATURE LOLO MALF M2 2.5 DEG C 10 X
OIL TEMPERATURE HIHI MALF M2 80 DEG C 10 X
BEARING TEMPERATURE HIHI MALF (EACH SENSOR) M2 105 DEG C 10 X
LUBRICATION SYSTEM GROUND FAULT MALF M2 1 X
LUBRICATION SYSTEM READY MALF M2 1 X
LUBRICATION SYSTEM RUNNING MALF M2 1/10 X 10 SEC TIMER FOR INITIAL TURN-ON DELAY, 1 SEC TIMER FOR FAULT WHILE RUNNING
LUBRICATION SYSTEM FAULT M2 1 X
PULLEYS (EACH PULLEY)

PULLEY BEARING TEMPERATURE HI ALARM (EACH SIDE) A1 75 DEG C NO X
PULLEY BEARING TEMPERATURE SIGNAL INVALID ALARM (EACH SIDE) A2 -25 / 250 DEG C 0.5 X DISABLES BEARING TEMPERATURE INPUT
PULLEY BEARING TEMPERATURE HIHI MALF (EACH SIDE) M2 85 DEG C 10 X
BELTLINE - PULLCORDS
PULLCORD FEEDER MONITORING ALARM A1 0.3 X
INDIVIDUAL SWITCH ALARM (EACH PULLCORD) A1 0.3 X X DIAGNOSTICS ONLY
GENERAL PULLCORD MALF M2 0.3 X X X
BELTLINE - ALIGNMENT
ALIGNMENT ALARM (EACH ALIGNMENT SWITCH) A1 4 X

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NOTES
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DESCRIPTION O
M E
C R I
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T A
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ALIGNMENT MALF (SELECTED ALIGNMENT SWITCHES) M2 4 X X
BELTLINE - SENSOR LOOP RIP DETECTION SYSTEMS (HEAD AND TAIL)

EARLY WARNING ALARM A1 1 X X
GROUP ALARM A2 1 X X SYSTEM FAULT
HEALTHY MALF M2 1 X X
BELTLINE - RIP DETECTION

ELECTRO-MECHANICAL SWITCH MALF (EACH BELT FEEDER) M2 1 X X AT EACH FEEDER DISCHARGE LOCATION, CV-05 ONLY
WIRE ROPE SWITCH MALF M2 1 X X
BELTLINE - SPLICE FAILURE DETECTION SYSTEM

SYSTEM FAULT A1 2 X
SPLICE DETECTION ALARM A1 2 X
SPLICE DETECTED MALF M1 2 X X TRIGGERS UPSTREAM CONVEYOR SHUTDOWN

RESET O
A
F O W A P
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A
E E N T 7
NOTES
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M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
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BELTLINE - MISC
HORN / BEACON BREAKER FAULT (EACH SECTION) SP 2 X X X
PLUGGED CHUTE - NUCLEAR SWITCH MALF M2 2 X X
PLUGGED CHUTE - TILT SWITCH MALF M2 2 X X
IMMEDIATE STOP SWITCH MALF (EACH DRIVE AND CONVEYOR HEAD) M2 0.3 X X X
BELT LINE - SPEED MONITORING

POSITIVE SLIP HI ALARM (EACH PULLEY) A1 1.50% 5 X
TACHOMETER INVALID ALARM (EACH TACHOMETER) A2 3 / 28 MA 0.5 X DISABLES TACHOMETER INPUT
TACHOMETER FAULT (EACH TACHOMETER) A2 0.7 X DISABLES TACHOMETER INPUT
NEGATIVE SLIP HI ALARM (EACH PULLEY) A2 -1.50% 5 X TRIGGERS BELT FEEDERS SPEED SETBACK ( CV-05 ONLY)
NEGATIVE SLIP HIHI MALF (EACH PULLEY) M1 -10% 5 X TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
CONVEYOR STALL MALF M3 3.50% 10 X X
UNDERSPEED MALF M3 10% UNDER 1 X X WITH RESPECT TO SPEED SETPOINT, WITH CONVEYOR IN RUNNING STATE
WITH RESPECT TO SPEED SETPOINT M3 5% OVER 1 X X X WITH RESPECT TO SPEED SETPOINT, WITH CONVEYOR IN RUNNING STATE
CONVEYOR VELOCITY INVALID MALF M4 NA X
HI OVERSPEED MALF M4 20% OVER 1 X X WITH RESPECT TO SPEED SETPOINT, WITH CONVEYOR IN RUNNING STATE
HIHI OVERSPEED SWITCH MALF (EACH SWITC) M4 118% 1 X X
SUSTAINED OVERSPEED LEVEL1 MALF M4 5 % OVER 5 X X WITH RESPECT TO SPEED SETPOINT, WITH CONVEYOR IN RUNNING STATE
SUSTAINED OVERSPEED LEVEL2 MALF M5 5 % OVER 10 X X WITH RESPECT TO SPEED SETPOINT, WITH CONVEYOR IN RUNNING STATE
CONFIRMED HIHI OVERSPEED MALF M5 NA X X
MAINTENANCE MODE MOTION DETECTED MALF M5 NA X X
TAKE UP - CARRIAGE
POSITION LO SWITCH ALARM A1 NO X
POSITION HI SWITCH ALARM A1 NO X
POSITION LOLO SWITCH MALF M2 0.2 X
POSITION HIHI SWITCH MALF M2 0.2 X

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NOTES
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DESCRIPTION O
M E
C R I
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T A
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TAKE UP - WINCH (CV-05 AND CV-06 ONLY)

MOTOR GROUND FAULT A1 NO X
WINCH ROPE EMPTY SWITCH ALARM A2 2 X STOPS FORWARD MOTION (DOWN)
WINCH ROPE FULL SWITCH ALARM A2 2 X STOPS REVERSE MOTION (UP)
MOTOR FORWARD CONTACTOR ALARM A2 2 X X STOPS FORWARD MOTION (DOWN)
MOTOR REVERSE CONTACTOR ALARM A2 2 X X STOPS REVERSE MOTION (UP)
MOTOR OVERLOAD ALARM A2 2 X STOPS WINCH MOTOR
E-STOP SWITCH MALF M2 0.3 X X STOPS WINCH MOTOR AND CONVEYOR
TAKE UP - COUNTERWEIGHT
POSITION LO SWITCH ALARM A1 NO X
POSITION HI SWITCH ALARM A1 NO X
POSITION LOLO SWITCH MALF M2 0.2 X STOPS FORWARD MOTION (DOWN) AND CONVEYOR
POSITION HIHI SWITCH MALF M2 0.2 X STOPS REVERSE MOTION (UP) AND CONVEYOR
TAKE UP - COUNTERWEIGHT - LASER POSITION SENSOR (CV-05 AND CV-06 ONLY)

POSITION LO ALARM A1 15% 0.2 X
POSITION HI ALARM A1 85% 0.2 X
POSITION SIGNAL INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES POSITION TRANSDUCER INPUT
JAM ALARM A2 0.4 % / SEC 9 X STOPS WINCH MOTOR
OUT OF POSITION FAULT M2 NA X X STOPS CONVEYOR BUT NOT WINCH MOTOR
TONNAGE (PLC 5 ONLY)

WEIGHT SCALE DIFFERENCE HI ALARM A1 500 TPH 10 X
TONNAGE HI ALARM A2 5800 TPH 10 X X X TRIGGERS BELT FEEDERS SPEED SETBACK
TONNAGE HIHI MALF M1 6400 TPH 10 X X TRIGGERS FEEDERS SHUTDOWN
WEIGHT SCALES (EACH SCALE, PLC 5 ONLY)

WEIGHT SCALE FAULT A2 1 X DISABLES WEIGHT SCALE INPUT AND TRIGGERS TONNAGE LIMIT 2 (5200TPH)
SIGNAL INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES WEIGHT SCALE INPUT AND TRIGGERS TONNAGE LIMIT 2 (5200TPH)

RESET O
A
F O W A P
L
S I P I U
A
E E N T 7
NOTES
R T
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M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
L Y
BELT TENSION / LOAD CELLS

LOAD CELL DIFFERENCE HI ALARM A1 15 T 10 X
SIGNAL INVALID ALARM (EACH LOAD CELL) A2 3 / 28 MA 0.5 X DISABLES LOAD CELL INPUT
BELT TENSION HI ALARM A2 260 T X 135 T FOR CV-07, TRIGGERS BELT FEEDERS SPEED SETBACK ON CV-05
BELT TENSION HIHI MALF M1 290 T 10 X 150 T FOR CV-07, TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
10

RESET O
A
F O W A P
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S I P I U
A
E E N T 7
NOTES
R T
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M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
L Y
SHUTTLE/STOCKPILE
AFD DRIVE - DRIVE FEEDER

GROUND FAULT A1 10 X
MAIN BREAKER MALF M3 1 X
BREAKERS CB1 & CB2 MALF M3 1 X
AFD DRIVE - INTERFACE MONITORING

DRIVE ALARM A1 NA X
FORWARD FAULT M2 8 X STOPS FORWARD MOTION (TOWARD STOCKPILE)
REVERSE FAULT M2 8 X STOPS REVERSE MOTION (TOWARD CONVEYOR)
DRIVE FAULT M3 NA X
READY MALF M3 8 X
PTC TEMP RELAY MALF M3 300 X
RUNNING MALF M3 8 X
BRAKE SYSTEM
INSULATION MONITORING ALARM A1 NO X
CONTROL VOLTAGE MALF M3 3 X
MAIN BREAKER MALF M3 3 X
BREAKERS CB1 & CB2 MALF M3 3 X
BRAKE RELEASE FAULT M3 3 X
BRAKE RELEASED CHECK FAULT M3 0.5 X

RESET O
A
F O W A P
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S I P I U
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E E N T 7
NOTES
R T
T L 3 O
M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
L Y
CARRIAGE
POS LO MALF - END OF TRAVEL REVERSE SWITCH A2 NO X X STOPS REVERSE MOTION (TOWARD CONVEYOR)
POS HI MALF - END OF TRAVEL FORWARD SWITCH A2 NO X X STOPS FORWARD MOTION (TOWARD STOCKPILE)
OUT OF POSITION MALF M1 0.5 M 3 X X TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
CARRIAGE JAM ALARM M2 0.075 M / SEC 9 X
POS LOLO MALF - OVERTRAVEL REVERSE SWITCH M3 1 X
POS HIHI MALF - OVERTRAVEL FORWARD SWITCH M3 1 X
MISC
CONTROL PANEL INSULATION MONITORING ALARM A1 NO X
AUX PANEL GROUND FAULT A1 NO X
ENCLOSURE FIRE SYSTEM FAULT A1 1.5 X
ENCLOSURE FIRE DETECTED MALF M3 1.5 X
LOCAL STOP SW INTERLOCK M3 0.3 X X
PULLCORD MALF (EACH PULLCORD) M3 0.3 X X STOPS SHUTTLE MOTOR AND TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
E-STOP SWITCH - CONVEYOR INTERLOCK (EACH SWITCH) M3 0.3 X X STOPS SHUTTLE MOTOR AND TRIGGERS UPSTREAM CONVEYOR SHUTDOWN
STOCKPILE
LEVEL DIFF HI ALARM A1 10% 4 X
LEVEL LO ALARM A1 20% 4 X
LEVEL SIGNAL INVALID ALARM (EACH SENSOR) A2 3 / 28 MA 0.5 X DISABLES CORRESPONDING STOCKPILE LEVEL INPUT
LEVEL HI ALARM A2 95% 4 X X TRIGGERS BELT FEEDERS SHUTDOWN
LEVEL SIGNAL CHECK ALARM A2 NA X TRIGGERS BELT FEEDERS SHUTDOWN
LEVEL HIHI MALF M1 99% 4 X X TRIGGERS UPSTREAM CONVEYOR SHUTDOWN

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NOTES
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M I S D
DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
L Y
AREA AUXILIARIES
SUBST - 23KV
23 KV BREAKER - TRIP COIL MONITORING ALARM A1 0.3 X
23 KV BREAKER - OVERCURRENT ALARM A1 0.3 X
23 KV BREAKER - OVERVOLTAGE ALARM A1 0.3 X
23 KV BREAKER - UNDERVOLTAGE ALARM A1 0.3 X
23 KV BREAKER - TRUCK POSITION ALARM A1 10 X
H.V HOUSE FIRE SYSTEM TROUBLE ALARM A1 0.3 X
H.V HOUSE FIRE ALARM A1 0.3 X
H.V HOUSE AC UNIT GROUND FAULT A1 NO X
23 KV INCOMMING WRONG PHASE SEQ ALARM SP 0.3 X
HARMONIC FILTER MALF M2 0.3 X
HV HOUSE E-STOP SWITCH MALF M2 0.3 X X X TRIPS 23KV BREAKER (HARDWIRED)
H.V HOUSE FIRE DETECTED MALF M3 0.3 X TRIPS 23KV BREAKER (SOFTWARE TRIP)
SUBST - 400V
23 KV POWER LBS FUSE BLOWN ALARM A1 2 X
23 KV POWER LBS OPEN ALARM A1 2 X
XFO OIL LEVEL ALARM A1 2 X
XFO PRESSURE RELIEF ALARM A1 2 X
XFO OIL TEMPERATURE ALARM A1 NO X
XFO HOT SPOT PTC RELAY ALARM A1 2 X
XFO NEUTRAL GROUND RES GROUND FAULT A1 NO X
XFO TEMPERATURE HIHI ALARM A1 2 X

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NOTES
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DESCRIPTION O
M E
C R I
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E R
N S P
T E L
E
T A
L Y
SUBST - MCC
E1 MAIN BREAKER TRIPPED ALARM A1 0.3 X
MCC E-STOP SW MALF M2 0.3 X
120 VDC POWER SUPPLY FAULT MALF M2 0.3 X
SUBST - MISC
UTILITY PANEL GROUND FAULT A1 NO X
WELDING RECEPTACLE GROUND FAULT (EACH RECPT) A1 NO X
MAINTENANCE CRANE GROUND FAULT A1 NO X
75 KVA LIGHTING XFO GROUND FAULT A1 NO X
DEEP WELL PUMP GROUND FAULT A1 NO X
SERVICE HOIST GROUND FAULT A1 NO X
CTRL PANEL FEEDER - ISOLATION MONITORING ALARM A1 NO X
SUBST - UPS (EACH UNIT)

INCOMMING FEEDER GROUND FAULT A1 NO X
SYSTEM BYPASS ALARM A1 2 X
INVERTER FEED FAILURE ALARM A2 2 X
BATTERY VOLTAGE LO ALARM A2 2 X X
MAIN LINE SIDE FAILURE MALF M2 2 X X
AFD HOUSES - MISC (EACH HOUSE)

DOOR OPEN ALARM (EACH DOOR) A1 NO X
FIRE SYSTEM TROUBLE ALARM A1 0.3 X
FIRE SYSTEM ALARM A1 0.3 X
DOOR OPEN INTERLOCK M2 5 MIN X MULTIPLE DOORS OPEN
E-STOP SWITCH MALF M2 0.3 X X X TRIPS 23KV BREAKER (SOFTWARE TRIP)
FIRE DETECTED MALF M3 0.3 X TRIPS 23KV BREAKER (SOFTWARE TRIP)

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A
F O W A P
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E E N T 7
NOTES
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DESCRIPTION O
M E
C R I
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E R
N S P
T E L
E
T A
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AFD HOUSES - COOLERS

GROUND FAULT ALARM (EACH COOLING UNIT) A1 NO X
UNIT FAULT ALARM (EACH COOLING UNIT) A2 2 X DISABLES COOLER AND TRIGGERS SWITCHOVER TO STANDBY UNIT
STANDBY UNIT GATE POSITION ALARM A2 9 X CV-06 ONLY
MULTIPLE UNITS FAULT MALF M2 NA X
AUX - DUST SUPPRESSION SYSTEM

INCOMMING FEEDER GROUND FAULT A1 NO X
AIR PRESSURE LO ALARM A1 NO X
WATER PRESSURE LO ALARM A1 NO X 2 INPUTS ON CV-07
SYSTEM CONTACTOR ALARM (EACH SYSTEM) A1 3 X X
COMPRESSOR FAULT ALARM A2 3 X DISABLES COMPRESSOR
CONTROL VOLTAGE ALARM A2 3 X
MATERIAL LEVEL SIGNAL INVALID ALARM A2 3 / 28 MA 0.5 X DISABLES MATERIAL LEVEL TRANSDUCER INPUT, CV-07 ONLY
AUX - VENT FANS (AFD HOUSES, HV HOUSE, EACH FAN)

CONTROL TEMP HI ALARM A1 NO X
CONTACTOR ALARM A2 2 X X STOPS FAN
OVERLOAD ALARM A2 2 X STOPS FAN
AUX - SUPPLY FANS (EACH FAN)

AC FEEDER GROUND FAULT A1 NO X
AFD MANUAL FAULT A2 120 X X STOPS FAN
AFD READY FAULT A2 120 X STOPS FAN

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NOTES
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DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
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AUX - SUMP PUMP (PLC 5 ONLY)

CONTROL LEVEL HI ALARM A1 NO X
CONTACTOR ALARM A2 2 X X STOPS PUMP
OVERLOAD ALARM A2 2 X STOPS PUMP
AUX - MISC
SUPPLY FAN FILTER PRESSURE HI ALARM (EACH FAN) A1 NO X
GRINELL FIRE SYSTEM TROUBLE ALARM A1 NO X
GRINELL SYSTEM FIRE DETECTED ALARM A1 NO X

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E E N T 7
NOTES
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DESCRIPTION O
M E
C R I
I E S
E R
N S P
T E L
E
T A
L Y
PLC SYSTEM SUPERVISION
PLC - CPU A/B

CPU BATTERY FAULT A2 NA X
CPU FAULT A2 NA X TRIGGERS SWITCHOVER TO STANDBY CPU
PLC - PROFIBUS - 1 (REMOTE I/O SYSTEM)

GENERAL STATIONS FAILURE ALARM A1 NA X
OP37 STATION ALARM A2 NA X TRIGGERS OPERATION MODE TO REMOTE-AUTO
PULLCORD / ALIGNMENT STATIONS ALARM (EACH ZONE) SP NA X
AFD DRIVE STATION MALF (EACH AFD DRIVE) M2 NA X
BRAKE STATION MALF (EACH BRAKE STATION) M4 NA X
PLC - MISC NETWORKS

H1 / OTN - PLC-WINCC STATION ALARM A1 NA X
RS-485 - SUBSTATION METER ALARM (EACH METER) A1 NA X
PROFIBUS 2 - AFD DRIVE FAILURE ALARM (EACH AFD DRIVE) SP NA X
PLC - LOCAL I/O SYSTEM

EXPANSION RACK 2-4 MALF M2 NA X
EXPANSION RACK 1 MALF M4 NA X
PLC - WATCHDOG
SYSTEM BYPASS ALARM A1 NO X
SYSTEM FAULT M4 1 X

MANUFACTURER: VENDOR:
MATERIAL: Coarse Copper Ore

SIZE: 250 x 0 mm AMBIENT TEMP.: MAX 34 °C
BULK DENSITY FOR VOLUME: 1.6 t/m3 MIN. -20 °C
FOR WEIGHT: 2.1 t/m3 MAX. RAIN FALL: See Section 9 of MR
ANGLE OF REPOSE: 37 deg. ANNUAL : mm/yr
SURCHARGE ANGLE: (CEMA) 15 deg. SINGLE STORM : mm/hr
HARDGROVE INDEX: Later MAX. SNOW FALL: See Section 9 of MR
MOISTURE CONTENT : ANNUAL: mm/yr
Max 8 % SINGLE RECORDED: mm/hr
Min 3 % MAX. WIND VELOCITY: 110 km/hr
ABRASIVENESS: Abrasive PREVAILING WIND DIRECTION: See Section 9 of MR
CORROSIVENESS: No PLANT SITE ELEV. (above MSL): 3000 m
DESIGN CAPACITY: 8,700 t/h (Dry metric) SEISMIC ZONE: UBC Seismic Zone 4
BELT WIDTH: 1800 mm ELECT. AREA CLASSIFICATION: None
BELT SPEED: (max) 6 m/sec OPERATING SCHEDULE: 24 hrs/day
BELT LOADING : % 7 days/wk
(OF CEMA LOAD CROSSSECTION) 365 days/yr
*Largest piece (occasional) 250 x 250 x 500 mm
**UBC Seismic Zone 4
CALCULATIONS: CEMA X DIN OTHER NEW ELECT. MOTOR POWER: 4 X 2500 kw (S)
ALLOWABLE BELT SAG 1 % (B) RUNNING TENSION: 2520 kN (S)
MINIMUM EDGE DISTANCE: 180 mm (B) ACCEL. TENSION: 2040 kN (S)
METHOD OF ACCEL. CONTROL: AFD (B) BRAKE RATING: kw (S) 3220 kN (S)
ACCELERATION TIME: 40 sec (S) DRIVE WRAP ANGLE: 170+180 deg (S)
COASTING TIME: N/A sec (S) DRIVE FRICTION FACTOR:
COASTING DISTANCE: N/A m (S) RUNNING: 0.35 (S)
BRAKING TIME (LEVEL 1): 80 sec (S) DECEL: 0.25 - 0.35 (S)
BRAKING DISTANCE: 240 m (S) COUNTER WEIGHT: 200 kN (S)
STARTING TORQUE: 100% N-m (S) TAKEUP DISPLACEMENT: m (S)
BRAKEAWAY TORQUE: 130% N-m (S) ORIGINAL CAPACITY: (S)
DRIVE EFFICIENCY: 95 % (S) ELECT. MOTOR POWER: 3 x 2500 kw (S)
4 feed points
1
Drop: 3 Drive pulley
536.42
6
m 2
Gravity Hydraulic adjustment
Drive pulley
5 4 for maintenance
Take-Up
Work point Work point By Seller

Length 5,904.92 m
NOTES
All dimensions are in meters
Max. Loading Angle: 10°
Max. Conveyor Angle: 15°
* 1 (B) INDICATES BUYER. (A) INDICATES SELLER

2 ALL (B) ITEMS SHALL BE COMPLETED BY BUYER. ALL (A) ITEMS SHALL BE COMPLETED BY SELLER
3 NOT APPLICABLE (NA) SHALL BE ENTERED WHERE INFORMATION IS NOT RELEVANT
2 9/13/06 REVISED AS NOTED PS CB
0 ISSUED FOR PURCHASE
B ISSUED FOR BIDS MFD FG FG CZ
A 6.17.05 ISSUED FOR COORDINATION AND APPROVAL MFD FG FG CZ
REV DATE R E V I S I O N ENG SUPV CHIEF P.E CLIENT
EQUIPMENT N° PROJECT: JOB N°: 25100
120-CV-005 M/R N°: 25100-220-MRA-MHCB-0001 REV
EQUIPMENT TITLE LOS PELAMBRES DS N°: 25100-220-MHD-MHCB-00001
COARSE ORE CONVEYOR N° 1 2
SHEET 1 OF 8
DRIVE TRAIN: CV-005D (only) TYPE: X ELECTRIC MOTOR WITH GEAR REDUCER
HYDRAULIC MOTOR
GEAR REDUCER SPECIFIED BY BECHTEL SUPPLIER DATA
DESIGN CODE AGMA 6010-E
MANUFACTURER FLENDER
MODEL NO.
REDUCER TYPE: PARALLEL SHAFT
X RIGHT ANGLE TRIPLE REDUCTION
SHAFT MOUNTED (up to 40 kw or 150 mm dia. shaft)
REDUCER MOUNTING SHAFT MOUNTED "V" BELT DRIVE
DIRECTLY CONNECTED SHAFT MOUNTED
X COMMON BASE PLATE
CHAIN DRIVE IS NOT ACCEPTABLE.
REDUCER DESIGN FACTORS MINIMUM SERVICE RATINGS:
SHALL BE APPLIED OVER THE MECHANICAL: 1.5
NAME PLATE KW OF THE THERMAL: 1.0
MOTOR. DURABILITY: 2.0 (pitting)
STRENGTH: 3.0 (teeth)
INPUT SHAFT DIA. 180 mm
OUTPUT SHAFT DIA. OD FLANGE 1200 mm
INPUT SPEED: 1020 RPM
OUTPUT SPEED: 45.47 RPM
HOUSING CAST IRON GGG40
BEARING TYPE
BEARING L-10G LIFE: 80,000 hrs min. for continuous brake loading. 80,000 hrs
BEARING SEAL (at nominal speed)
ACCESSORIES: X FILLER PLUG Provision for Installatioin
X DRAIN PLUG or forced lubrication &
X OIL LEVEL INDICATOR oil cooler in future.
X BREATHER Internal piping is installed
X HEATER WITH LOW & HIGH TEMP. SWITCHES
LUBRICATION: SPLASH
X FORCED
OPERATING TEMPERATURE: As per discussions 70 °C MAX. °C
COOLING METHOD DRIVE FAN NONE DR. FAN
X "FLENDER" AIR-OIL EXTERNAL HEAT EXCH. X HEAT EXCHANGER
OUTSIDE DIMENSIONS/WEIGHT kg
METHOD OF SOFT START HYDRAULIC CPLG. W/CONST.FILLING
REQUIRED WITH DRIVES & DELAY CHAMBER
AT 60 KW (75 HP) OR HIGHER. HYDRAULIC CPLG.-SCOOP TYPE
REQUIRED FOR CONVEYORS WITH WOUND ROTOR MOTOR (ALTERNATE)
CONCAVE VERTICAL CURVES X FREQUENCY CONTROL
ACCELERATING TENSION D.C. MOTOR
SHALL NOT EXCEED 150 %
OF RATED BELT TENSION.
NOTES
06/28/06

SHEET 2 OF 8
SPECIFIED BY BECHTEL SUPPLIER DATA
COUPLINGS (TERTIARY PULLEY) HIGH SPEED LOW SPEED
MANUFACTURER: NAESCHER
TYPE AND MODEL NO.: 30313-540, Proj. 49227
BORE DIA.: 540.00 mm mm
SIZE: TAS3013-540/675 (Locking device)
SERVICE FACTOR 3.20
V-BELTS:
QTY:
SIZE:
MOTOR SHEAVE P.D.
DRIVEN SHEAVE P.D.
HOLDBACK:
MANUFACTURER:
TYPE AND MODEL NO.:
TORQUE RATING:
HYDRAULIC COUPLING:
MANUFACTURER:
TYPE:
MODEL NO.
RATING:
TAKE-UP:
TYPE:
TRAVEL:
WINCH TAKE-UP
GRAVITY TU WEIGHT:
LOCATION- WINCH TU
LOCATION- GRVTY TU
BRAKE: (DISK 31/32)

TYPE: MECHANICAL CALIPER-DISK HYDRAULIC APPLIED
MANUFACTURER: JOHNSON
DISK DIA (mm) 2500 MM
NO OF DISKS TWO ON TERTIARY PULLEY, TOTAL ON CONVEYOR: SIX
CALIPERS PER DISK TWO
RATING: 561KN PER DISK
LOCATION TERTIARY PULLEY (NON-DRIVEN)
HYDRAULICS-
DESCRIPTION REFER TO O&M MANUALS & PIDs
MOTOR kW
FLYWHEEL: YES NO
LOCATION:
SIZE:
HYDRAULIC DRIVE: YES X NOT REQUIRED

MANUFACTURER:
TYPE AND MODEL NO.:
SIZE:
SPEED:
DESIGN PRESSURE:
OPERATING PRESSURE:
TORQUE RATING:
EFFICIENCY:
06/28/06

SHEET 3 OF 8
BELTING:
MANUFACTURER
BRAND NAME
DESIGNATION/CODE
TYPE: FABRIC STEEL CORD
BELT WIDTH
TOTAL LENGTH:
TAPED LENGTH:
TENSION RATING:
MAX. OPER. TENSION:
ULTIMATE TENSILE STRENGTH
BELT WEIGHT:
TYPE OF FABRIC
NO OF PLIES
BREAKER ON FACE
FABRIC BELT BREAKER THICKNESS
TEMPERATURE RATING :
COEFF. OF THERMAL EXPANSION ( HR ):
FILL MATERIAL:
FRICTION RATING BETWEEN PLIES:
CORD DIA. :
CABLE BREAKING STRENGTH:
CABLE SPACING:
STEEL CORD MODULUS OF ELASTICITY AT RATED TENSION:
PULL-OUT STRENGTH OF CABLE :
> 10,000 cycles
ADHESION BETWEEN COVER AND BONDING RUBBER:
IMPACT RESISTANCE: PHOENIX TEST RIG
HOT VULCANIZED COLD VULCANIZED MECH.

NO. OF STEPS
LENGTH OF STEPS:
BELT SPLICE LENGTH OF SPLICE:
DYNAMIC SPLICE STRENGTH AT MAX. LOAD DIN 2210
STATIC SPLICE BREAKING STRENGTH IN % OF ULTIMATE

TENSILE STRENGTH
THICKNESS: TOP:
BOTTOM :
COVER MINIMUM TENSILE STRENGTH:
RMA GRADE:
TOLERANCE: PLUS:
MINUS:
REPAIRS CARCASS:
COVER:
BELT LENGTH / REEL:

PACKING NO. OF REELS:
REEL DIA.:
REEL GROSS WEIGHT:
NOTES

SHEET 4 OF 8
IDLERS
MODEL N°
GARLAND
35° 35° RETURN RETURN

RETURN
CARRY IMPACT TRANSI- RETURN RUBBER "V" CARRY RETURN
"V" 5-ROLL 3 ROLL
3 EQUAL 3 EQUAL TION FLAT DISC 2 ROLL OR TRAIN. TRAIN
INVERT.
ROLLS ROLLS TYPE 3 ROLL
QUANTITY REQUIRED:(S)
LOAD RATING:
SPACING: (S)
* IMPACT ZONE:
* UNDER SKIRTBRD: (S)
GENERAL:
DISTANCE FROM
HEAD OR TAIL PULLEY
ROLL DIA.
SHELL THICKNESS:(S)
SHAFT DIA (S).
BEARING DIA.(S)
BEARING TYPE: (S)
BEARING L-10 LIFE(S)
SEAL TYPE:(B)
MULTI - LABYRINTH
SEALED FOR LIFE
CEMA NO./DIN
END SHIELD:(B)
ADJUSTABLE TROUGHING
ANGLES:(B)
INCREMENT:
SAFETY DEVICES ACCESSORIES
(B) START/STOP CONTROL SW. (B) PULLEY GUARD (B) DUAL BELT SCRAPER
(B) ZERO SPEED SWITCH (B) CPLG. GUARD
TYPE (S): (B) RETURN BELT V PLOW
(B) BELT ALIGNMENT SWITCH. (B) BELT RIP PROTECTION (B) V PLOW AT TU PULLEY
(B) EMERG. PULL CORD SWITCH (B) PLUG CHUTE DETECTOR (B) BRAKE
1 SIDE 2 SIDES (B) BELT SEAL
(B) PRE-START HORN (B) FEED/DISCH. CHUTE
(B) DRIBBLE CONVEYOR: WIDTH (S) (B) LOADING SKIRTBOARD

LENGTH (S) (B) TRAMP IRON MAGNET
MOTOR KW (S) (B) BELT SCALE (2)
(B) BUYER (B) METAL DETECTOR
(S) SELLER (B) TRIPPER
Y YES
N NO
NOTES

SHEET 5 OF 8
PULLEY ASSEMBLIES
PULLEYS & SHAFTS PILLOW BLOCKS

LOCA- BRG.
TYPE (Note
TION D F a b c d1 d2 d3 e f
1)
LAGGING WEIGHT TYPE SEAL SERIAL N° L-10
(*) LIFE
mm mm mm mm mm mm mm mm mm mm A B mm kg Hours
1
2
3
4
5
6
f b e
a
F
d1 d2
d3
D
(*) Attach profile sketch with pulley location number
** Weight includes Shell, Shaft, bearings & locking assemblies
Fillet radii shall not be less than 25 % of the minor shaft dia.
Fillet radii shall be two times the difference in diameters, that is: R = 2 x (D - d)
Fillet radii shall not be less than 10 mm
NOTES
1 Enter C (CROWNED FACE) or F (FLAT FACE) in column "A".

Enter S (STANDARD PULLEY) or E (ENGINEERED PULLEY) in column "B".

SHEET 6 OF 8
PULLEYS STANDARD PULLEY - NA (B) ENGINEERED PULLEY
CODES: FOR TOLERANCES & LOAD RATINGS:

FOR N.D. EXAMINATION
FOR WELDING:
APPLICATION:
FACE WIDTH : FABRIC BELT
INDICATOR RUNOUT:
BEFORE LAGGING:
AFTER LAGGING:
LAGGING: DRIVE PULLEYS:
HARDNESS (SHORE A)
THICKNESS
LAGGING- OTHER PULLEYS:
HARDNESS(SHORE A)
THICKNESS:
HUB LOCKING DEVICE: TYPE
TYPE
MAKE/MODEL NO:
END DISCS: TYPE:
THICKNESS:
ALLOWABLE STRESS:
MATERIAL:
SHAFTS:
SERVICE FACTOR
BENDING MOMENT:
TORSIONAL MOMENT
SLOPE
ULTRA SONIC : ASTM A 388

N.D.EXAMINATION a. No indications greater than 75 % of the reference back reflection
AND ACCEPTANCE b. No area showing a 90 % or greater loss of back reflection.
CRITERIA MAGNETIC PARTICLE : ASTM E 709
a. No cracks.
MATERIAL: UNDER 150 mm ( 6 in ) DIA.: COMMERCIAL COLD ROLLED STEEL (CRS)

150 mm AND LARGER DIA. : FORGED STEEL
TURNDOWN: TURN DOWN OF SHAFT UNDER 150 mm DIA. IS NOT PERMITTED.
FINISH : 1.25 microns (32 micro-inch) or better
ALLOWABLE STRESS
COMBINED BENDING & TORSION
WITH KEYWAY
WITHOUT KEYWAY
BENDING ONLY
WITH KEYWAY
WITHOUT KEYWAY
NOTES

SHEET 7 OF 8
MISCELLANEOUS STRUCTURAL STEEL & OTHER MATERIALS
STRINGERS;
SIZE
TRUSS;
W(mm) x H(mm) x SPAN(m)
TOTAL WEIGHT
GALLERY; W(mm) x H(mm) x SPAN(m)
THICKNESS mm
GALLERY ENCLOSURE;
MATERIAL:
THICKNESS: mm
HOODS; MATERIAL:
THICKNESS: mm
WINDBOARDS; MATERIAL:
THICKNESS: mm
FLOORING; TYPE:
TOTAL WEIGHT: kg
STAIR TREADS;
TYPE:
SIZE: mm
DECK PLATE; GAGE:
TOTAL LENGTH: m
FEED/DISCHARGE MATERIAL & No:
CHUTES THICKNESS: mm
LINER MATERIAL:
FEED AND TRANSFER THICKNESS: mm
CHUTES TOTAL WEIGHT: kg
MATERIAL:
THICKNESS: mm
TOTAL WEIGHT: kg
FEED /TRANSFER CHUTE WIDTH
For 900 mm and smaller belts
For 1000 mm and wider belts
TOTAL WEIGHT:
SKIRTBOARDS: LENGTH m
THICKNESS mm
SKIRTBOARD MATERIAL
LINERS: THICKNESS
TOTAL WEIGHT:
SEALING STRIPS
DUST ENCLOSURE MATERIAL
AT FEED AREA THICKNESS
WEIGHT MECHANICAL (S) WEIGHT: PLATE AND STRUCTURAL STEEL (S)
TOTAL SHIPPING WEIGHT; kg TOTAL SHIPPING WEIGHT; kg

HEAVIEST PIECE FOR SHIPMENT: kg HEAVIEST PIECE FOR SHIPMENT: kg
HEAVIEST PIECE FOR ERECTION: kg HEAVIEST PIECE FOR ERECTION: kg
HEAVIEST PIECE FOR MAINTENANCE kg
NUMBER OF PACKAGES:
NOTES

SHEET 8 OF 8
MATERIAL: Coarse Copper Ore

SIZE: 250 x 0 mm AMBIENT TEMP.: MAX 34 °C
BULK DENSITY FOR VOLUME: 1.6 t/m3 MIN. -20 °C
FOR WEIGHT: 2.1 t/m3 MAX. RAIN FALL: See Section 9 of MR
ANGLE OF REPOSE: 37 deg. ANNUAL : mm/yr
SURCHARGE ANGLE: (CEMA) 15 deg. SINGLE STORM : mm/hr
HARDGROVE INDEX: Later MAX. SNOW FALL: See Section 9 of MR
MOISTURE CONTENT : ANNUAL: mm/yr
Max 8 % SINGLE RECORDED: mm/hr
Min 3 % MAX. WIND VELOCITY: 110 km/hr
ABRASIVENESS: Abrasive PREVAILING WIND DIRECTION: See Section 9 of MR
CORROSIVENESS: No PLANT SITE ELEV. (above MSL): 3000 m
DESIGN CAPACITY: 8,700 t/h (Dry metric) SEISMIC ZONE: UBC Seismic Zone 4
BELT WIDTH: 1800 mm ELECT. AREA CLASSIFICATION: None
BELT SPEED: (max) 6 m/sec OPERATING SCHEDULE: 24 hrs/day
BELT LOADING : % 7 days/wk
(OF CEMA LOAD CROSSSECTION) 365 days/yr
*Largest piece (occasional) 250 x 250 x 500 mm
**UBC Seismic Zone 4
CALCULATIONS: CEMA X DIN OTHER NEW ELECT. MOTOR POWER: 4 X 2500 kw (S)
ALLOWABLE BELT SAG 1 % (B) RUNNING TENSION: 2520 kN (S)
MINIMUM EDGE DISTANCE: 180 mm (B) ACCEL. TENSION: 2040 kN (S)
METHOD OF ACCEL. CONTROL: AFD (B) BRAKE RATING: kw (S) 3220 kN (S)
ACCELERATION TIME: N/A sec (S) DRIVE WRAP ANGLE: 170+180 deg (S)
COASTING TIME: N/A sec (S) DRIVE FRICTION FACTOR:
COASTING DISTANCE: 120 m (S) RUNNING: 0.35 (S)
BRAKING TIME (LEVEL 1): 80 sec (S) DECEL: 0.25 - 0.35 (S)
BRAKING DISTANCE: 240 m (S) COUNTER WEIGHT: 200 kN (S)
STARTING TORQUE: 100% N-m (S) TAKEUP DISPLACEMENT: m (S)
BRAKEAWAY TORQUE: 130% N-m (S) ORIGINAL CAPACITY: (S)
DRIVE EFFICIENCY: 95 % (S) ELECT. MOTOR POWER: 3 x 2500 kw (S)
CONVEYOR PROFILE (3) Tertiary pulley FEED (1) Primary

Drive Pulley
Drop
526.62m 6
4
(2) Secondary Hydraulic adjustment
5 Drive Pulley for maintenance
Gravity
take up
Length 5,280.82
NOTES
All dimensions are in meters
Max. Loading Angle: 10°
Max. Conveyor Angle: 15°
* 1 (B) INDICATES BUYER. (A) INDICATES SELLER

2 ALL (B) ITEMS SHALL BE COMPLETED BY BUYER. ALL (A) ITEMS SHALL BE COMPLETED BY SELLER
3 NOT APPLICABLE (NA) SHALL BE ENTERED WHERE INFORMATION IS NOT RELEVANT
0 ISSUED FOR PURCHASE
B ISSUED FOR BIDS MFD FG FG CZ
A 6.17.05 ISSUED FOR COORDINATION AND APPROVAL MFD FG FG CZ
REV DATE R E V I S I O N ENG SUPV CHIEF P.E CLIENT
SHEET 1 OF 8
DRIVE TRAIN: CV-006D (only) TYPE: X ELECTRIC MOTOR WITH GEAR REDUCER
HYDRAULIC MOTOR
GEAR REDUCER SPECIFIED BY BECHTEL SUPPLIER DATA
DESIGN CODE AGMA 6010-E
MANUFACTURER FLENDER
MODEL NO.
REDUCER TYPE: PARALLEL SHAFT
X RIGHT ANGLE TRIPLE REDUCTION
SHAFT MOUNTED (up to 40 kw or 150 mm dia. shaft)
REDUCER MOUNTING SHAFT MOUNTED "V" BELT DRIVE
DIRECTLY CONNECTED SHAFT MOUNTED
X COMMON BASE PLATE
CHAIN DRIVE IS NOT ACCEPTABLE.
REDUCER DESIGN FACTORS MINIMUM SERVICE RATINGS:
SHALL BE APPLIED OVER THE MECHANICAL: 1.5
NAME PLATE KW OF THE THERMAL: 1.0
MOTOR. DURABILITY: 2.0 (pitting)
STRENGTH: 3.0 (teeth)
INPUT SHAFT DIA. 180 mm
OUTPUT SHAFT DIA. OD FLANGE 1200 mm
INPUT SPEED: 1020 RPM
OUTPUT SPEED: 45.47 RPM
HOUSING CAST IRON GGG40
BEARING TYPE
BEARING L-10G LIFE: 80,000 hrs min. for continuous brake loading. 80,000 hrs
BEARING SEAL (at nominal speed)
ACCESSORIES: X FILLER PLUG Provision for Installatioin
X DRAIN PLUG or forced lubrication &
X OIL LEVEL INDICATOR oil cooler in future.
X BREATHER Internal piping is installed
X HEATER WITH LOW & HIGH TEMP. SWITCHES
LUBRICATION: SPLASH
X FORCED
OPERATING TEMPERATURE: As per discussions 70 °C MAX. °C
COOLING METHOD DRIVE FAN NONE DR. FAN
X FLENDER AIR-OIL EXTERNAL HEAT EXCH. X HEAT EXCHANGER
OUTSIDE DIMENSIONS/WEIGHT 4680 x 1760 x 2126 mm (length x width x height) 29,370 kg
METHOD OF SOFT START HYDRAULIC CPLG. W/CONST.FILLING
REQUIRED WITH DRIVES & DELAY CHAMBER
AT 60 KW (75 HP) OR HIGHER. HYDRAULIC CPLG.-SCOOP TYPE
REQUIRED FOR CONVEYORS WITH WOUND ROTOR MOTOR (ALTERNATE)
CONCAVE VERTICAL CURVES X FREQUENCY CONTROL
ACCELERATING TENSION D.C. MOTOR
SHALL NOT EXCEED 150 %
OF RATED BELT TENSION.
NOTES
06/28/06

SHEET 2 OF 8
COUPLINGS (TERTIARY PULLEY) HIGH SPEED LOW SPEED
MANUFACTURER: NAESCHER
TYPE AND MODEL NO.: 30313-540, Proj. 49227
BORE DIA.: 540.00 mm mm
SIZE: TAS3013-540/675 (Locking device)
SERVICE FACTOR 3.20
V-BELTS:
QTY:
SIZE:
MOTOR SHEAVE P.D.
DRIVEN SHEAVE P.D.
HOLDBACK:
MANUFACTURER:
TYPE AND MODEL NO.:
TORQUE RATING:
HYDRAULIC COUPLING:
MANUFACTURER:
TYPE:
MODEL NO.
RATING:
TAKE-UP:
TYPE:
TRAVEL:
WINCH TAKE-UP
GRAVITY TU WEIGHT:
LOCATION- WINCH TU
LOCATION- GRVTY TU
BRAKE: (DISK 31/32)

TYPE: MECHANICAL CALIPER-DISK HYDRAULIC APPLIED
MANUFACTURER: JOHNSON
DISK DIA (mm) 2500 MM
NO OF DISKS TWO ON TERTIARY PULLEY, TOTAL ON CONVEYOR: SIX
CALIPERS PER DISK TWO
RATING: 561KN PER DISK
LOCATION TERTIARY PULLEY (NON-DRIVEN)
HYDRAULICS-
DESCRIPTION REFER TO O&M MANUALS & PIDs
MOTOR kW
FLYWHEEL: YES X NO
LOCATION: HIGH SPEED COUPLING
SIZE:
HYDRAULIC DRIVE: YES X NOT REQUIRED

MANUFACTURER:
TYPE AND MODEL NO.:
SIZE:
SPEED:
DESIGN PRESSURE:
OPERATING PRESSURE:
TORQUE RATING:
EFFICIENCY:
06/28/06

SHEET 3 OF 8
BELTING:
MANUFACTURER
BRAND NAME
DESIGNATION/CODE
TYPE: FABRIC STEEL CORD
BELT WIDTH
TOTAL LENGTH:
TAPED LENGTH:
TENSION RATING:
MAX. OPER. TENSION:
ULTIMATE TENSILE STRENGTH
BELT WEIGHT:
TYPE OF FABRIC
NO OF PLIES
BREAKER ON FACE
FABRIC BELT BREAKER THICKNESS
TEMPERATURE RATING :
COEFF. OF THERMAL EXPANSION ( HR ):
FILL MATERIAL:
FRICTION RATING BETWEEN PLIES:
CORD DIA. :
CABLE BREAKING STRENGTH:
CABLE SPACING:
STEEL CORD MODULUS OF ELASTICITY AT RATED TENSION:
PULL-OUT STRENGTH OF CABLE :
> 10,000 cycles
ADHESION BETWEEN COVER AND BONDING RUBBER:
IMPACT RESISTANCE: PHOENIX TEST RIG
HOT VULCANIZED COLD VULCANIZED MECH.

NO. OF STEPS
LENGTH OF STEPS:
BELT SPLICE LENGTH OF SPLICE:
DYNAMIC SPLICE STRENGTH AT MAX. LOAD DIN 2210
STATIC SPLICE BREAKING STRENGTH IN % OF ULTIMATE

TENSILE STRENGTH
THICKNESS: TOP:
BOTTOM :
COVER MINIMUM TENSILE STRENGTH:
RMA GRADE:
TOLERANCE: PLUS:
MINUS:
REPAIRS CARCASS:
COVER:
BELT LENGTH / REEL:

PACKING NO. OF REELS:
REEL DIA.:
REEL GROSS WEIGHT:
NOTES
6.17.05

SHEET 4 OF 8
IDLERS
MODEL N°
GARLAND
35° 35° RETURN RETURN

RETURN
CARRY IMPACT TRANSI- RETURN RUBBER "V" CARRY RETURN
"V" 5-ROLL 3 ROLL
3 EQUAL 3 EQUAL TION FLAT DISC 2 ROLL OR TRAIN. TRAIN
INVERT.
ROLLS ROLLS TYPE 3 ROLL
QUANTITY REQUIRED:(S)
LOAD RATING:
SPACING: (S)
* IMPACT ZONE:
* UNDER SKIRTBRD: (S)
GENERAL:
DISTANCE FROM
HEAD OR TAIL PULLEY
ROLL DIA.
SHELL THICKNESS:(S)
SHAFT DIA (S).
BEARING DIA.(S)
BEARING TYPE: (S)
BEARING L-10 LIFE(S)
SEAL TYPE:(B)
MULTI - LABYRINTH
SEALED FOR LIFE
CEMA NO./DIN
END SHIELD:(B)
ADJUSTABLE TROUGHING
ANGLES:(B)
INCREMENT:
SAFETY DEVICES ACCESSORIES
(B) START/STOP CONTROL SW. (B) PULLEY GUARD (B) DUAL BELT SCRAPER
(B) ZERO SPEED SWITCH (B) CPLG. GUARD
TYPE (S): (B) RETURN BELT V PLOW
(B) BELT ALIGNMENT SWITCH. (B) BELT RIP PROTECTION (B) V PLOW AT TU PULLEY
(B) EMERG. PULL CORD SWITCH (B) PLUG CHUTE DETECTOR (B) BRAKE
1 SIDE 2 SIDES (B) BELT SEAL
(B) PRE-START HORN (B) FEED/DISCH. CHUTE
(B) DRIBBLE CONVEYOR: WIDTH (S) (B) LOADING SKIRTBOARD

LENGTH (S) (B) TRAMP IRON MAGNET
MOTOR KW (S) (B) BELT SCALE (2)
(B) BUYER (B) METAL DETECTOR
(S) SELLER (B) TRIPPER
Y YES
N NO
NOTES

6.17.05 EQUIPMENT TITLE LOS PELAMBRES DS N°: 25100-220-MHD-MHCB-00002
COARSE ORE CONVEYOR N° 2 2.00
SHEET 5 OF 8
PULLEY ASSEMBLIES
PULLEYS & SHAFTS PILLOW BLOCKS

LOCA- BRG.
TYPE (Note
TION D F a b c d1 d2 d3 e f
1)
LAGGING WEIGHT TYPE SEAL SERIAL N° L-10
(*) LIFE
mm mm mm mm mm mm mm mm mm mm A B mm kg Hours
1
2
3
4
5
6
f b e
a
F
d1 d2
d3
D
(*) Attach profile sketch with pulley location number
** Weight includes Shell, Shaft, bearings & locking assemblies
Fillet radii shall not be less than 25 % of the minor shaft dia.
Fillet radii shall be two times the difference in diameters, that is: R = 2 x (D - d)
Fillet radii shall not be less than 10 mm
NOTES
1 6.17.05
Enter S (STANDARD PULLEY) or E (ENGINEERED PULLEY) in column "B".
EQUIPMENT N° PROJECT: JOB N°: 25100 0

COARSE ORE CONVEYOR N° 2 2.00
SHEET 6 OF 8
PULLEYS STANDARD PULLEY - NA (B) ENGINEERED PULLEY
CODES: FOR TOLERANCES & LOAD RATINGS:

FOR N.D. EXAMINATION
FOR WELDING:
APPLICATION:
FACE WIDTH : FABRIC BELT
INDICATOR RUNOUT:
BEFORE LAGGING:
AFTER LAGGING:
LAGGING: DRIVE PULLEYS:
HARDNESS (SHORE A)
THICKNESS
LAGGING- OTHER PULLEYS:
HARDNESS(SHORE A)
THICKNESS:
HUB LOCKING DEVICE: TYPE
TYPE
MAKE/MODEL NO:
END DISCS: TYPE:
THICKNESS:
ALLOWABLE STRESS:
MATERIAL:
SHAFTS:
SERVICE FACTOR
BENDING MOMENT:
TORSIONAL MOMENT
SLOPE
ULTRA SONIC : ASTM A 388

N.D.EXAMINATION a. No indications greater than 75 % of the reference back reflection
AND ACCEPTANCE b. No area showing a 90 % or greater loss of back reflection.
CRITERIA MAGNETIC PARTICLE : ASTM E 709
a. No cracks.
MATERIAL: UNDER 150 mm ( 6 in ) DIA.: COMMERCIAL COLD ROLLED STEEL (CRS)

150 mm AND LARGER DIA. : FORGED STEEL
TURNDOWN: TURN DOWN OF SHAFT UNDER 150 mm DIA. IS NOT PERMITTED.
FINISH : 1.25 microns (32 micro-inch) or better
ALLOWABLE STRESS
COMBINED BENDING & TORSION
WITH KEYWAY
WITHOUT KEYWAY
BENDING ONLY
WITH KEYWAY
WITHOUT KEYWAY
NOTES
6.17.05

SHEET 7 OF 8
MISCELLANEOUS STRUCTURAL STEEL & OTHER MATERIALS
STRINGERS;
SIZE
TRUSS;
W(mm) x H(mm) x SPAN(m)
TOTAL WEIGHT
GALLERY; W(mm) x H(mm) x SPAN(m)
THICKNESS mm
GALLERY ENCLOSURE;
MATERIAL:
THICKNESS: mm
HOODS; MATERIAL:
THICKNESS: mm
WINDBOARDS; MATERIAL:
THICKNESS: mm
FLOORING; TYPE:
TOTAL WEIGHT: kg
STAIR TREADS;
TYPE:
SIZE: mm
DECK PLATE; GAGE:
TOTAL LENGTH: m
FEED/DISCHARGE MATERIAL & No:
CHUTES THICKNESS: mm
LINER MATERIAL:
FEED AND TRANSFER THICKNESS: mm
CHUTES TOTAL WEIGHT: kg
MATERIAL:
THICKNESS: mm
TOTAL WEIGHT: kg
FEED /TRANSFER CHUTE WIDTH
For 900 mm and smaller belts
For 1000 mm and wider belts
TOTAL WEIGHT:
SKIRTBOARDS: LENGTH m
THICKNESS mm
SKIRTBOARD MATERIAL
LINERS: THICKNESS
TOTAL WEIGHT:
SEALING STRIPS
DUST ENCLOSURE MATERIAL
AT FEED AREA THICKNESS
WEIGHT MECHANICAL (S) WEIGHT: PLATE AND STRUCTURAL STEEL (S)
TOTAL SHIPPING WEIGHT; kg TOTAL SHIPPING WEIGHT; kg

HEAVIEST PIECE FOR SHIPMENT: kg HEAVIEST PIECE FOR SHIPMENT: kg
HEAVIEST PIECE FOR ERECTION: kg HEAVIEST PIECE FOR ERECTION: kg
HEAVIEST PIECE FOR MAINTENANCE kg
NUMBER OF PACKAGES:
NOTES

SHEET 8 OF 8
C:\Docs y Planos\OM Manual\vol 1 english mechanical\Section 2 (Drawings)\1. Lpla0303.dwg
2 of 2
C:\Docs y Planos\OM Manual\vol 1 english mechanical\Section 2 (Drawings)\2. Lpla0314.dwg
2 of 2
C:\Docs y Planos\OM Manual\vol 1 english mechanical\Section 2 (Drawings)\3. Lple322A1.dwg
1 of 2
1 of 2
C:\Docs y Planos\OM Manual\vol 1 english mechanical\Section 2 (Drawings)\5. Lple3261.dwg
1 of 2
1 of 2
1 of 2
1 of 2
1 of 2
Documentation
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Code / Project LOS PELAMBRES

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Customer Thyssen Krupp Robins USA

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Order.-No. 316047
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Flender Order.-No. 4214492

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Driven machine Förderbandantrieb

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Main gear unit B3FH28

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Year built 2006

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Voerde / Friedrichsfeld 2006-08-22
A. Friedr. Flender AG ⋅ D 46393 Bocholt ⋅ Tel. 02871/92-0 ⋅ Telefax 02871/92-2596 ⋅ http://www.flender.com

Documentation chart
LOS PELAMBRES
Please quote in correspondence TD 4214492 EN

Order-no.: 321752
Item Product Documents / Operating instructions

Technical data TD 4214492 EN
00 Drive system Dimension drawing 6 107 291 b
Drive plan 6 110 802 e
Operating instructions BA 3600 EN 08.98 Coupling
Coupling Dimension drawing
020 6 106 880 c
RWS 710 Spare part drawing
Spare parts list SL 4214492-020 DE/EN
BA 5010 EN 06.03 Gear unit
BA 7300 EN 01.05 Lubricants
BA 5100 EN Oil drain valve
BA 5122 EN Breather filter
Operating instructions BA 5926 EN Temperature monitor
BA 6100 EN Resistance thermometer
BA BA HYC.ANZ.000 EN Oil level control
Gear unit
040/185 BA HEL.PAT.000 EN Cartridge heater
B3FH 28
BA TUR.SEN.032 EN Pulse transmitter
Dimension drawing See item 00
Spare part drawing 6 107 299 -
Spare parts list EL 4214492-040 DE/EN
EL 4214492-185 DE/EN
List of equipment
BA 1.319.555 EN Oil supply system
BA STE.PUM.000 EN Gear pump
BA 5921 EN Double change-over filter
BA FUN.OLK.001 EN Air oil-cooler
BA MVA.REG.000 EN Temperature control valve
Operating instructions
BA 5914 EN Manometer
BA DAN.DUM.000 EN Pressure transducer
Oil supply system
065 BA 5924 EN Thermometer
OLGS 11
BA 6100 EN Resistance thermometer
BA 5927 EN Flow monitor
Dimension drawing 6 113 279 -
Lubrication schedule 6 113 280 -
Connection plan 6 113 281
List of equipment GL 1.319.555 EN
A. FRIEDR. FLENDER AG, D - 46393 Bocholt Datum Name Abt.

Tel. 02871/92-0; Fax 02871/922596 25.08.2006 Hammacher HDVD.FR
Operating Instructions Type B3FH Page
Section 1 1 of 1
Technical Data Size 28
Please quote in correspondence TD 4214492-040/185 EN
Project : LOS PELAMBRES
Gear unit : B3FH 28

Motor power : 2500 kW
Output power : 2500 kW
Actual ratio : 22,432
Input speed : 1020 1/min
Output speed : 45,47 1/min
Weight main gear unit (without oil filling) : ∼ 29370 kg
Heaviest component weight : ∼14300 kg
Oil quantity : ∼ 1300l
Oil viscosity : ISO VG 220 (PAO-oil)
Code number our BA 7300 : A34
Interior conservation : 24 months begin September 2006
Installation:
Ambient temperature : -12 ... +34 °C
Space : big hall
Diese technische Unterlage hat gesetzlichen Schutz ( DIN 34 )
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: THL/STG HD

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 2006-08-22 Rev.: )
Operating Instructions
BA 3600 EN 08.98
Flexible RUPEX couplings,
type RWN, RWS and RWB, RBS
RWN
RWS
RWB
RBS
A. Friedr. Flender AG ⋅ 46393 Bocholt ⋅ Tel. 02871/92-0 ⋅ Telefax 02871/92-2596 ⋅ www.flender.com

Contents
1. Technical data 4
1.1 Validity of the nominal torques TKN 4
1.2 Types RWN and RWS 4
1.3 Types RWB and RBS 6
2. General notes 7
2.1 General 7
3. Safety notes 8
3.1 Safety notes 8
3.1.1 Notes and symbols in the operating instructions 8
4. Handling and storage 9

4.1 Scope of supply 9
4.2 Handling 9
4.3 Storage 9
4.3.1 Storage of the coupling parts 9
4.3.2 Storage of the buffers 9
4.3.2.1 General 9
4.3.2.2 Storage room 9
5. Technical description 10
5.1 General description 10
6. Assembly 11
6.1 Notes on fitting the finished bore, the axial securing, the set screws, the balancing 11
6.1.1 Finished bore 11
6.1.1.1 Keyway 12
6.1.2 Axial securing 12
6.1.3 Set screws 12
6.1.4 Balancing 13
6.2 General installation notes 13
6.3 Mounting the coupling parts 14
6.4 Aligning 14
6.5 Possible misalignments 15
6.5.1 Axial misalignment 15
6.5.2 Angular misalignment 15
6.5.3 Radial misalignment 15
6.6 Assignments of the tightening torques 16
7. Startup 16
7.1 Measures before startup 16
8. Operation 17
8.1 General operating data 17
9. Disturbances, reasons and remedy 17

9.1 General 17
9.2 Possible malfunctions 17
BA 3600 EN 08.98

10. Maintenance and repair 18
10.1 General 18
10.2 Change of wear parts 18
11. Spare parts stock, service facility addresses 19

11.1 Service facility addresses 19
12. Declaration by the manufacturer 24
BA 3600 EN 08.98

1. Technical data
1.1 Validity of the nominal torques TKN

Validity of nominal torques TKN (with original RUPEX buffer of buna N, hardness 80 Shore only):
S daily operating cycle up to 24 h
S during the starting process or during operation, torque impulses up to the triple nominal torque are
allowed up to 25 times per hour.
S Operation within the prescribed alignment
S Operation in the temperature range from - 30 °C to + 80 °C (ambient temperature or temperature of
the shaft ends).
For permanent trouble-free operation, the coupling has to be designed with a
Caution! service factor appropriate to the respective application. When changing the
operating conditions (performance, speed, changes on power engine and
machine), a check of the design is absolutely necessary.
1.2 Types RWN and RWS
w1 u
S1 S1
1 P u 2 1 P u 2
l l l l
da
da
d2
d2
d2
d2
D1
D1
D1
D1
Size 105 - 360 Size 400
u u
S1 S1
1 P u 2 1 P u 2
l l l l
da
da
d2
d2
d2
d2
D1
D1
D1
D1
v v v v
Size 450 - 500 Size 560 - 2000
BA 3600 EN 08.98

Nominal Speed Bore Weight 2)
torque
TKN nmax from to da l v P S1 w1 u RWN RWS
Size
1) RWN RWS RWN RWS Part 1 Part 2 Part 1 Part 2
D1/2 D1 D2 D1 D2 d1 d2
Nm 1/min 1/min mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg
105 200 5000 5000 10 32 38 32 38 105 53 59 45 30 2... 4 12 13 0.8 1 0.9 1.1
125 350 5000 5000 14 40 48 40 48 125 65 68 50 35 2... 4 15 16 1.4 1.5 1.5 1.6
144 500 4900 5000 18 45 55 50 60 144 76 84 55 35 2... 4 15 16 1.9 2.6 2.1 2.8
162 750 4300 5000 22 50 60 55 65 162 85 92 60 40 2... 5 18 20 2.8 3.9 3 4.2
178 950 3800 4900 24 60 70 780 75 178 102 108 70 40 2... 5 18 20 4.1 5.6 4.4 6.1
198 1300 3400 4600 28 70 80 80 85 198 120 128 80 40 2... 5 18 20 5.9 7 6.4 7.6
228 2200 3000 4400 28 80 90 85 95 228 129 140 90 50 2... 5 24 26 7.3 11.5 7.9 12.5
252 2750 2700 4200 38 90 100 100 110 252 150 160 100 50 2... 5 24 26 10.5 15.5 11.5 16.5
285 4300 2400 3900 48 100 110 110 120 285 164 175 110 60 3... 6 30 32 16 23 17.5 25
320 5500 2100 3500 55 110 120 125 130 320 180 192 125 60 3... 6 30 32 23 30 25 32
360 7800 1900 3100 65 120 130 135 140 360 200 210 140 75 3... 6 42 42 32 46 35 50
400 12500 1700 2800 75 140 140 150 150 400 230 230 160 75 3... 6 42 53 53 57 57
450 18500 1500 2500 85 160 160 170 170 450 260 260 180 90 4... 7 52 78 78 84 84
500 25000 1350 2200 95 180 180 190 190 500 290 290 200 90 4... 7 52 99 99 105 105
100 140 140 165 165 250 250 140 140 150 150
560 39000 1200 2000 > 140 180 180 200 200 560 300 300 220 70 120 4... 8 68 145 145 155 155
> 180 200 200 210 210 320 320 145 145 155 155
100 140 140 165 165 250 250 175 175 190 190
630 52000 1050 1800 > 140 180 180 200 200 630 300 300 240 80 120 4... 8 68 185 185 200 200
> 180 220 220 235 246 355 355 200 200 215 215
110 160 160 190 190 290 290 255 255 275 275
710 84000 950 1600 > 160 200 200 220 220 710 330 330 260 80 140 5... 9 80 260 260 280 280
> 200 240 240 250 250 385 385 270 270 290 290
125 180 180 210 210 320 320 330 330 360 360
800 110000 850 1400 > 180 220 220 240 240 800 360 360 290 90 140 5... 9 80 350 350 380 380
> 220 260 260 280 280 420 420 360 360 390 390
140 180 180 210 210 320 320 450 450 490 490
> 180 220 220 240 240 360 360 450 450 490 490
900 150000 750 1250 900 320 100 160 5...10 90
> 220 260 260 280 280 425 425 480 480 520 520
> 260 290 290 310 310 465 465 510 510 550 550
150 200 200 230 230 355 355 560 560 610 610
> 200 240 240 260 260 395 395 580 580 630 630
1000 195000 680 1100 1000 350 110 160 5...10 90
> 240 280 280 300 300 460 460 630 630 680 680
> 280 320 320 340 340 515 515 660 660 710 710
160 200 200 240 240 360 360 730 730 790 790
> 200 250 250 270 270 410 410 750 750 810 810
1120 270000 600 1000 1120 380 120 180 6...11 100
> 250 300 300 330 330 495 495 800 800 870 870
> 300 350 350 370 370 560 560 840 840 910 910
180 230 230 270 270 410 410 920 920 1000 1000
> 230 280 280 300 300 460 460 950 950 1050 1050
1250 345000 550 900 1250 420 130 180 6...11 100
> 280 330 330 360 360 540 540 1000 1000 1050 1050
> 330 380 380 400 400 610 610 1100 1100 1150 1150
200 260 260 310 310 465 465 1400 1400 1500 1500
> 260 320 320 350 350 525 525 1450 1450 1550 1550
1400 530000 490 800 1400 480 145 210 6...12 120
> 320 380 380 410 410 620 620 1550 1550 1650 1650
> 380 440 440 460 460 700 700 1650 1650 1750 1750
260 320 320 370 370 565 565 1900 1900 2050 2050
> 320 380 380 410 410 625 625 1950 1950 2100 2100
1600 750000 430 700 1600 540 165 210 6...12 120
> 380 440 440 480 380 720 720 2050 2050 2200 2200
> 440 480 480 510 510 770 770 2150 2150 2300 2300
320 380 380 440 440 660 660 2750 2750 3000 3000
> 380 440 440 480 480 720 720 2800 2800 3050 3050
1800 975000 380 600 1800 600 185 240 8...16 140
> 440 500 500 540 540 820 820 3000 3000 3250 3250
> 500 540 540 580 580 870 870 3150 3150 3400 3400
380 440 440 500 500 760 760 3400 3400 3700 3700
> 440 500 500 540 540 820 820 3500 3500 3800 3800
2000 1300000 340 550 2000 660 200 240 8...16 140
> 500 560 560 610 610 920 920 3700 3700 4000 4000
> 560 600 600 640 640 960 960 3800 3800 4100 4100
Table 1.1: Torques TKN, speeds nmax, weights and sizes of type RWN and RWS
1) Observe the validity of the nominal torques TKN according to 1.1!
2) Weights are valid for max. bores.
BA 3600 EN 08.98

1.3 Types RWB and RBS
S1 b1
P u
Part 1 Part 3
D1
D3
2
d3
1
l
a
d
d
Nominal Bore Weight 2)

Speed
torque from to
Size TKN 1) nmax RWB RBS da l u P S1 d1 b1 RWB RBS
D1/3 D1 D3 D1 D3 d2 d3 Part 1 Part 3 Part 1 Part 3
Nm 1/min mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg
144 500 3400 18 45 55 50 60 144 76 84 55 16 35 2... 4 200 75 1.9 6.6 2.1 7.1
162 750 2750 22 50 60 55 65 162 85 92 60 20 40 2... 5 2.8 13 3 14
178 950 2750 24 60 70 70 75 178 102 108 70 20 40 2... 5 250 95 4.1 13.5 4.4 14.5
198 1300 2750 28 70 80 80 85 198 120 128 80 20 40 2... 5 5.9 15 6.4 16
178 950 2150 24 60 70 70 75 178 102 108 70 20 40 2... 5 4.1 21 4.4 22.5
315 118
198 1300 2150 28 70 80 80 85 198 120 128 80 20 40 2... 5 5.9 22.5 6.4 24.5
228 2200 1700 28 80 90 85 95 228 129 140 90 26 50 2... 5 7.3 41 7.9 44
400 150
252 2750 1700 38 90 100 100 110 252 150 160 100 26 50 2... 5 10.5 46 11.5 50
252 2750 1400 38 90 100 100 110 252 150 160 100 26 50 2... 5 10.5 74 11.5 80
500 190
285 4300 1400 48 100 110 110 120 285 164 175 110 32 60 3... 6 16 79 17.5 86
285 4300 1100 48 100 110 110 120 285 164 175 110 32 60 3... 6 16 130 17.5 140
320 5500 1100 55 110 120 125 130 320 180 192 125 32 60 3... 6 630 236 23 135 25 145
360 7800 1100 65 120 130 135 140 360 200 210 140 42 75 3... 6 32 145 35 155
320 5500 950 55 110 120 125 130 320 180 192 125 32 60 3... 6 710 265 23 180 25 195
Table 1.1: Torques TKN, speeds nmax, weights and sizes of type RWB and RBS
1) Observe the validity of the nominal torques TKN according to 1.1!
2) Weights are valid for max. bores.
BA 3600 EN 08.98

2. General notes
2.1 General
These Operating Instructions constitute part of the coupling shipment and should be kept in the
immediate vicinity of the coupling at all times.
Only a precise knowledge of the Operating Instructions will ensure trouble-free operation of the
coupling. It is therefore in the interest of our customer that the operating instructions are read,
understood and observed in all respects by the persons responsible for handling, installation and
operation.
Note: We accept no liability for any damage or malfunction resulting from non-observance
of the operating instructions.
The ”coupling” dealt with in these operating instructions was developed for stationary use in general
engineering.
The coupling is only designed for the field of application as specified in Section 1 ”Technical data”.
Operating conditions which differ from the stated will require fresh contractual agreements.
The coupling described here is in accordance with the state of the art at the time of these operating
instructions go into print.
In the interest of further development, we reserve the right to introduce modifications which, while
retaining the essential features, can be regarded as desirable to increase its efficiency and safety.
The copyright of these Operating Instructions remains the property of FLENDER AG.
These operating instructions may not be duplicated in part or whole, utilized for the purpose of publicity
or communicated to third parties without our expressed consent.
Please contact our works listed below in respect of all technical queries.
FLENDER AG
D 46393 Bocholt
Telephone: 02871/92-2800
Telefax: 02871/92-2801
or one of our service branches which are listed in Section 11 ”Stocking spare parts, service facility
addresses”.
BA 3600 EN 08.98

3. Safety notes
3.1 Safety notes
S The coupling is constructed in accordance with the state of the art and is reliable in the condition as
shipped. Unauthorized modifications which impair its reliability are not permissible. This also applies
to guards which are fitted as protection against accidental contact.
S The coupling may only be used and operated within the scope of the condition specified in the contract
of performance and supply.
S The customer should ensure that the persons entrusted with installation, operation, care and
maintenance as well as repair have read and understood the operating instructions and observe them
in all respects in order to:
– prevent hazard to life and limb of the user and third parties
– ensure the reliability of the coupling

and
– prevent failure and environmental pollution due to incorrect handling.
S The relevant regulations concerning industrial safety and pollution control should be observed during
handling, installation, operation as well as care and maintenance.
S The coupling may only be operated, serviced and repaired by authorized, trained and properly
instructed personnel.
S All work should be carried out with care with the safety aspect in mind.
S All work on the coupling may only be carried out when it is stationary.
The coupling must be secured to prevent accidental start up (e.g. by locking the key switch or by
removing the fuses and the power supply). A notice should be displayed at the switch-on point stating
that work is in progress on the coupling.
S The drive unit should be shut off at once if changes in the coupling are detected during operation, such
as e.g. changed running noises.
S The coupling must be protected by means of suitable guards to prevent accidental contact.
S During installation of the coupling in units or systems, the manufacturer of the units or systems is
obliged to incorporate the requirements, notes and descriptions contained in these operating
instructions in his own operating instructions.
3.1.1 Notes and symbols in the operating instructions
Instructions in the operating instructions which concern operating safety are emphasized as follows:
This symbol draws attention tosafety measures which must be observed to prevent
personal injury.
This symbol draws attention to safety measures which must be observed to prevent
Caution! damage to the coupling.
Note: This note draws attention to general operating notes which should be especially
observed.
BA 3600 EN 08.98

4. Handling and storage
4.1 Scope of supply
The scope of the shipment is listed in the shipping documents. They should be checked for
completeness on receipt. Any shipping damage and/or missing parts should be reported in writing at
once. After consulting FLENDER an expert is to be called in.
4.2 Handling
The packing of the coupling will differ depending on method of shipment and size. The packing, unless
otherwise agreed contractually, complies with HPE Packing Guidelines.
The symbols shown on the packing should be noted. Their meaning is as follows:
bild-transport
This way Fragile Keep Keep Centre of Use no Attach

up dry cool gravity hand hook here
Caution! Make sure that suitable hoists are used.
4.3 Storage
4.3.1 Storage of the coupling parts
The coupling is delivered in a preserved state and can be stored at a covered dry place up to 6 months.
If the coupling shall be stored for a longer period of time, an appropriate long-term preservation is
necessary (consultation with FLENDER required).
Before cleaning the coupling parts and applying the long-term preservation,
Caution! the buffers are to be removed.
4.3.2 Storage of the buffers
4.3.2.1 General
Properly stored buffers keep their characteristics for up to 5 years. Unfavourable storage conditions and
improper treatment of the buffers result in a negative change of the physical characteristics. These
changes can be caused by the effects of e.g. ozone, extreme temperatures, light, moisture or solvents.
4.3.2.2 Storage room
The storage room should be dry and dust-free. The buffers must not be stored together with chemicals,
solvents, fuels, acids, etc. Furthermore, they should be protected against light, especially against direct
sun light and strong artificial light with a high ultra-violet percentage.
The storage romms must not contain any ozone-producing devices like e.g.
Caution! fluorescent light sources, mercury-vapour lamps, electric high-voltage
devices. Damp storage rooms are unsuitable. Make sure that no condensation
develops. The relative humidity of air is most favourable below 65 %.
BA 3600 EN 08.98

5. Technical description
5.1 General description
1 2 1 3
P
6 5 4 8 10
RWN / RWS RWB / RBS
The RUPEX coupling type RWN and RWS consists of two coupling parts and the pins with the flexible
plastic buffers required for torque transmission. In the RWN version, the hub parts (1 and 2) are of grey
cast iron. In the RWS version, they are of steel.
The RUPEX coupling type RWB and RBS consists of a coupling part and a brake drum, with the pins
and flexible plastic buffers required for torque transmission. In the RWB version, the hub part (1) and
the brake drum (3) are of grey cast iron. In the RBS version, they are of steel.
Up to size 360, the ground steel pins are attached to the buffers only in the coupling part (2) (RWN and
RWS) or the brake drum (3) (RWB and RBS). From size 400 they are attached alternately in the coupling
parts (1 and 2). In the assembled state, the buffers engage the buffer bores of the counterpart.
The flexible plastic buffers of buna N have a hardness of 80 Shore. Buffers of differing material quality
and/or hardness are available within limits. With regard to the availability of these special buffers and
the extent to which the properties of the coupling are affected, please consult FLENDER.
BA 3600 EN 08.98

6. Assembly
6.1 Notes on fitting the finished bore, the axial securing, the set screws, the balancing
6.1.1 Finished bore
S Remove buffers.
S Remove the anti-corrosion agent from coupling parts
Observe manufacturer’s instructions on handling solvents.
When fitting the finished bore, align the parts carefully. For the permissible radial and axial excentricity
see DIN ISO 286 degree of fundamental tolerance IT8. The location of the parts ( ) is to be carried
out on the marked surfaces.
The maximum permissible boring diameters (see Section 1.) are designed for
Caution! driving connections without tightening according to DIN 6885/1 and must not
be exceeded in any case.
If other shaft hub connections (e.g. splined hub profile, tapered or graded bore, driving connection with
tightening, etc.) shall be fitted instead of the intended driving connections, FLENDER is to be consulted.
Non-observance of these notes may lead to the drifting of coupling.
There is a danger to life due to broken pieces flying around!
d1
A A
d1
D1
D1
3.2 3.2
IT8 A
IT8 A
Part 1 / Part 2 / Part 1/2 Part 3
In case of drive by means of parallel keys, the following fit pairings are prescripted for the bores:
Bore
Fit selection above to Shaft tolerances Boring tolerances
mm mm
25 k6
Shaft tolerance to FLENDER
25 100 m6 H7
standard
100 n6
50 k6
Shaft tolerance to DIN 748/1 H7
50 m6
50 K7
h6
Unified system shaft 50 M7
all h8 N7
Table 6.1: Fit pairings
Observing the fit correspondance is absolutely necessary, on the one hand in

Caution! order to keep low the backlash in the shaft hub connection or, on the other
hand, to keep the hub tension caused by the overdimension within the
permissible load depending on the use of the tolerance fields. It cannot be
excluded, that the shaft hub connection is endangered when the fit
correspondance is not observed.
Non-observance of these notes may lead to the bursting of the coupling.

There is a danger to life due to broken pieces flying around!
BA 3600 EN 08.98

6.1.1.1 Keyway
The keyways have to be designed according to the existing parallel keys. For keyways, the tolerance
field of the hub keyway width ISO JS 9 is to be observed.
For more difficult operating conditions, as it is the case for e.g. reversing operation of operation with
impulses, the tolerance filed of the hub keyway width ISO P9 is prescribed.
Caution! The keyways are to be set and centered between the buffer bores.
6.1.2 Axial securing

For axially securing the coupling parts, a set screw or an end plate has to be provided for. When using
end plates, FLENDER is to be consulted with regard to the insertion of recess in the coupling parts.
6.1.3 Set screws
Headless pins with notched cut point according to DIN 916 are to be used as set screws.
It is absolutely necessary to observe the following guidelines!
The length of the set screw is to be chosen so that it completely fills the cut hole
but that it does not protect over the hub (Lmin = d1 x 1.2).
Part 1 / Part 2 / Part 1/2 Part 3
Type RWN Type RWS

Bore range Set screw size Bore range Set screw size
above to d1 above to d1
mm mm mm mm mm mm
8 30 M 6 8 30 M 6
30 38 M 8 30 75 M 8
38 65 M10 75 95 M12
65 95 M12 95 110 M16
95 110 M16 110 150 M20
110 150 M20 150 230 M24
150 230 M24 230 600 M30
230 600 M30
Table 6.2: Set screw assignment
BA 3600 EN 08.98

Size 105 125 144 162 178 198 228 252 285 320 360 400 450
Distance dimension e1 15 20 25 25 35 40 40 50 55 60 70 80 80
Size 500 560 630 710 800 900 1000 1120 1250 1400 1600 1800 2000
Distance dimension e1 90 100 110 130 115 160 175 160 200 240 250 300 330
Break drum 200 x 75 250 x 95 315 x 118 400 x 150 500 x 190 630 x 236 710 x 265
Distance dimension e3 12 12 25 30 50 75 90
Tabelle 6.3: Distance dimensions of the set screws
Generally, the set screws are to be arranged on the keyway. This does not apply
Caution! to coupling parts 1+2 of sizes 105 and 125 where the set screw should be
arranged by 180° shifted to the keyway.
6.1.4 Balancing
Prebored couplings resp. prebored coupling parts are shipped unbalanced. For these parts et is
recommended to balance them depeding on the application case after finish boring (see also DIN 740,
VDI guideline 2060).
Balancing is usually carried out by material cutting through boring. In order ro restrict the material
quantity to be cut to a minium, the biggest possible balancing radius is to be selected.
For parts 1/2, cutting has to be carried out between the bores without
Caution! through-boring of the bottom. For part 32, the break surface must not be
damaged under any circumstances.
Finished bored couplings or coupling parts are balanced according to the instructions of the ording
party.
Balancing bore
Part 1 / Part 2 Part 3 Part 1 / Part 2 Part 3

Part 1/2 Part 1/2
Arrangement of the balancing bore Arrangement of the balancing bore

in case of one level balancing in case of two level balancing
6.2 General installation notes
For the installation the safety notes in Section 3. are to be observed.
The installation has to be carried out with utmost care by trained personnel.
Already during the planning phase it is to be observed that sufficient room is to be provided for the
installation and later inspection and maintenance work.
Before starting the installation a sufficient number of hoists must be provided for.
BA 3600 EN 08.98

6.3 Mounting the coupling parts
Before starting the assembly, clean the shaft ends, the brake drum and the coupling parts carefully.
Before cleaning the coupling parts with solvents, remove the buffers.
Observe the manufactuer’s instructions on handling the solvents.
The coupling parts and the brake drum are to be fitted by means of suitable
Caution! devices in order to prevent damage to the shaft bearing arrangement by the
axial fitting force.
Make sure that suitable hoists are used.
If it shall be possible to exchange the buffers or to move the coupled machines, the dimension P should
be taken into consideration during assembly according to 6.6.
Tightening of the set screws only by means of a hexgon socket head wrench
Caution! according to DIN 911, without an extension pipe.
Non-observance of these notes may lead to the burrsting of the coupling.

There is danger to life due to broken pieces flying around!
The assembly process is made easier by heating the coupling parts and the brake drum (3) (to max.
+150 °C). If using temperatures greater than +80 °C, the buffers/bolts must be removed from the
coupling parts before heating them.
Protect yourself against burns by hot parts!
After mounting the coupling parts or the brake drum, replace the buffers (if removed beforehand).
Tighten the nuts (7) and bolts (11) using a torque wrench (for correct torques, see section 6.6). Secure
bolts (11) with a few spots of adhesive (e.g. Loctite, type 242). Coupling parts which have been
previously heated must be allowed to cool to a temperature of less than 80 °C.
Loop together the machines to be coupled.

Danger of squeezing!
Observe the dimension S1 (see Section 1.).

6.4 Aligning
The couplings compensate for positional variations of the shaft ends to be connected up to the data
shown under item 6.5.
When aligning, keep the radial and angular misalignment of the shaft ends as small as possible because
hereby the service life of the flexible is increased under otherwise the same operating conditions.
The alignment should be realised in the order:

Ruler
1. angular alignment
2. radial alignment
and should be carried out in two axial planes vertical to

each other. This is possible by means of a feeler gauge
(angular misalignment) and a ruler (radial misalignment).
The distance dimension S1 is to be kept (see Section 1.).
By using a dial gauge, the alignment precision can be

Feeler gauge
increased.
BA 3600 EN 08.98

6.5 Possible misalignments
S1max S1max
D Kr
DKa
D Kw
S1min S1min
Axial misalignment Angular misalignment Radial misalignment

figure 6.1 figure 6.2 figure 6.3
Misalignments of the coupling parts may result from an inexact alignment during the assembly but also
from the operation of the plant (expansion due to heat, bending of the shaft, machine frame to soft, etc.).
The following max. permissible misalignments must not be exceeded during

Caution! operation under any circumstances.
6.5.1 Axial misalignment
Axial misalignment DKa (figure 6.1) of the

coupling parts to each other is permissible
within the ”permissible variation” for the
dimension S1 (see Section 1.).
6.5.2 Angular misalignment
The permissible angular misalignment DKw

Size
(figure 6.2) has to be determined taking into

consideration the speed factor Sn of figure 6.4.
DKwperm. =S1 max - S1 min = 0.00175 x da x Sn
da = Coupling size
6.5.3 Radial misalignment
The permissible radial misalignment DKr

(figure 6.3) has to be determined taking into
consideration the speed factor Sn of figure Speed factor
6.4.
DKrperm. = 0.00175 da Sn
da = Coupling size
Speed n [1/min]
figure 6.4
Angular and radial misalignments may occur at the same time. The sum of both
Caution! misalignments must not exceed the max. permissible value of the angular or
radial misalignment.
(Kw + Kr)existing ≤ DKw x Sn or DKr x Sn
BA 3600 EN 08.98

6.6 Assignments of the tightening torques
Tightening torque Wrench width

Size P TA Sw
mm Nm mm
105 30 12 10
125 35 30 13
144 35 30 13
162 40 60 17
178 40 60 17
198 40 60 17
228 50 65 19
252 50 65 19
285 60 150 24
320 60 150 24
360 75 220 27
400 75 220 27
450 90 180 24
500 90 180 24
560 120 340 30
630 120 340 30
710 140 580 36
800 140 580 36
900 160 600 36
1000 160 600 36
1120 180 1150 46
1250 180 1150 46
1400 210 1150 46
1600 210 1150 46
1800 240 2000 55
2000 240 2000 55
Table 6.4: Assignments of the tightening torques
7. Startup
7.1 Measures before startup
Before startup, check the tightening of the set screws, the alignment and the distance dimension S1 and
correct if necessary and check all screw connections for the prescribed tightening torques (see Section
1. and Section 6.). Finally, the coupling guard to prevent accidental contact is to be fixed.
BA 3600 EN 08.98

8. Operation
8.1 General operating data
During operation, the coupling should be checked for:
– any changes in running noises
– sudden shaking.
If irregularities are detected during operation, the drive assembly should be set
Caution! off immediately. The cause of the malfunction should be determined with the
aid of the Troubleshooting Table (Section 9.).
The Troubleshooting Table lists possible malfunctions, their causes and
suggestions for remedying them.
If the cause cannot be determined or there is no facility for repair with suitable
equipment, we recommend calling in one of our service fitters (see Section 11.).
9. Disturbances, reasons and remedy
9.1 General
The malfunctions listed below can only be hints for a troubleshooting.
In case of a complex plant, all other components have always to be included in the troubleshooting.
The coupling has to run with low noise and without shaking in all operating phases. Any deviating
behaviour is to be regarded as malfunction and should be repaired immediately.
Before maintenance work, repairs or other work, the operator should make sure
that the whole drive train is stationary. Especially the drive motors are to be
secured against accidental start up.
Futhermore, we refer to the relevant regulations on the prevention of accidents
at the place of installation.
9.2 Possible malfunctions
Malfunctions Causes Remedy
Sudden change of the noise Change of alignment Shut down the plant
level and/or sudden shaking
possibly repair the reason for
the change of alignment
(e.g. fasten loose foundation bolts)
Buffers worn, Shut down the plant

no dampening
Disassemble coupling and remove
the rests of the buffers
Check coupling parts and

exchange damaged coupling parts
Buffers are to be changed in sets
Check alignment and correct

if necessary, see Section 6.
Assembly of coupling acc.

to Section 6. ”Assembly”
and Section 7. ”Start up”.
BA 3600 EN 08.98

10. Maintenance and repair
10.1 General
The circumferential backlash between the two coupling parts should be checked according to the
maintenance intervals, however, at least once a year. As far as an increased backlash of the coupling
is not detrimental to the operation of the coupling, the elastic buffers may remain in use until a defined
wear limit is reached before they should be changed. For evaluating the wear, in Table 10.1, the
permissible circumferential backlash is listed, which is converted to the chord dimension DSV on the
outer coupling diameter. In order to determine the dimension DSV, a coupling part is turned until stop
without torque and a mark is made on the coupling part (see figure 10.1). By turning the coupling part
in the opposite direction of rotation until stop, the marks move apart. The distance between the marks
is the chord dimension DSV. If the dimension DSV exceeds the value listed in Table 10.1, the buffers
should be changed.
Caution! The buffers should be changed in sets.
figure 10.1 D SV
125 162 228 285 360 450 560 710 900 1120 1400 1800
Size 105
144 198 252 320 400 500 630 800 1000 1250 1600 2000
DSV 3.0 3.5 4.0 4.5 6.0 7.0 8.5 10.0 12.0 13.5 15.0 18.0 20.0
Table 10.1: Wear mark
10.2 Change of wear parts
Only use original RUPEX buffers as spare buffers, in order to guarantee a perfect transmission of the
torque and a trouble-free function.
Note: Changing the buffers is possible without moving the coupled machines.
Up to coupling size 400, the bolts with the plastic buffers can be removed through the buffer holes after
releasing and removing the nuts, and up to coupling size 450, after releasing and removing the hexagon
bolts and end plates.
After renewing the plastic buffers, assemble the unit in the opposite sequence. Secure the nuts or bolts
with adhesive (e.g. Loctite 242).
Carefully observe the instructions of Section 6. ”Installation” and Section 7. ”Start up” for the
re-installation.
BA 3600 EN 08.98

11. Spare parts stock, service facility addresses
Maintaining a stock of the most essential spare and wear parts is an important prerequisite for the
permanent service ability of the coupling.
When ordering spare parts, the following data should be stated:
– Part No. (see Section 5.)
– Description / Size (the size designation corresponds to the outer diameter da in mm)
– Quantity
We assume warranty only for original spare parts supplied by us.
We would expressly draw attention to the fact that spare parts and accessories
Caution! not supplied by us have not been tested or approved by us either. Fitting and/or
use of such products can therefore under certain circumstances adversely
affect structurally specified properties of the coupling and will thus impair
active and/or passive safety. No form of reliability or warranty will be assumed
by FLENDER for damage occasioned by use of non-original spare parts and
accessories.
Please note that production and supply specifications frequently exist for components and we will
always offer spare parts in accordance with the state of the art and in accordance with the latest legal
requirements.
11.1 Service facility addresses
When ordering spare parts or requesting a service fitter, please contact FLENDER AG first of all.
FLENDER Germany
A. FRIEDR. FLENDER AG
46393 Bocholt - Tel.: (0 28 71) 92-0 - Fax: (0 28 71) 92 25 96
E-mail: contact@flender.com S www.flender.com
Shipping address: Alfred - Flender - Strasse 77 - 46395 Bocholt
A. FRIEDR. FLENDER AG - Kupplungswerk Mussum

Industriepark Bocholt - Schlavenhorst 100 - 46395 Bocholt - Tel.: (0 28 71) 92 28 68 - Fax: (0 28 71) 92 25 79
E-mail: couplings@flender.com S www.flender.com
A. FRIEDR. FLENDER AG - Werk Friedrichsfeld

Am Industriepark 2 - 46562 Voerde - Tel.: (0 28 71) 92-0 - Fax: (0 28 71) 92 25 96
A. FRIEDR. FLENDER AG - Getriebewerk Penig

Thierbacher Strasse 24 - 09322 Penig - Tel.: (03 73 81) 60 - Fax: (03 73 81) 8 02 86
E-mail: ute.tappert@flender.com S www.flender.com
FLENDER - TÜBINGEN GMBH

72007 Tübingen - Tel.: (0 70 71) 7 07-0 - Fax: (0 70 71) 70 74 00
E-mail: sales-motox@flender-motox.com S www.flender.com
Shipping address: Bahnhofstrasse 40 - 72072 Tübingen
LOHER GMBH
94095 Ruhstorf - Tel.: (0 85 31) 3 90 - Fax: (0 85 31) 3 94 37
E-mail: info@loher.de S www.loher.de
Shipping address: Hans-Loher-Strasse 32 - 94099 Ruhstorf
FLENDER SERVICE GMBH

44607 Herne - Tel.: (0 23 23) 940-0 - Fax: (0 23 23) 940 333
E-mail: infos@flender-service.com S www.flender-service.com
24h Service Hotline +49 (0) 17 22 81 01 00
Shipping address: Südstrasse 111 - 44625 Herne
A. FRIEDR. FLENDER AG - FLENDER GUSS

Obere Hauptstrasse 228-230 - 09228 Chemnitz / Wittgensdorf - Tel.: (0 37 22) 64-0 - Fax: (0 37 22) 64 21 89
E-mail: flender.guss@flender-guss.com S www.flender-guss.de
BA 3600 EN 08.98

Germany
46393 BOCHOLT - TEL.: (0 28 71) 92 - 0 - FAX: (0 28 71) 92 25 96
SHIPPING ADDRESS: ALFRED - FLENDER - STRASSE 77 - 46395 BOCHOLT
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
VERTRIEBSZENTRUM BOCHOLT 46393 Bocholt
Alfred-Flender-Strasse 77, 46395 Bocholt
Tel.: (0 28 71) 92 - 0
Fax: (0 28 71) 92 - 14 35
E-mail: vz.bocholt@flender.com
___________________________________________________________________________________________________________
VERTRIEBSZENTRUM STUTTGART 70472 Stuttgart

Friolzheimer Strasse 3, 70499 Stuttgart
Tel.: (07 11) 7 80 54 - 51
Fax: (07 11) 7 80 54 - 50
E-mail: vz.stuttgart@flender.com
___________________________________________________________________________________________________________
VERTRIEBSZENTRUM MÜNCHEN 85750 Karlsfeld

Liebigstrasse 14, 85757 Karlsfeld
Tel.: (0 81 31) 90 03 - 0
Fax: (0 81 31) 90 03 - 33
E-mail: vz.muenchen@flender.com
___________________________________________________________________________________________________________
VERTRIEBSZENTRUM BERLIN Schlossallee 8, 13156 Berlin

Tel.: (0 30) 91 42 50 58
Fax: (0 30) 47 48 79 30
E-mail: vz.berlin@flender.com
___________________________________________________________________________________________________________
BA 3600 EN 08.98

FLENDER International (2003-12-01)
EUROPE Flender - Graffenstaden SA PORTUGAL

1, rue du Vieux Moulin Rodamientos FEYC, S.A
67400 Illkirch-Graffenstaden R. Jaime Lopes Dias, 1668 CV
AUSTRIA B.P. 84 1750 - 124 Lissabon
Flender Ges.m.b.H. Phone: +351 (0) 21 - 7 54 24 10
67402 Illkirch - Graffenstaden
Industriezentrum Nö-Süd Fax: +351 (0) 21 - 7 54 24 19
Phone: +33 (0) 3 - 88 67 60 00
Strasse 4, Objekt 14, Postfach 132 E-mail: info@rfportugal.com
Fax: +33 (0) 3 - 88 67 06 17
2355 Wiener Neudorf
E-mail: flencomm@flender-graff.com
Phone: +43 (0) 22 36 6 45 70 ROMANIA
Fax: +43 (0) 22 36 6 45 70 10 A. Friedr. Flender AG
E-mail: office@flender.at GREECE
Flender Hellas Ltd. Branch Office
www.flender.at 98 - 106, Soseaua Mihai Bravu
2, Delfon str., 11146 Athens
Phone: +30 210 - 2 91 72 80 Sector 2, Bloc D 16, Sc 1, Apartament 4
BELGIUM & LUXEMBOURG 021331 Bucuresti - 2
N.V. Flender Belge S.A. Fax: +30 210 - 2 91 71 02
E-mail: flender@otenet.gr Phone: +40 (0) 21 - 4 91 10 08
Cyriel Buyssestraat 130 Fax: +40 (0) 21 - 4 91 10 08
1800 Vilvoorde Mangrinox S.A. E-mail: flender@fx.ro
Phone: +32 (0) 2 - 2 53 10 30 14, Grevenon str., 11855 Athens
Fax: +32 (0) 2 - 2 53 09 66 Phone: +30 210 - 3 42 32 01 RUSSIA
E-mail: sales@flender.be Fax: +30 210 - 3 45 99 28 F & F GmbH
E-mail: mangrinox@otenet.gr Tjuschina 4-6
BULGARIA 191119 St. Petersburg
A. Friedr. Flender AG HUNGARY Phone: +7 (0) 8 12 - 3 20 90 34
Branch Office A. Friedr. Flender AG Fax: +7 (0) 8 12 - 3 40 27 60
c/o Auto - Profi GmbH Branch Office E-mail: flendergus@mail.spbnit.ru
Alabin Str. 52, 1000 Sofia Bécsi Út 3-5, 1023 Budapest
Phone: +359 (0) 2 - 9 80 66 06 Phone: +36 (0) 1 - 3 45 07 90 / 91 SLOVAKIA
Fax: +359 (0) 2 - 9 80 33 01 Fax: +36 (0) 1 - 3 45 07 92 A. Friedr. Flender AG
E-mail: sofia@auto-profi.com E-mail: jambor.laszlo@axelero.hu Branch Office
Vajanského 49
P.O. Box 286, 08001 Presov
CROATIA / SLOVENIA ITALY Phone: +421 (0) 51 - 7 70 32 67
BOSNIA-HERZEGOVINA Flender Cigala S.p.A. Fax: +421 (0) 51 - 7 70 32 67
A. Friedr. Flender AG Parco Tecnologico Manzoni E-mail: micenko.flender@nextra.sk
Branch Office Palazzina G
c/o HUM - Naklada d.o.o. Viale delle industrie, 17 SPAIN
Mandroviceva 3, 10000 Zagreb 20040 Caponago (MI) Flender Ibérica S.A.
Phone: +385 (0) 1 - 2 30 60 25 Phone: +39 (0) 02 - 95 96 31 Poligono Industrial San Marcos
Fax: +385 (0) 1 - 2 30 60 24 Fax: +39 (0) 02 -95 74 39 30 Calle Morse, 31 (Parcela D-15)
E-mail: flender@hi.hinet.hr E-mail: info@flendercigala.it 28906 Getafe - Madrid
Phone: +34 (0) 91 - 6 83 61 86
CZECH REPUBLIC THE NETHERLANDS Fax: +34 (0) 91 - 6 83 46 50
A. Friedr. Flender AG Flender Nederland B.V. E-mail: f-iberica@flender.es
Branch Office Industrieterrein Lansinghage www.flender.es
Hotel DUO, Teplicka 17 Platinastraat 133
19000 Praha 9 2718 ST Zoetermeer SWEDEN
Phone: +420 (0) 2 - 83 88 23 00 Postbus 725 Flender Scandinavia
Fax: +420 (0) 2 - 83 88 22 05 2700 AS Zoetermeer Äsenvägen 2
E-mail: flender_pumprla@hotelduo.cz Phone: +31 (0) 79 - 3 61 54 70 44339 Lerum
Fax: +31 (0) 79 - 3 61 54 69 Phone: +46 (0) 302 - 1 25 90
DENMARK E-mail: sales@flender.nl Fax: +46 (0) 302 - 1 25 56
Flender Scandinavia A/S www.flender.nl E-mail: kontakt@flenderscandinavia.com
Rugmarken 35 B, 3520 Farum www.flenderscandinavia.com
SALES OFFICES:
Phone: +45 - 70 22 60 03 Flender Nederland B.V.
Fax: +45 - 44 99 16 62 SWITZERLAND
Lage Brink 5-7 Flender AG
E-mail: kontakt@flenderscandinavia.com 7317 BD Apeldoorn
www.flenderscandinavia.com Zeughausstr. 48
Postbus 1073 5600 Lenzburg
7301 BH Apeldoorn Phone: +41 (0) 62 8 85 76 00
ESTHONIA / LATVIA / LITHUANIA Phone: +31 (0) 55 - 5 27 50 00 Fax: +41 (0) 62 8 85 76 76
Flender Branch Office Fax: +31 (0) 55 - 5 21 80 11 E-mail: info@flender.ch
Addinol Mineralöl Marketing OÜ E-mail: tom.alberts@flender-group.com www.flender.ch
Suur-Söjamäe 32 Bruinhof B.V.
11415 Tallinn / Esthonia Boterdiep 37 TURKEY
Phone: +372 (0) 6 - 27 99 99 3077 AW Rotterdam Flender Güc Aktarma Sistemleri
Fax: +372 (0) 6 - 27 99 90 Postbus 9607 Sanayi ve Ticaret Ltd. Sti.
E-mail: flender@addinol.ee 3007 AP Rotterdam IMES Sanayi, Sitesi
www.addinol.ee Phone: +31 (0) 10 - 4 97 08 08 E Blok 502. Sokak No. 22
Fax: +31 (0) 10 - 4 82 43 50 81260 Dudullu - Istanbul
FINLAND E-mail: info@bruinhof.nl Phone: +90 (0) 2 16 - 4 66 51 41
Flender Oy www.bruinhof.nl Fax: +90 (0) 2 16 3 64 59 13
Ruosilantie 2 B, 00390 Helsinki E-mail: cuzkan@flendertr.com
Phone: +358 (0) 9 - 4 77 84 10 www.flendertr.com
NORWAY
Fax: +358 (0) 9 - 4 36 14 10 Elektroprosess AS
E-mail: webmaster@flender.fi UKRAINE
Frysjaveien 40, 0884 Oslo A. Friedr. Flender AG
www.flender.fi Postboks 165, Kjelsås Branch Office, c/o DIV - Deutsche Industrie-
0411 Oslo vertretung, Prospect Pobedy 44
FRANCE Phone: +47 (0) 2 - 2 02 10 30 252057 Kiev
Flender s.a.r.l. Fax: +47 (0) 2 - 2 02 10 50 / 51 Phone: +380 (0) 44 - 4 46 80 49
3, rue Jean Monnet - B.P. 5 E-mail: post@elektroprosess.no Fax: +380 (0) 44 - 2 30 29 30
78996 Elancourt Cedex E-mail: flender@div.kiev.ua
Phone: +33 (0) 1 - 30 66 39 00 POLAND
Fax: +33 (0) 1 - 30 66 35 13 A. Friedr. Flender AG UNITED KINGDOM & EIRE
E-mail: sales@flender.fr Branch Office Flender Power Transmission Ltd.
SALES OFFICES: Przedstawicielstwo w Polsce Thornbury Works, Leeds Road
Flender s.a.r.l. ul. Wyzwolenia 27 Bradford
36, rue Jean Broquin 43 - 190 Mikolów West Yorkshire BD3 7EB
69006 Lyon Phone: +48 (0) 32 - 2 26 45 61 Phone: +44 (0) 12 74 65 77 00
Phone: +33 (0) 4 - 72 83 95 20 Fax: +48 (0) 32 - 2 26 45 62 Fax: +44 (0) 12 74 66 98 36
Fax: +33 (0) 4 - 72 83 95 39 E-mail: flender@pro.onet.pl E-mail: flenders@flender-power.co.uk
E-mail: sales@flender.fr www.flender.pl www.flender-power.co.uk
BA 3600 EN 08.98

SERBIA-MONTENEGRO SALES OFFICES: USA
ALBANIA / MACEDONIA Flender Brasil Ltda. Flender Corporation
A. Friedr. Flender AG Rua James Watt, 142 950 Tollgate Road
Branch Office conj. 142 - Brooklin Novo P.O. Box 1449, Elgin, IL. 60123
c/o G.P.Inzenjering d.o.o. 04576 - 050, São Paulo - SP Phone: +1 (0) 8 47 - 9 31 19 90
III Bulevar 54 / 19 Phone: +55 (0) 11 - 55 05 99 33 Fax: +1 (0) 8 47 - 9 31 07 11
11070 Novi Beograd Fax: +55 (0) 11 - 55 05 30 10 E-mail: flender@flenderusa.com
Phone: +381 (0) 11 - 60 44 73 E-mail: flesao@uol.com.br www.flenderusa.com
Fax: +381 (0) 11 - 3 11 67 91 Flender Corporation
E-mail: flender@eunet.yu Flender Brasil Ltda. Service Centers West
Rua Campos Salles, 1095 4234 Foster Ave.
sala 04 - Centro 14015 - 110, Bakersfield, CA. 93308
Ribeirão Preto - SP
AFRICA Phone: +55 (0) 16 - 6 35 15 90
Phone: +1 (0) 6 61 - 3 25 44 78
Fax: +1 (0) 6 61 - 3 25 44 70
Fax: +55 (0) 16 - 6 35 11 05 E-mail: flender1@lightspeed.net
NORTH AFRICAN COUNTRIES E-mail: flender.ribpreto@uol.com.br
Please refer to Flender s.a.r.l. VENEZUELA
3, rue Jean Monnet - B.P. 5 F. H. Transmisiones S.A.
78996 Elancourt Cedex CANADA Urbanización Buena Vista
Phone: +33 (0) 1 - 30 66 39 00 Flender Power Transmission Inc. Calle Johan Schafer o Segunda Calle
Fax: +33 (0) 1 - 30 66 35 13 215 Shields Court, Units 4 - 6 Municipio Sucre, Petare
E-mail: sales@flender.fr Markham, Ontario L3R 8V2 Caracas
Phone: +1 (0) 9 05 - 3 05 10 21 Phone: +58 (0) 2 - 21 52 61
Fax: +1 (0) 9 05 - 3 05 10 23 Fax: +58 (0) 2 - 21 18 38
EGYPT E-mail: flender@ca.inter.net E-mail: fhtransm@telcel.net.ve
Sons of Farid Hassanen www.flenderpti.com www.fhtransmisiones.com
81 Matbaa Ahlia Street
Boulac 11221, Cairo SALES OFFICE: ASIA
Phone: +20 (0) 2 - 5 75 15 44 Flender Power Transmission Inc.
Fax: +20 (0) 2 - 5 75 17 02 34992 Bemina Court BANGLADESH / SRI LANKA
E-mail: hussein@sonfarid.com Abbotsford - Vancouver Please refer to Flender Limited
B.C. V3G 1C2 No. 2 St. George’s Gate Road
Phone: +1 (0) 6 04 - 8 59 66 75 5th Floor, Hastings
SOUTH AFRICA Fax: +1 (0) 6 04 - 8 59 68 78 Kolkata - 700 022
Flender Power Transmission (Pty.) Ltd. E-mail: tvickers@rapidnet.net Phone: +91 (0) 33 - 2 23 05 45
Cnr. Furnace St & Quality Rd. Fax: +91 (0) 33 - 2 23 18 57
P.O. Box 131, Isando 1600 E-mail: flender@flenderindia.com
Johannesburg CHILE / ARGENTINA / BOLIVIA
Phone: +27 (0) 11 - 5 71 20 00 ECUADOR / PARAGUAY / URUGUAY PEOPLE’S REPUBLIC OF CHINA
Fax: +27 (0) 11 - 3 92 24 34 Flender Cono Sur Limitada Flender Power Transmission
E-mail: sales@flender.co.za Avda. Galvarino Gallardo 1534 (Tianjin) Co. Ltd.
www.flender.co.za Providencia, Santiago ShuangHu Rd.- Shuangchen Rd. West
Phone: +56 (0) 2 - 2 35 32 49 Beichen Economic Development
SALES OFFICES: Area (BEDA)
Flender Power Transmission (Pty.) Ltd. Fax: +56 (0) 2 - 2 64 20 25
E-mail: flender@flender.cl Tianjin 300400
Unit 3 Marconi Park Phone: +86 (0) 22 - 26 97 20 63
9 Marconi Crescent, Montague Gardens www.flender.cl
Fax: +86 (0) 22 - 26 97 20 61
P.O. Box 37291 E-mail: flender@flendertj.com
Chempet 7442, Cape Town www.flendertj.com
Phone: +27 (0) 21 - 5 51 50 03 COLOMBIA
Fax: +27 (0) 21 - 5 52 38 24 A.G.P. Representaciones Ltda. Flender Power Transmission
E-mail: sales@flender.co.za Flender Liaison Office Colombia (Tianjin) Co. Ltd.
Av Boyaca No 23A Beijing Office
Flender Power Transmission (Pty.) Ltd. 50 Bodega UA 7-1, Bogotá C-415, Lufthansa Center
Unit 3 Goshawk Park Phone: +57 (0) 1 - 5 70 63 53 50 Liangmaqiao Road, Chaoyang District
Falcon Industrial Estate Fax: +57 (0) 1 - 5 70 73 35 Beijing 100016
P.O. Box 1608 E-mail: aguerrero@agp.com.co Phone: +86 (0) 10 - 64 62 21 51
New Germany 3620, Durban www.agp.com.co Fax: +86 (0) 10 - 64 62 21 43
Phone: +27 (0) 31 - 7 05 38 92 E-mail: beijing@flenderprc.com.cn
Fax: +27 (0) 31 - 7 05 38 72 Flender Power Transmission
E-mail: sales@flender.co.za MEXICO (Tianjin) Co. Ltd.
Flender Power Transmission (Pty.) Ltd. Flender de Mexico S.A. de C.V. Shanghai Office
9 Industrial Crescent, Ext. 25 17, Pte, 713 Centro 1101-1102 Harbour Ring Plaza
P.O. Box 17609, Witbank 1035 72000 Puebla 18 Xizang Zhong Rd.
Phone: +27 (0) 13 - 6 92 34 38 Phone: +52 (0) 2 22 - 2 37 19 00 Shanghai 200 001
Fax: +27 (0) 13 - 6 92 34 52 Fax: +52 (0) 2 22 - 2 37 11 33 Phone: +86 (0) 21 - 53 85 31 48
E-mail: sales@flender.co.za E-mail: szugasti@flendermexico.com Fax: +86 (0) 21 - 53 85 31 46
www.flendermexico.com E-mail: shanghai@flenderprc.com.cn
Flender Power Transmission (Pty.) Ltd. Flender Power Transmission
Unit 14 King Fisher Park, Alton SALES OFFICES: (Tianjin) Co. Ltd.
Cnr. Ceramic Curve & Alumina Allee Flender de Mexico S.A. de C.V. Wuhan Office
P.O. Box 101995 Lago Nargis No. 38 Rm. 1503, Jianyin Building,
Meerensee 3901, Richards Bay Col. Granada, 709 Jianshedadao
Phone: +27 (0) 35 - 7 51 15 63 11520 Mexico, D.F. Wuhan 430 015
Fax: +27 (0) 35 - 7 51 15 64 Phone: +52 (0) 55 - 52 54 30 37 Phone: +86 (0) 27 - 85 48 67 15
E-mail: sales@flender.co.za Fax: +52 (0) 55 - 55 31 69 39 Fax: +86 (0) 27 - 85 48 68 36
E-mail: info@flendermexico.com E-mail: wuhan@flenderprc.com.cn
Flender de Mexico S.A. de C.V. Flender Power Transmission
AMERICA Ave. San Pedro No. 231-5 (Tianjin) Co. Ltd.
Col. Miravalle Guangzhou Office
64660 Monterrey, N.L. Rm. 2802, Guangzhou International
ARGENTINA Electronics Tower
Chilicote S.A. Phone: +52 (0) 81 - 83 63 82 82
Fax: +52 (0) 81 - 83 63 82 83 403 Huanshi Rd. East
Avda. Julio A. Roca 546
E-mail: info@flendermexico.com Guangzhou 510 095
C 1067 ABN Buenos Aires
Phone: +86 (0) 20 - 87 32 60 42
Phone: +54 (0) 11 - 43 31 66 10 Fax: +86 (0) 20 - 87 32 60 45
Fax: +54 (0) 11 - 43 31 42 78 E-mail: guangzhou@flenderprc.com.cn
E-mail: chilicote@chilicote.com.ar PERU
Potencia Industrial E.I.R.L. Flender Power Transmission
Calle Victor González Olaechea N° 110 (Tianjin) Co. Ltd.
BRASIL Urb. La Aurora - Miraflores, Chengdu Office
Flender Brasil Ltda. P.O.Box: Av. 2 de Mayo N° 679 G-6 / F Guoxin Mansion,
Rua Quatorze, 60 - Cidade Industrial Of.108-Miraflores 77 Xiyu Street
32211 - 970, Contagem - MG Casilla N° 392, Lima 18 Chengdu 610 015
Phone: +55 (0) 31 - 33 69 21 00 Phone: +51 (0) 1 - 2 42 84 68 Phone: +86 (0) 28 - 86 19 83 72
Fax: +55 (0) 31 - 33 69 21 66 Fax: +51 (0) 1 - 2 42 08 62 Fax: +86 (0) 28 - 86 19 88 10
E-mail: vendas@flenderbrasil.com E-mail: cesarzam@chavin.rcp.net.pe E-mail: chengdu@flenderprc.com.cn
BA 3600 EN 08.98

Flender Power Transmission ISRAEL SINGAPORE
(Tianjin) Co. Ltd. Greenshpon Engineering Works Ltd. Flender Singapore Pte. Ltd.
Shenyang Office Haamelim Street 20 13 A, Tech Park Crescent
Rm. 2-163, Tower I, City Plaza Shenyan P.O. Box 10108, 26110 Haifa Singapore 637843
206 Nanjing Street (N), Heping District Phone: +972 (0) 4 - 8 72 11 87 Phone: +65 (0) - 68 97 94 66
Shenyang 110 001 Fax: +972 (0) 4 - 8 72 62 31 Fax: +65 (0) - 68 97 94 11
Phone: +86 (0) 24 - 23 34 20 48 E-mail: sales@greenshpon.com E-mail: flender@singnet.com.sg
Fax: +86 (0) 24 - 23 34 20 46 www.greenshpon.com www.flender.com.sg
E-mail: shenyang@flenderprc.com.cn
JAPAN SYRIA
Flender Power Transmission Flender Japan Co., Ltd. Misrabi Co & Trading
(Tianjin) Co. Ltd. WBG Marive East 21F Mezzeh Autostrade Transportation
Xi’an Office Nakasa 2 - 6 Building 4/A, 5th Floor
Rm. 302, Shaanzi Zhong Da Mihama-ku, Chiba-shi P.O. Box 12450, Damascus
International Mansion Chiba 261-7121 Phone: +963 (0) 11 - 6 11 67 94
30 Southern Rd. Phone: +81 (0) 43 - 2 13 39 30 Fax: +963 (0) 11 - 6 11 09 08
Xi’an 710 002 Fax: +81 (0) 43 - 2 13 39 55 E-mail: ismael.misrabi@gmx.net
Phone: +86 (0) 29 - 7 20 32 68 E-mail: contact@flender-japan.com
Fax: +86 (0) 29 - 7 20 32 04
E-mail: xian@flenderprc.com.cn TAIWAN
KOREA A. Friedr. Flender AG
Flender Ltd. Taiwan Branch Company
INDIA 7th Fl. Dorim Bldg. 1F, No. 5, Lane 240
Flender Limited 1823 Bangbae-Dong, Seocho-Ku, Nan Yang Street, Hsichih
Head Office: Seoul 137-060 Taipei Hsien 221
No. 2 St. George’s Gate Road Phone: +82 (0) 2 - 34 78 63 37 Phone: +886 (0) 2 - 26 93 24 41
5th Floor, Hastings Fax: +82 (0) 2 - 34 78 63 45 Fax: +886 (0) 2 - 26 94 36 11
Kolkata - 700 022 E-mail: flender@unitel.co.kr E-mail: flender_tw@flender.com.tw
Phone: +91 (0) 33 - 22 23 05 45
Fax: +91 (0) 33 - 22 23 08 30 KUWAIT THAILAND
E-mail: flender@flenderindia.com South Gulf Company Flender Singapore Pte. Ltd.
Al-Reqai, Plot 1, Block 96 Representative Office
Flender Limited P.O. Box 26229, Safat 13123 23/F M Thai Tower, All Seasons Place
Industrial Growth Centre Phone: +965 (0) - 4 88 39 15 87 Wireless Road, Phatumwan
Rakhajungle, Nimpura Fax: +965 (0) - 4 88 39 14 Bangkok 10330
Kharagpur - 721 302 E-mail: adelameen@hotmail.com Phone: +66 (0) 2 - 6 27 91 09
Phone: +91 (0) 3222 - 23 33 07 Fax: +66 (0) 2 - 6 27 90 01
Fax: +91 (0) 3222 - 23 33 64 LEBANON E-mail: christian.beckers@flender.th.com
E-mail: works@flenderindia.com Gabriel Acar & Fils s.a.r.l.
Dahr-el-Jamal VIETNAM
SALES OFFICES: Zone Industrielle, Sin-el-Fil Flender Singapore Pte. Ltd.
Flender Limited B.P. 80484, Beyrouth Representative Office
Eastern Regional Sales Office Phone: +961 (0) 1 - 49 82 72 Suite 6/6A, 16F Saigon Tower
No. 2 St. George’s Gate Road Fax: +961 (0) 1 - 49 49 71 29 Le Duan Street, District 1
5th Floor, Hastings E-mail: gacar@beirut.com Ho Chi Minh City, Vietnam
Kolkata - 700 022
Phone: +84 (0) 8 - 8 23 62 97
Phone: +91 (0) 33 - 22 23 05 45
MALAYSIA Fax: +84 (0) 8 - 8 23 62 88
Fax: +91 (0) 33 - 22 23 08 30 E-mail: flender@hcm.vnn.vn
Flender Singapore Pte. Ltd.
E-mail: ero@flenderindia.com
Representative Office
Flender Limited 37 A - 2, Jalan PJU 1/39
Western Regional Sales Office Dataran Prima AUSTRALIA
Plot No. 23, Sector 19 - C 47301 Petaling Jaya
Vashi, Navi Mumbai - 400 705 Selangor Darul Ehsan
Phone: +91 (0) 22 - 27 65 72 27 Phone: +60 (0) 3 - 78 80 42 63
Fax: +60 (0) 3 - 78 80 42 73 Flender (Australia) Pty. Ltd.
Fax: +91 (0) 22 - 27 65 72 28 9 Nello Place, P.O. Box 6047
E-mail: wro@flenderindia.com E-mail: flender@tm.net.my
Wetherill Park
Flender Limited N.S.W. 2164, Sydney
PAKISTAN Phone: +61 (0) 2 - 97 56 23 22
Southern Regional Sales Office Please refer to
41 Nelson Manickam Road Fax: +61 (0) 2 - 97 56 48 92, 97 56 14 92
A. Friedr. Flender AG
Aminjikarai, E-mail: sales@flender.com.au
46393 Bocholt
Chennai - 600 029 www.flender.com.au
Phone: +49 (0) 28 71 - 92 22 59
Phone: +91 (0) 44 - 23 74 39 21 Fax: +49 (0) 28 71 - 92 15 16 SALES OFFICES:
Fax: +91 (0) 44 - 23 74 39 19 E-mail: ludger.wittag@flender.com Flender (Australia) Pty. Ltd.
E-mail: sro@flenderindia.com Suite 3, 261 Centre Rd.
PHILIPPINES Bentleigh, VIC 3204 Melbourne
Flender Limited Phone: +61 (0) 3 - 95 57 08 11
Northern Regional Sales Office Flender Singapore Pte. Ltd.
Representative Office Fax: +61 (0) 3 - 95 57 08 22
209-A, Masjid Moth, 2nd Floor E-mail: sales@flender.com.au
(Behind South Extension II) 28/F, Unit 2814
New Delhi - 110 049 The Enterprise Centre Flender (Australia) Pty. Ltd.
Phone: +91 (0) 11 - 26 25 02 21 6766 Ayala Avenue corner Suite 5, 1407 Logan Rd.
Fax: +91 (0) 11 - 26 25 63 72 Paeso de Roxas, Makati City Mt. Gravatt
E-mail: nro@flenderindia.com Phone: +63 (0) 2 - 8 49 39 93 QLD 4122, Brisbane
Fax: +63 (0) 2 - 8 49 39 17 Phone: +61 (0) 7 - 34 22 23 89
E-mail: roman@flender.com.ph Fax: +61 (0) 7 - 34 22 24 03
INDONESIA E-mail: sales@flender.com.au
Flender Singapore Pte. Ltd. BAHRAIN / IRAQ / JORDAN / LYBIA Flender (Australia) Pty. Ltd.
Representative Office OMAN / QATAR / U.A.E. / YEMEN
Please refer to A. Friedr. Flender AG Suite 2 403 Great Eastern Highway
Perkantoran Puri Niaga II W.A. 6104, Redcliffe - Perth
Jalan Puri Kencana Blok J1 Middle East Sales Office
IMES Sanayi Sitesi Phone: +61 (0) 8 - 94 77 41 66
No. 2i, Kembangan Fax: +61 (0) 8 - 94 77 65 11
Jakarta Barat 11610 E Blok 502, Sokak No. 22
81260 Dudullu - Istanbul E-mail: sales@flender.com.au
Phone: +62 (0) 21 - 5 82 86 24
Fax: +62 (0) 21 - 5 82 86 23 Phone: +90 (0) 2 16 - 4 99 66 23
Fax: +90 (0) 2 16 - 3 64 59 13 NEW ZEALAND
E-mail: bobwall@cbn.net.id Please refer to Flender (Australia) Pty. Ltd.
E-mail: meso@flendertr.com
9 Nello Place, P.O. Box 6047
IRAN SAUDI ARABIA Wetherill Park
Cimaghand Co. Ltd. South Gulf Co. N.S.W. 2164, Sydney
P.O. Box 15745-493 Al-Khobar, Dahran Str. Phone: +61 (0) 2 - 97 56 23 22
No. 13, 16th East Street Middle East Trade Center Fax: +61 (0) 2 - 97 56 48 92
Beyhaghi Ave., Argentina Sq. 3rd floor, Flat # 23 E-mail: sales@flender.com.au
Tehran 15156 P.O. Box 20434 31952 Al-Khobar
Phone: +98 (0) 21 - 8 73 02 14 Phone: +966 (0) 3 - 8 87 53 32
Fax: +98 (0) 21 - 8 73 39 70 Fax: +966 (0) 3 - 8 87 53 31
E-mail: info@cimaghand.com E-mail: adelameen@hotmail.com
BA 3600 EN 08.98

12. Declaration by the manufacturer
Declaration by the manufacturer

in accordance with EC Engineering Guideline 98/37/EC, Appendix II B
We hereby declare that the
Flexible RUPEX couplings,

type RWN, RWS and RWB, RBS
described in these Operating Instructions are intended for incorporation in a machine, and that
it is prohibited to put them into service before verifying that the machine into which they are
incorporated complies with the EC Guidelines (original edition 98/37/EC including any subse-
quent amendments thereto).
This Manufacturer’s Declaration takes into account all the unified standards (inasmuch as
they apply to our products) published by the European Commission in the Official Journal of
the European Community.
Bocholt, 1998-08-24
Signature (person responible for products)
BA 3600 EN 08.98

Bauart RWS Seite
Stückliste (SL) Type Page
Parts list Größe 710,0 1/1
Size
Übersetzung
ratio
Bei Korrespondenz bitte angeben
Please quote in correspondence SL 4214492-020 DE/EN
Hierzu gehört Zeichnungs-Nr.
Please refer to DWG No. 6106880
Teil-Nr. Menge Benennung Zeichnungs-Nr. Material-Nr. Gw(kg)
Part No. No. off Description Drawings No. Ident no. Weight
E 0001 1 ST RUPEX R TEIL 1/2 VARI (I) 000.009.900.069

RUPEX R PART 1/2 VARI (I)
E* 0004 7 ST BLZN 710/0800 O 42CrMoS4 5285048/E 000.000.500.378 2,7
BOLT 710/0800 O 42CrMoS4
E* 0005 7 ST PUFFER 710 80 SHORE PERBUNAN 9001624/C 000.000.390.490 1,0
BUFFER 710 80 SHORE PERBUNAN
E* 0006 7 ST SCHEIBE 50,0 B D 125 200 HV 000.000.342.733 0,3
DISC 50,0 B D 125 200 HV
E* 0008 7 ST SCHB-END 060/024X10 D C45 5285042/B 000.000.500.385 0,2
END PLATE 060/024X10 D C45
E* 0011 7 ST SCHRB-SKT M24X050 D 933 8.8 000.000.321.414 0,3
HEXAGON HEAD SCREW M24X050 D 933 8.8
E* 0012 7 ST RING-SICHER 050X2 D 471 FED-ST 000.000.343.250 0,0
CIRCLIP 050X2 D 471 FED-ST
E 0002 1 ST RUPEX R TEIL 1/2 VARI (II) 000.009.900.070
RUPEX R PART 1/2 VARI (II)
E* 0004 7 ST BLZN 710/0800 O 42CrMoS4 5285048/E 000.000.500.378 2,7
BOLT 710/0800 O 42CrMoS4
E* 0005 7 ST PUFFER 710 80 SHORE PERBUNAN 9001624/C 000.000.390.490 1,0
BUFFER 710 80 SHORE PERBUNAN
E* 0006 7 ST SCHEIBE 50,0 B D 125 200 HV 000.000.342.733 0,3
DISC 50,0 B D 125 200 HV
E* 0008 7 ST SCHB-END 060/024X10 D C45 5285042/B 000.000.500.385 0,2
END PLATE 060/024X10 D C45
E* 0011 7 ST SCHRB-SKT M24X050 D 933 8.8 000.000.321.414 0,3
HEXAGON HEAD SCREW M24X050 D 933 8.8
E* 0012 7 ST RING-SICHER 050X2 D 471 FED-ST 000.000.343.250 0,0
CIRCLIP 050X2 D 471 FED-ST
Die mit * gekennzeichneten Teile gehören zu einer Baugruppe (G). Die Baugruppe ist nur komplett auszutauschen.
The parts marked with * belong to a subassembly (G). The subassemblymust be replaced complete.
A. Friedr.Flender AG, D 46393 Bocholt, Datum Date KLEIN-HESSLING,MARION FR. 2850

Tel.+49(0)2871/92-0, Fax+49(0)2871/922596, http://www.flender.com 03.07.2006 Rev.:
BA 5010 EN 06.03
Gear Unit Types
H.SH, H.VH, H.HH, H.DH, H.KH, H.FH, H.HM, H.DM, H.KM, H.FM, H.PH
B.SH, B.VH, B.HH, B.DH, B.KH, B.FH, B.HM, B.DM, B.KM, B.FM
Sizes 3 to 26
H.SH B.SH
H.VH B.VH
H.HH
H.DH B.HH
H.KH B.DH
H.PH B.KH
H.FH B.FH
H.HM B.HM
H.DM B.DM
H.KM B.KM
H.FM B.FM

Contents
1. Technical data 5
1.1 General technical data 5
1.1.1 Weights 6
1.1.2 Measuring-surface sound-pressure level 7
1.1.2.1 Measuring-surface sound-pressure level for bevel-helical gear units (B...) with fan 7
1.1.2.2 Measuring-surface sound-pressure level for bevel-helical gear units (B...) without fan 8
1.1.2.3 Measuring-surface sound-pressure level for helical gear units (H...) with fan 9
1.1.2.4 Measuring-surface sound-pressure level for helical gear units (H...) without fan 10
2. General notes 11
2.1 Introduction 11
2.2 Copyright 11
3. Safety notes 11
3.1 Proper use 11
3.2 Obligations of the user 12
3.3 Environmental protection 12
3.4 Special dangers 13
3.5 Warnings and symbols used in these Instructions 13
4. Handling and storage 13

4.1 Scope of supply 13
4.2 Handling 13
4.3 Storing the gear units 15
4.4 Standard preservation 15
5. Technical description 16
5.1 General description 16
5.2 Output designs 17
5.3 Housing 17
5.4 Toothed components 19
5.5 Lubrication 19
5.5.1 Dip lubrication 19
5.5.2 Pressure lubrication through add-on oil supply system 20
5.6 Shaft bearings 20
5.7 Shaft seals 21
5.7.1 Radial shaft sealing rings 21
5.7.2 Labyrinth seals 21
5.7.3 Taconite seals 21
5.8 Backstop 23
5.9 Cooling 24
5.9.1 Fan 24
5.9.2 Cooling coil 25
5.9.3 Add-on air oil-cooling units 26
5.9.4 Add-on water oil-cooling units 27
5.10 Heating element 28
5.11 Oil-temperature measurement 29
5.12 Oil-level monitoring system 29
5.13 Bearing monitoring system 30
5.14 Speed transmitter 30
BA 5010 EN 06.03

6. Assembly 31
6.1 General information on installation 31
6.2 Installation of gear unit on housing base 31
6.2.1 Foundation 31
6.2.2 Description of installation work 32
6.2.2.1 Aligning surfaces, aligning thread 33
6.2.2.2 Mounting on a foundation frame 33
6.2.2.3 Mounting on a concrete foundation by means of stone bolts or foundation blocks 34
6.2.2.4 Mounting on a concrete foundation by means of anchor bolts 35
6.3 Couplings 37
6.4 Assembly of a shaft-mounting gear unit with hollow shaft and parallel keyway 39
6.4.1 Preparatory work 39
6.4.2 Assembly 39
6.4.2.1 Fitting 40
6.4.2.2 Axial fastening 40
6.4.3 Dismantling 41
6.5 Shaft-mounting gear unit with hollow shaft and internal spline to DIN 5480 43
6.5.1 Preparatory work 43
6.5.2 Assembly 43
6.5.2.1 Fitting 44
6.6 Shaft-mounting gear unit with hollow shaft and shrink disk 47
6.6.1 Assembly 47
6.6.1.1 Fitting 47
6.6.2 Shrink disk, type HSD 48
6.6.2.1 Assembly of shrink disk 48
6.6.2.2 Demounting and remounting the shrink disk 49
6.6.2.3 Cleaning and greasing the shrink disk 50
6.7 Shaft-mounting gear unit with flanged shaft 52
6.8 Shaft mounting gear unit with block flange 53
6.9 Mounting the torque arm for gear housing 54
6.9.1 Attaching the torque arm 54
6.10 Mounting supports for gear-unit swing bases 55
6.10.1 Attaching the support 55
6.11 Gear unit with cooling coil 56
6.12 Gear unit with add-on components 56
6.13 Gear unit with air oil-cooler 56
6.14 Gear unit with water oil-cooler 56
6.15 Gear units with heating element 56
6.16 Gear units with oil-temperature measurement 56
6.17 Gear units with oil-level monitoring 56
6.18 Gear units with speed transmitter 56
6.19 Final work 56
BA 5010 EN 06.03

7. Start-up 57
7.1 Procedure before start-up 57
7.1.1 Removal of preservative agent 57
7.1.2 Charging with lubricant 58
7.1.2.1 Oil quantities 59
7.2 Start-up 60
7.2.1 Oil level 60
7.2.2 Gear unit with cooling coil or external oil cooling or oil supply system 60
7.2.3 Gear unit with backstop 60
7.2.4 Checking procedure 60
7.3 Removal from service 60
7.3.1 Interior preservation during longer disuse 61
7.3.1.1 Interior preservation with gear oil 61
7.3.1.2 Interior preservation with preservative agent 61
7.3.1.3 Interior preservation procedure 61
7.3.2 Exterior preservation 62
7.3.2.1 Exterior preservation procedure 62
8. Operation 62
9. Faults, causes and remedy 62

9.1 General information on faults and malfunctions 62
9.2 Possible faults 63
10. Maintenance and repair 65

10.1 General notes on maintenance 65
10.2 Description of maintenance and repair work 66
10.2.1 Test water-content of oil 66
10.2.2 Changing the oil 66
10.2.3 Cleaning the breather screw 66
10.2.4 Refilling Taconite seals with grease 66
10.2.5 Cleaning the fan and gear unit 67
10.2.6 Checking cooling coil 67
10.2.7 Checking air oil-cooler 67
10.2.8 Checking water oil-cooler 68
10.2.9 Topping up oil 68
10.2.10 Checking tightness of fastening bolts 68
10.3 Final work 69
10.3.1 General inspection of gear unit 69
10.4 Lubricants 69
11. Spare parts, customer-service addresses 69

11.1 Stocking spare parts 69
11.2 Spare-part and customer-service addresses 70
12. Declaration by the manufacturer 75
BA 5010 EN 06.03

1. Technical data
1.1 General technical data
The most important technical data are shown on the rating plate. These data and the contractual
agreements between FLENDER and the customer for the gear unit determine the limits of its correct
use.
1
2
3
4 5
6 7
8 9 10
11
12
1 Company logo and production location 7 Speed n2
2 Special information 8 Type of oil
3 Order no. - item - serial no. 9 Viscosity of oil in VG class
4 Type / Size *) 10 Quantity of oil in litres for main gear housing
5 Power rating P2 in kW or T2 in Nm 11 Operating instructions number(s)
6 Speed n1 12 Special information
e.g. *)
B 3 S H 13
Size . . . . . . . . . . . . . . . . . 3 ... 26
Installation . . . . . . . . . . . H = horizontal
M= horizontal design without base
(from size 13)
Type of output shaft . . . S = solid shaft
V = solid shaft, reinforced
H = hollow shaft with parallel keyway
D = hollow shaft for shrink disk
K = hollow shaft with internal-spline
to DIN 5480
F = flanged shaft
P = Design of paper processing machine
Number of stages . . . . . 1, 2, 3 or 4
Gear-unit type . . . . . . . . H = Helical gear unit
B = Bevel-helical gear unit
( 2, 3 or 4 stages only)
Data on weights and measuring-surface sound-pressure levels of the various gear types are given in
items 1.1.1 and 1.1.2.
For further technical data, refer to the drawings in the gear-unit documentation.
BA 5010 EN 06.03

1.1.1 Weights
Approx. weight (kg) for size

Type
3 4 5 6 7 8 9 10 11 12 13 14
H1SH 128 – 302 – 547 – 862 – 1515 – 2395 –
H2.H 115 190 300 355 505 590 830 960 1335 1615 2000 2570
H2.M – – – – – – – – – – 1880 2430
H3.H – – 320 365 540 625 875 1020 1400 1675 2295 2625
H3.M – – – – – – – – – – 2155 2490
H4.H – – – – 550 645 875 1010 1460 1725 2390 2730
H4.M – – – – – – – – – – 2270 2600
B2.H 140 235 360 410 615 700 1000 1155 1640 1910 2450 2825
B2.M – – – – – – – – – – 2350 2725
B3.H 130 210 325 380 550 635 890 1020 1455 1730 2380 2750
B3.M – – – – – – – – – – 2260 2615
B4.H – – 335 385 555 655 890 1025 1485 1750 2395 2735
B4.M – – – – – – – – – – 2280 2605
Approx. weight (kg) for size

Type
15 16 17 18 19 20 21 22 23 24 25 26
H1SH 3200 – 4250 – 5800 – – – – – – –
H2.H 3430 3655 4650 5125 6600 7500 8900 9600 11600 13000 15500 17200
H2.M 3240 3465 4420 4870 6300 7200 8400 9200 11000 12300 14700 16200
H3.H 3475 3875 4560 5030 6700 8100 9100 9800 11500 13400 16100 17600
H3.M 3260 3625 4250 4740 6200 7600 8500 9300 10600 12500 15200 16500
H4.H 3635 3965 4680 5185 6800 8200 9200 9900 11600 13500 16100 17600
H4.M 3440 3740 4445 4915 6300 7700 8600 9400 10700 12600 15200 16500
B2.H 3990 4345 5620 6150 – – – – – – – –
B2.M 3795 4160 5320 5860 – – – – – – – –
B3.H 3730 3955 4990 5495 7000 8100 9200 9900 11500 13400 16000 17500
B3.M 3540 3765 4760 5240 6500 7600 8600 9400 10600 12500 15100 16400
B4.H 3630 3985 4695 5200 6800 8200 9200 9900 11600 13500 16100 17600
B4.M 3435 3765 4460 4930 6300 7700 8600 9400 10700 12600 15200 16500
Table 1.1: Weights (approx. values only)
Note: All weights are for gear unit without oil filling or add-ons. For the exact weights, refer
to the drawings in the gear-unit documentation.
BA 5010 EN 06.03

1.1.2 Measuring-surface sound-pressure level
The measuring-surface sound-pressure level for the gear unit at a distance of 1 metre can be found in
tables 1.1.2.1 to 1.1.2.4.
The measurement is carried out to DIN 45635 Parts 1 and 23, using the sound-intensity method.
The workplace of the operating personnel is defined as the area on the measuring-surface at a distance
of 1 metre in the vicinity of which persons may be present.
The sound-pressure level applies to the warmed-up gear unit at input speed n1 and output power P2
stated on the rating plate. If several figures are given, the highest speed and power values apply.
The measuring surface sound-pressure level does not include add-on lubricating units.
If repeat measurements on site do not produce conclusive results with regard to measuring technology,
the measurement obtained on the FLENDER test bench will apply.
The sound-pressure levels stated in the table were obtained by statistical calculation by our Quality
Control Dept. The gear unit can be statistically expected to comply with these sound-pressure levels.
1.1.2.1 Measuring-surface sound-pressure level for bevel-helical gear units (B...) with fan
Measuring-surface sound-pressure level LpA in dB(A) for bevel-helical gear units with fan
n1 Gear-unit size
Type iN 1/min 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
5 1500 73 76 79 81 83 84 85 87 88 89 91 92 94 – – – – – – – – – – –
. 1000 67 71 73 74 77 78 79 80 82 83 84 85 87 89 90 – – – – – – – – –
8 750 61 64 66 67 70 71 72 73 75 76 77 78 81 82 83 85 – – – – – – – –
9 1500 70 73 75 76 78 81 82 83 84 85 86 87 88 90 – – – – – – – – – –
B2 . 1000 63 67 68 70 73 74 75 77 79 80 81 82 83 84 86 87 – – – – – – – –
14 750 1) 61 62 64 66 67 68 70 72 73 74 75 77 78 79 80 – – – – – – – –
16 1500 67 71 74 76 78 79 80 81 83 84 87 88 89 90 – – – – – – – – – –
. 1000 60 64 67 68 70 72 73 74 78 79 80 81 82 83 84 84 – – – – – – – –
22.4 750 1) 1) 61 63 65 67 68 69 71 72 73 73 74 74 75 76 – – – – – – – –
12.5 1500 69 72 75 77 79 80 81 82 83 85 88 89 90 91 93 93 93 93 95 95 – – – –
. 1000 62 65 68 69 71 72 73 74 77 78 80 82 83 83 84 85 86 86 88 88 89 90 91 –
31.5 750 1) 1) 63 64 66 68 69 70 71 73 74 75 76 77 78 78 79 79 81 81 82 84 85 85
35.5 1500 67 69 72 73 74 75 77 79 82 84 86 87 88 89 90 91 92 92 93 93 – – – –
B3 . 1000 1) 63 65 66 67 69 71 72 73 75 77 78 79 80 81 82 83 84 85 86 86 87 88 89
56 750 1) 1) 1) 1) 62 64 65 67 69 70 71 72 73 74 75 76 77 78 79 79 80 81 82 82
63 1500 66 68 70 71 73 74 76 78 81 83 85 86 87 88 89 90 91 91 92 92 – – – –
. 1000 1) 61 63 64 66 68 69 71 73 75 77 78 79 80 81 81 82 82 83 84 84 85 86 86
90 750 1) 1) 1) 1) 61 63 64 66 67 68 70 71 72 73 74 75 75 76 77 77 78 79 79 80
1) LpA < 60 dB(A)
BA 5010 EN 06.03

1.1.2.2 Measuring-surface sound-pressure level for bevel-helical gear units (B...) without fan
Measuring-surface sound-pressure level LpA in dB(A) for bevel-helical gear units without fan
n1 Gear-unit size
Type iN 1/min 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
5 1500 72 75 78 80 82 83 84 86 87 88 89 90 93 – – – – – – – – – – –
. 1000 66 70 72 73 76 77 78 79 81 82 83 84 86 88 89 – – – – – – – – –
8 750 1) 63 65 66 69 71 72 73 74 75 77 78 80 82 83 84 – – – – – – – –
9 1500 67 71 74 75 77 79 80 81 83 84 85 86 87 89 – – – – – – – – – –
B2 . 1000 61 65 67 69 72 73 74 76 77 78 80 81 82 83 85 86 – – – – – – – –
14 750 1) 1) 60 63 65 66 67 69 71 72 73 74 76 77 78 79 – – – – – – – –
16 1500 63 66 69 71 72 74 75 77 78 80 81 82 85 85 – – – – – – – – – –
. 1000 1) 61 63 65 67 68 69 71 72 74 75 77 79 80 81 81 – – – – – – – –
22.4 750 1) 1) 1) 1) 60 62 63 64 66 67 68 70 72 73 74 75 – – – – – – – –
12.5 1500 65 68 71 74 75 76 77 79 81 83 84 85 86 87 87 88 89 90 91 92 – – – –
. 1000 1) 63 66 68 69 70 72 73 75 77 78 80 80 81 82 82 84 85 86 86 88 89 90 –
31.5 750 1) 1) 1) 61 62 64 65 66 68 71 71 73 73 74 75 75 77 78 79 79 81 82 83 84
35.5 1500 60 65 67 70 71 71 72 74 77 79 80 81 82 83 83 84 86 86 88 88 – – – –
B3 . 1000 1) 1) 62 65 65 66 66 69 71 73 75 76 76 77 77 78 80 81 82 83 84 85 86 87
56 750 1) 1) 1) 1) 1) 1) 1) 62 65 67 68 69 70 70 71 72 74 74 75 76 78 80 80 80
63 1500 1) 61 64 70 67 68 68 70 73 75 76 78 78 79 79 80 82 83 84 84 – – – –
. 1000 1) 1) 1) 63 62 62 62 65 68 70 71 72 73 73 74 75 76 77 78 79 81 81 83 83
90 750 1) 1) 1) 1) 1) 1) 1) 1) 61 63 64 65 66 67 67 68 70 70 72 72 74 75 76 76
80 1500 – – 64 65 67 68 70 72 75 76 77 79 80 81 82 83 84 85 86 86 87 88 87 89
. 1000 – – 1) 1) 61 63 64 67 69 70 72 73 74 75 76 77 78 79 80 80 81 82 82 83
125 750 – – 1) 1) 1) 1) 1) 1) 62 64 65 66 68 68 69 71 71 72 73 74 74 75 75 76
140 1500 – – 60 61 63 65 66 68 71 72 73 75 76 77 78 79 80 81 82 82 83 84 85 86
B4 . 1000 – – 1) 1) 1) 1) 61 63 65 67 68 69 71 71 72 74 75 75 76 77 78 78 79 80
224 750 – – 1) 1) 1) 1) 1) 1) 1) 1) 61 62 64 65 66 67 68 69 69 70 71 72 73 73
250 1500 – – 1) 1) 1) 62 63 65 67 69 70 71 73 73 75 76 77 77 78 79 80 80 81 82
. 1000 – – 1) 1) 1) 1) 1) 1) 62 63 64 66 67 68 69 70 71 72 73 73 74 75 76 77
400 750 – – 1) 1) 1) 1) 1) 1) 1) 1) 1) 1) 1) 61 62 63 64 65 66 66 67 68 69 70
1) LpA 60 dB(A)
BA 5010 EN 06.03

1.1.2.3 Measuring-surface sound-pressure level for helical gear units (H...) with fan
Measuring-surface sound-pressure level LpA in dB(A) for helical gear units with fan
n1 Gear-unit size
Type iN 1/min 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1.25 1500 76 – 81 – 84 – 87 – 91 – – – – – – – – – – – – – – –
. 1000 71 – 76 – 79 – 81 – 83 – 85 – – – – – – – – – – – – –
2 750 67 – 72 – 75 – 78 – 80 – 82 – 85 – – – – – – – – – – –
2.24 1500 73 – 79 – 82 – 84 – 89 – 90 – – – – – – – – – – – – –
H1 . 1000 68 – 74 – 77 – 79 – 82 – 84 – 87 – – – – – – – – – – –
3.55 750 64 – 70 – 72 – 75 – 78 – 80 – 83 – 84 – – – – – – – – –
4 1500 70 – 77 – 81 – 83 – 86 – 89 – 93 – – – – – – – – – – –
. 1000 65 – 71 – 75 – 77 – 80 – 82 – 84 – 85 – 87 – – – – – – –
5.6 750 61 – 68 – 71 – 72 – 75 – 77 – 79 – 81 – 83 – – – – – – –
6.3 1500 – 75 76 77 80 81 82 84 85 86 88 90 92 94 96 96 – – – – – – – –
. 1000 – 69 71 72 74 75 77 79 80 81 83 84 85 86 87 88 88 89 90 – – – – –
10 750 – 66 68 69 70 72 73 75 76 77 79 80 81 82 83 83 84 84 85 85 86 – – –
11.2 1500 – 73 75 77 79 80 81 82 85 88 90 91 92 93 95 95 – – – – – – – –
H2 . 1000 – 68 69 70 72 73 75 77 79 80 82 83 84 85 85 86 86 87 87 87 88 88 – –
16 750 – 64 66 67 69 70 71 73 74 76 78 79 79 80 81 81 82 82 83 83 83 84 84 85
18 1500 – 71 73 75 77 78 80 82 84 86 87 90 91 92 93 94 94 95 95 95 – – – –
. 1000 – 65 67 68 71 72 73 75 77 78 80 81 82 83 83 84 85 85 86 86 86 87 87 87
28 750 – 62 64 65 67 68 69 71 73 74 75 77 78 79 79 80 80 81 81 81 82 82 82 83
22.4 1500 – – 71 72 75 75 77 77 80 80 81 81 84 84 84 85 – – – – – – – –
. 1000 – – 65 66 69 70 71 72 74 75 75 75 78 78 78 79 – – – – – – – –
35.5 750 – – 62 62 66 67 67 68 70 70 71 72 74 74 75 76 – – – – – – – –
40 1500 – – 70 71 73 74 76 76 79 79 80 80 83 82 83 83 – – – – – – – –
H3 . 1000 – – 64 65 67 68 69 70 73 73 73 74 77 77 77 77 – – – – – – – –
63 750 – – 62 62 63 64 65 66 69 69 69 70 72 73 73 73 – – – – – – – –
71 1500 – – 70 70 72 72 75 75 78 78 78 78 82 82 82 82 – – – – – – – –
. 1000 – – 64 64 65 66 68 69 71 72 72 72 75 75 75 76 – – – – – – – –
112 750 – – 61 61 62 62 64 65 67 67 68 68 71 71 71 72 – – – – – – – –
1) LpA 60 dB(A)
BA 5010 EN 06.03

1.1.2.4 Measuring-surface sound-pressure level for helical gear units (H...) without fan
Measuring-surface sound-pressure level LpA in dB(A) for helical gear units without fan
n1 Gear-unit size
Type iN 1/min 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1.25 1500 73 – 77 – 79 – 81 – 83 – – – – – – – – – – – – – – –
. 1000 69 – 72 – 75 – 76 – 78 – 80 – – – – – – – – – – – – –
2 750 65 – 69 – 71 – 73 – 75 – 77 – 79 – – – – – – – – – – –
2.24 1500 70 – 75 – 77 – 79 – 81 – 83 – – – – – – – – – – – – –
H1 . 1000 66 – 70 – 72 – 74 – 76 – 78 – 80 – – – – – – – – – – –
3.55 750 62 – 67 – 68 – 71 – 73 – 75 – 77 – 79 – – – – – – – – –
4 1500 67 – 72 – 74 – 76 – 78 – 79 – 82 – – – – – – – – – – –
. 1000 1) – 67 – 70 – 71 – 73 – 75 – 77 – 79 – 81 – – – – – – –
5.6 750 1) – 63 – 66 – 67 – 70 – 71 – 74 – 76 – 78 – – – – – – –
6.3 1500 – 71 74 75 76 77 79 79 80 81 81 82 84 85 85 86 – – – – – – – –
. 1000 – 66 69 70 71 72 74 74 75 76 76 77 80 80 80 81 83 83 84 – – – – –
10 750 – 63 66 67 67 69 70 71 72 73 73 74 76 77 77 78 80 80 81 81 81 – – –
11.2 1500 – 69 72 73 74 75 77 77 78 79 79 80 82 83 83 84 – – – – – – – –
H2 . 1000 – 64 67 68 69 70 72 72 73 74 74 75 77 78 78 79 81 81 82 82 83 83 – –
16 750 – 61 64 65 66 67 69 69 70 71 71 72 74 75 75 76 77 78 79 79 79 80 81 81
18 1500 – 66 69 70 71 72 74 74 75 76 77 78 80 80 81 82 83 84 84 85 – – – –
. 1000 – 61 64 65 66 68 69 69 70 71 72 73 75 75 76 77 78 79 79 80 80 81 81 82
28 750 – 1) 61 62 63 64 66 66 67 68 69 70 72 72 73 73 75 75 76 76 77 77 78 78
22.4 1500 – – 68 69 73 74 74 75 77 77 78 79 81 81 82 83 83 84 85 86 86 87 – –
. 1000 – – 63 65 68 69 69 71 72 73 73 74 76 77 77 78 79 79 81 81 81 82 83 83
35.5 750 – – 60 61 65 66 65 67 69 69 70 71 73 73 74 75 75 76 77 78 78 79 79 80
35.5 1500 – – 65 67 70 71 71 73 74 75 76 76 78 79 79 80 81 81 83 83 84 84 – –
H3 . 1000 – – 1) 62 65 66 66 68 69 70 71 72 73 74 75 75 76 77 78 78 79 79 80 80
63 750 – – 1) 1) 62 63 63 65 66 67 67 68 70 71 71 72 73 73 75 75 76 76 77 77
71 1500 – – 62 64 67 68 68 70 71 72 73 74 76 76 77 78 78 79 80 81 81 82 82 83
. 1000 – – 1) 1) 62 63 63 65 66 67 68 69 71 71 72 73 73 74 75 76 76 77 77 78
112 750 – – 1) 1) 1) 1) 1) 62 63 64 65 66 68 68 69 70 70 71 72 72 73 73 74 75
100 1500 – – – – 66 67 68 69 70 71 72 73 75 75 76 76 77 78 78 78 79 80 81 81
. 1000 – – – – 62 63 63 64 65 66 67 68 70 70 71 72 72 73 73 74 74 76 76 77
140 750 – – – – 1) 1) 1) 61 62 63 64 64 66 67 68 68 69 69 70 70 71 72 73 73
160 1500 – – – – 64 65 66 66 68 68 69 70 72 73 73 74 74 75 75 76 76 78 78 79
H4 . 1000 – – – – 1) 60 61 62 63 64 64 65 67 68 68 69 70 70 71 71 72 73 74 74
250 750 – – – – 1) 1) 1) 1) 60 61 61 62 64 64 65 66 66 67 67 68 68 70 70 71
280 1500 – – – – 61 62 63 64 65 66 67 67 69 70 70 71 72 72 73 73 74 75 76 76
. 1000 – – – – 1) 1) 1) 1) 60 61 62 63 64 65 66 66 67 68 68 68 69 70 71 72
450 750 – – – – 1) 1) 1) 1) 1) 1) 1) 1) 61 62 62 63 64 64 55 65 65 67 68 68
1) LpA 60 dB(A)
BA 5010 EN 06.03

2. General notes
2.1 Introduction
These Operating Instructions (BA) are an integral part of the gear unit supplied and must be kept in its
vicinity for reference at all times.
All persons involved in the installation, operation, maintenance and repair of

Caution! the gear unit must have read and understood these Operating Instructions and
must comply with them. We accept no responsibility for damage or disruption
caused by disregard of these Instructions.
The ”FLENDER gear unit” described in these Operating Instructions (BA) has been developed for
stationary use in general engineering applications. Possible areas of use for gear units of this type are
(e.g.) sewage treatment, excavators, chemical industry, iron and steel industry, conveyor systems,
crane systems, foodstuffs industry, paper machinery, cableways, cement industry, etc.
The gear unit is designed only for the application described in section 1, ”Technical data”.
The gear unit described in these Instructions reflects the state of technical development at the time
these Instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies
and accessories which we regard as necessary to preserve their essential characteristics and improve
their efficiency and safety.
2.2 Copyright
The copyright to these Operating Instructions is held by FLENDER AG.
Technical enquiries should be addressed to the following works
for gear sizes 3 ... 16 for gear sizes 17 ... 26
A. FRIEDR. FLENDER AG A. FRIEDR. FLENDER AG

Getriebewerk Penig
Thierbacher Straße 24
D-09322 Penig D-46393 Bocholt
Tel.: 037381/60 Tel.: 02871/92-0

Fax: 037381/80286 Fax: 02871/92-2596
Internet: www.flender.com
or to one of our customer-service addresses. A list of our customer-service addresses is given in
section 11, ”Spare parts, customer-service addresses”.
3. Safety notes
3.1 Proper use
S The gear unit has been manufactured in accordance with the state of the art and is delivered in a
condition for safe and reliable use. Any changes on the part of the user are not permitted. This applies
equally to safety features designed to prevent accidental contact.
S The gear unit must be used and operated strictly in accordance with the conditions laid down in the
contract governing performance and supply agreed by FLENDER and the customer.
BA 5010 EN 06.03

3.2 Obligations of the user
S The operator must ensure that all persons involved in installation, operation, maintenance and repair
have read and understood these Operating Instructions and comply with them at all times in order
to:
– avoid injury or damage,
– ensure the safety and reliability of the unit,
and
– avoid disruptions and environmental damage through incorrect use.
S During transport, assembly, installation, dismantling, operation and maintenance of the unit, the
relevant safety and environmental regulations must be complied with at all times.
S The gear unit should be operated, maintained or repaired by authorised, trained and qualified
personnel.
S The gear unit must not be cleaned using high-pressure cleaning equipment.
S All work must be carried out with great care and with due regard to safety.
S All work on the gear unit must be carried out only when it is not in operation.
The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch
or removing the fuses from the power supply). A notice should be attached to the start switch stating
clearly that work is in progress.
S No welding work should be done on the gear unit.

The gear unit must not be used as an earthing point for welding operations. Toothed parts and
bearings may be irreparably damaged by welding.
S If any changes are noticed during operation (e.g. overheating or unusual noises), the drive assembly
must be switched off immediately.
S Rotating drive components such as couplings, gearwheels, belt drives etc. must be protected against
accidental contact.
S If the gear unit is intended for installation in plant or machinery, the manufacturer of such plant or
machinery must ensure that the contents of these Instructions are incorporated in his own
instructions.
S Notices attached to the gear unit, e.g. rating plate, direction arrows etc. must always be observed.
They must be kept free from dirt and paint at all times. Missing plates must be replaced.
S Screws which have been damaged during assembly or disassembly work must be replaced with new
ones of the same strength class and type.
S Spare parts should always be obtained from FLENDER (please refer to section 11, ”Spare parts,
customer-service addresses”.
3.3 Environmental protection
S When changing oil, the used oil must be collected in suitable containers. Any spillage of oil must be
removed immediately.
S Preservative agent should be stored separately from used oil.
S Used oil, preservative agent, oil-binding agents and oil-soaked cloths must be disposed of in
accordance with environmental legislation.
BA 5010 EN 06.03

3.4 Special dangers
S Depending on operating conditions, the surface of the gear unit may heat up considerably.
Danger of burns!
S When changing oil, take care to prevent scalding by hot oil.
S Small foreign matter such as sand, dust, etc. can get into the cover plates of the rotating parts and
be thrown back by these. Eye protection must therefor be worn while the gear unit is operating.
The gear unit is not suitable for operation in locations liable to explosion. When
Caution! operating in locations liable to explosion special additional safety procedures
must be observed.
3.5 Warnings and symbols used in these Instructions
This symbol indicates safety measures which must be observed to avoid personal
injury.
This symbol indicates safety measures which must be observed to avoid damage to
Caution! the gear unit.
Note: This symbol indicates general operating instructions which are of particular
importance.
4. Handling and storage
Observe the ”Safety instructions” in section 3.
4.1 Scope of supply
The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that
all the products listed have actually been delivered. Parts damaged during transport or missing parts
must be reported in writing immediately to FLENDER AG.
Caution! If damage has occurred, the gear unit must not be put into operation.
4.2 Handling
When handling FLENDER products, use only lifting and handling equipment of
sufficient load-bearing capacity!
Observe the notes regarding load distribution on the packaging.
The gear unit is delivered in the fully assembled condition. Additional items (e.g. oil cooler, pipes and
fittings) can be delivered separately packaged.
Different forms of packaging may be used, depending on the size of the unit and method of transport.
Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packaging must be observed at all times. These have the following
meanings:
bild-transport
This way Fragile Keep Keep Centre of Use no Attach

up dry cool gravity hand hook here
BA 5010 EN 06.03

Transport of the gear unit must be carried out so as to avoid personal damage
Caution! and damage to the gear unit.
If, for example, the free shaft ends are knocked, this may damage the gear unit.
Note: The gear units must be transported with suitable equipment only.
During transport the gear unit should be left without oil filling and on the transport
packaging.
Use only the 4 eyes provided to attach lifting equipment to the unit.
Caution! Do not use the front threads at the shaft ends to attach eye bolts for transport.
Slinging equipment must be adequate for the weight of the gear unit.
500004-10-1
H... B...
For drive units where additional components (such as motor, attached coupling etc.) are mounted on
the gear unit an additional attachment point may be required because of the shift in the centre of gravity.
Caution! Units which are slung by eyebolts must not be tilted.
500004-10-2
H... with motor
500004-10-3
B... with motor
BA 5010 EN 06.03

500004-10-4
B... with gear-unit swing
For a detailed view of the gear unit, refer to the drawings in the gear-unit documentation.
4.3 Storing the gear units
The gear unit must be stored in the position of use in a sheltered place; it must be placed on a
vibration-free, dry wooden base and covered over.
When storing the gear unit and any single components supplied with it, the preservative agent should
be left on them. It must not be damaged, otherwise there is a risk of corrosion.
Do not stack gear units on top of one another.
If the gear unit is being stored out of doors, it must be particularly carefully
Caution! covered, and care taken that neither moisture nor foreign material can collect
on the unit (consult FLENDER).
Note: Unless otherwise agreed by contract, the gear units must not be exposed to harmful
environmental factors such as chemical products, high air pollution, air humidity, and
ambient temperatures outside the range 0 to + 20 °C.
Provision for special environmental conditions during transport (e.g. transport by

ship) and storage (climate, termites, etc.) must be contractually agreed.
4.4 Standard preservation
The gear unit is provided with an internal preservative agent; the free shaft ends are painted for
protection.
The properties of the outer paint coat are as follows: Resistant to acids, weak alkalis, solvents,
atmospheric action, temperatures up to 120 °C (temporarily up to 140 °C) and to tropical conditions.
Note: Ensure that the paint is not damaged!

Mechanical damage (scratches), chemical damage (acids, alkalis) and thermal
damage (sparks, welding beads, heat) cause corrosion which may cause failure of
the external protective coating.
Unless otherwise contractually agreed, the internal preservation is guaranteed for

6 months, and the preservation of the free shaft ends for 24 months, provided that
storage is in dry, frostfree sheds. The period of validity of the guarantee starts on the
date of delivery of the gear unit.
For longer periods of storage (> 6 months) we advise regular checking and, if necessary, renewal of
the internal and external preservation (see section 7, ”Start-up”).
The output shaft must be rotated at least one turn to change the position of the rolling element in the
bearings. The input shaft must not come to a standstill in the same position as before rotation.
This procedure must be repeated and documented every 6 months until start-up.
BA 5010 EN 06.03

5. Technical description

The helical gear unit is supplied as a one-, two-, three- or four-stage helical gear unit. The bevel-helical
gear unit is supplied as a two-, three- or four-stage bevel-helical gear unit. It is designed for installation
in the horizontal position. If necessary, it can also be designed for installation in a different position.
It can be operated in both directions of rotation. The only exceptions are gear types with backstop or
overrunning clutch. If rotation reversal is required for these types of unit, FLENDER should be
consulted.
A number of shaft configurations (types and rotation directions) are possible. These are shown in the
following table as solid shafts:
Configuration
Type
A B C D E F G H I
H1SH
H2SH H2HM
H2HH H2DM
H2DH H2KM
H2KH H2FM
H2FH H2PH
H2VH
H3SH H3HM
H3HH H3DM
H3DH H3KM
H3KH H3FM
H3FH H3VH
H4SH H4HM
H4HH H4DM
H4DH H4KM
H4KH H4FM
H4FH H4VH
B2SH B2HM
B2HH B2DM
B2DH B2KM
B2KH B2FM
B2FH B2VH
B3SH B3HM
B3HH B3DM
B3DH B3KM
B3KH B3FM
B3FH B3VH
B4SH B4HM
B4HH B4DM
B4DH B4KM
B4KH B4FM
B4FH B4VH
The gear units are characterised by a low noise level. This is achieved by helical and bevel-helical gears
with a high contact ratio and special sound-damping housings.
The good temperature characteristics of the gear unit are achieved by its high degree of efficiency, large
housing surface and performance-related cooling system.
Note: Unless otherwise agreed by contract, the gear units must not be exposed to harmful
environmental factors such as chemical products, high air pollution, air humidity, and
ambient temperatures outside the range 0 to + 20 °C.
BA 5010 EN 06.03

5.2 Output designs
500005-10-7
..S. ..V. ..F. ..H. ..D. ..K.

solid shaft solid shaft flanged shaft hollow shaft hollow shaft hollow shaft with
reinforced with for internal-spline
parallel keyway shrink disk to DIN 5480
5.3 Housing
The housings are of cast iron. If required, they may also be of steel.
Housings up to size 12 are made in one part. The exception are types H1SH and H2PH, which have
a two-part housing similar to those of sizes 13 - 26 of the other types. The housing is rigid in design and
due to its form has excellent noise and temperature characteristics.
The housing is fitted with adequately dimensioned lifting eyes, inspection or assembly covers.
The oil level is checked by oil dipstick or by oil sight glass. An oil filler plug for filling with oil, an oil drain
plug for oil change and an air filter for aerating and ventilating the gear unit are provided.
Colour codes for ventilating, oil inlet, oil level and oil drainage:
Breather: yellow
Oil inlet: yellow
Oil level: red
Lubrication points: red
Oil drain: white
500005-10-1
2 3 4 1 14 17
6 7 1)
10 5 5
7
9
12
13
18
11 8
H..H 12
1) for H1SH only
BA 5010 EN 06.03

500005-10-2
3 14 3 1 4 15 2
17 7
10 5 5
6
9
13
12
11 16 8
H..H 13
500005-10-3
3 14 3 1 4 15 2
17 7
10 5 5
6
9
13
12
18 8
H..M 13
500005-10-4
2 3 4 1 14 17
6
9
5
5 10
13
12
18 11 8
B..H 12
BA 5010 EN 06.03

500005-10-5
3 14 3 1 4 15 2
17
7
9
5 5
10
13
12
11 16 8
B..H 13
500005-10-6
3 14 3 1 4 15 2
17
7
9
5 5
10
13
12
18 8
B..M 13
1 Housing 10 Rating plate

2 Lifting eyes 11 Gear-unit fastening
3 Cover 12 Fan cowl
4 Cover 13 Fan
5 Shaft seals 14 Inspection or assembly cover
6 Oil dipstick 15 Alignment surfaces
7 Housing ventilation 16 Alignment thread
8 Oil drain plug 17 Oil inlet
9 Cover or bearing journal 18 Fastening for torque arm
5.4 Toothed components
The toothed components of the gear unit are case-hardened. The helical gear teeth are ground;
depending on their size and transmission ratio, bevel-helical gear teeth are lapped, ground or
HPG-gear-cut. The high quality of the teeth leads to a significant noise reduction and ensures safe and
reliable running.
The gear wheels are joined to the shafts by interference fits and parallel keys. These types of joints
transmit with adequate reliability the torques generated.
5.5 Lubrication
5.5.1 Dip lubrication
Unless otherwise stated in the order documentation, the teeth and bearings are adequately
splash-lubricated with oil by the gearwheels. This means that the gear units require very little
maintenance.
BA 5010 EN 06.03

5.5.2 Pressure lubrication through add-on oil supply system
In non-horizontal positions, with high bearing speeds or peripheral velocities on the teeth, the splash
lubrication system may be replaced or supported by a pressure lubrication system.
The oil supply system is permanently attached to the gear unit and consists of a flange pump, a coarse
filter, a pressure-monitoring device and pipework. For gear units of sizes 13 to 26, the coarse filter is
replaced by a double change-over filter.
The direction of flow from the flange pumps is independent of the direction of rotation.
500005-10-8
3 2 2
1 1
H... 12 H... 13
500005-10-9
3 2 4 2
1 1
B... 12 B... 13
1 Flange pump 3 Coarse filter

2 Pressure monitor 4 Double change-over filter
In the case of gear units with add-on

Caution! oil supply system, before starting 0,5 bar
the unit up the pressure monitor To be connected
must always be connected ready for as opener or
operation. closer, as
required.
Depending on the order specification and application, the
flange pump may be replaced by a motor pump.
The operation and maintenance of the pump, pressure monitor, coarse filter or double change-over filter
are described in instructions included in the annex.
For technical data, refer to the order-specific equipment list.
5.6 Shaft bearings
All shafts are mounted in rolling bearings.
BA 5010 EN 06.03

5.7 Shaft seals
Depending on requirements, radial shaft sealing rings, labyrinth seals or Taconite seals are mounted
at the shaft exits to prevent oil from leaking from the housing and dirt from entering it.
5.7.1 Radial shaft sealing rings
Radial shaft sealing rings are the standard type of seal. They are fitted preferably with an additional dust
lip to protect the actual sealing lip from external contamination.
Caution! Use in an area with much dust is not possible.
500005-10-10
5.7.2 Labyrinth seals
Labyrinth seals are non-contacting and avoid wear to the shaft. They therefore require no maintenance
and ensure favourable temperature characteristics. They can be used only with certain transmission
ratios and minimum speeds.
Check in the spare parts drawing and the spare parts list whether the gear unit is provided with labyrinth
seals.
500005-10-11
For reliable operation, this type of seal requires horizontal positioning in a

Caution! splash-free and relatively dust-free environment. Overfilling of the gear unit
can cause leakage, as can oil with high foam content.
5.7.3 Taconite seals
Taconite seals were specially developed for use in a dusty environment. The penetration of dust is
prevented by a combination of seal elements (radial shaft sealing ring, lamellar seal and
grease-charged labyrinth seal).
500005-10-12
4
1 Radial shaft sealing ring 3 Grease-charged labyrinth seal (re-chargeable)

2 Lamellar seal 4 Flat grease nipple AM10x1 to DIN 3404
BA 5010 EN 06.03

Taconite seals are divided into the following types:
500005-10-13
Taconite ”E” Taconite ”F”
500005-10-14
2 4
1 1
3 2
Taconite “F-F” and “F-H” Taconite “F-K” and “F-F”
1 Output 3 Taconite ”F-H”

2 Taconite ”F-F” 4 Taconite ”F-K”
Taconite
Application Remarks
type variant
All input shafts
“E” with or without fan
Output shaft Re-chargeable labyrinth
Type S (solid shaft)
“F” Type V (solid shaft, reinforced)
Type F (flanged shaft)
Output shaft
Type H (hollow shaft with parallel keyway) Labyrinth re-chargeable on both sides,
“F-F” Type K (hollow shaft with internal spline incl. cowl to prevent contact on gear
to DIN 5480) side facing away from output
Type D (hollow shaft for shrink disk)
Output shaft
Type H (hollow shaft with parallel keyway)
”F-H” Type K (hollow shaft with internal-spline
Re-chargeable labyrinth on output side;
to DIN 5480)
dustproof cowl on opposite side
Output shaft
“F-K” Type D (hollow shaft for shrink disk)
For re-charging the labyrinth seals with grease, the specified frequencies must be observed (see
section 10, ”Maintenance and repair”).
BA 5010 EN 06.03

5.8 Backstop
For certain requirements, the gear unit can be fitted with a mechanical backstop. This permits only the
specified direction of rotation during the operation of the unit. The direction of rotation is marked by a
corresponding arrow on the input and output side of the gear unit.
The backstop is mounted oiltight on an adapter flange on the gear unit and integrated in its oil-circulation
system.
The backstop is fitted with centrifugally operated sprags. When the gear unit is running in the specified
direction, the inner ring and the cage with the sprags also rotates while the outer ring remains stationary.
At a certain rotation speed, the sprags lift off and the backstop then operates without any wear.
500005-10-21
1
5
6
1 Backstop outer ring 4 Shaft (adapter flange)

2 Backstop inner ring 5 Cover
3 Cage with sprags 6 Residual-oil drain for backstop
Note: The stop direction can be changed by turning the cage around. If a change in stop
direction is required, FLENDER should be consulted beforehand.
To avoid damaging the backstop or the gear unit, the motor must not be run in
Caution! the stop direction of the gear unit.
Observe the notice fixed to the gear unit.
The minimum lifting speeds must not be exceeded during operation.
Before connecting the motor, determine the direction of rotation of the three-phase current supply using
a phase-sequence indicator, and connect the motor in accordance with the pre-determined direction
of rotation.
BA 5010 EN 06.03

5.9 Cooling
Depending on requirement, the gear unit is fitted with a fan, a cooling coil, a water or air oil-cooling
system or a separate oil supply system. In the case of a separate oil supply system, the specific
instructions for this oil supply system must be observed.
5.9.1 Fan
The fan is mounted on a high-speed shaft of the gear unit and is protected from accidental contact by
a cowl. The fan sucks air through the grid on the cover and blows it along the air ducts on the side of
the gear housing. It thereby dissipates a certain amount of heat from the housing.
500005-10-15
1 1
2 2
H... B...
1 Fan 2 Fan cowl
For gear units fitted with a fan, sufficient space must be allowed for air intake
Caution! when mounting the safety guards for the coupling or other components.
The correct distance is given in the dimensioned drawing in the gear-unit
documentation.
It must be ensured that the fan cover is correctly fastened. The fan cover must
be protected against damage from outside. The fan must not come into contact
with the fan cover.
The cooling effect is considerably reduced if the fan or the gear housing are dirty (see section 10,
”Maintenance and repair”).
BA 5010 EN 06.03

5.9.2 Cooling coil
The cooling coil is located in the oil sump of the gear unit and is supplied with cooling water via a
connection to be provided by the user. Either fresh water, sea water or brackish water can be used for
cooling purposes. When water is flowing through the coil, a certain amount of heat is transferred from
the oil to the water and thereby removed from the system.
500005-10-16
X X
1, 2 3 3 1 2
H... B...
1 Cooling-water connection 2 Reducing screw 3 Output shaft
The water can flow through the gear unit in either direction. The pressure of the
Caution! cooling water must not exceed 8 bars.
If the gear unit is being withdrawn from service for a longer period or if there
is a danger of freezing, the cooling water must be drained off. Remove any
remaining water with compressed air.
The ends of the cooling coil must never be twisted because this could destroy
the cooling coil.
The reducing bolt must not be tightened or demounted because this may result
in damage to the cooling coil.
To avoid excess pressure, the cooling-water inlet must be fitted with a flow-control device, e.g. a
pressure reducer or suitable stop valve.
Cooling-water quantity required (l/min)

Type
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 to 26
H1SH 4 – 4 – 4 – 8 – 8 – 8 – 8 – 8 – 1) –
H2.H – 4 4 4 4 4 8 8 8 8 8 8 8 8 8 8 1) 1)
H2.M – – – – – – – – – – 8 8 8 8 8 8 1) 1)
H3.H – – 4 4 4 4 4 4 8 8 8 8 8 8 8 8 1) 1)
H3.M – – – – – – – – – – 8 8 8 8 8 8 1) 1)
B2.H – 4 8 4 8 4 8 8 8 8 8 8 8 8 8 8 – –
B3.H – 4 4 4 4 4 8 8 8 8 8 8 8 8 8 8 1) 1)
B2.M – – – – – – – – – – 8 8 8 8 8 8 – –
B3.M – – – – – – – – – – 8 8 8 8 8 8 1) 1)
Note: Refer to the order-specific dimensioned drawing for connecting dimensions.
1) on request
BA 5010 EN 06.03

5.9.3 Add-on air oil-cooling units
For types H1.., H2.. and B2.., a cooling unit with air oil-cooler may be applied if required in the order.
This unit is permanently mounted on the gear unit and consists of a flange pump, a coarse filter, a
pressure monitor, a temperature-control valve, the actual air oil-cooler and the necessary pipework. For
gear units of sizes 13 to 26, the coarse filter is replaced by a double change-over filter.
The air oil-cooler is designed to cool the gear oil by means of air from the surrounding atmosphere.
Depending on the volume flow, the oil passes through the cooler in one or more streams and through
the current of air blown in by the fan. For cold starts, a bypass pipe with a temperature-control valve
is provided for.
The flow direction of the flange pump used is independent of the direction of rotation, if nothing is
specified in the documentation to the contrary.
500005-10-17
3 2 2 4
6
6
5
5
1 1
H1.. / H2.. 12 H1.. / H2.. 13
500005-10-18
3 2 2 4
6
6
5
5
1 1
B2.. 12 B2.. 13
1 Flange pump 4 Double change-over filter

2 Pressure monitor (circuit diagram see item 5.5.2) 5 Air oil-cooler
3 Coarse filter 6 Temperature-control valve
When installing gear units with add-on air oil-cooling units, it must be ensured
Caution! that the air circulation is not obstructed.
The required minimum distance from adjacent components, walls, etc. is
indicated in the drawings in the unit documentation.
Add-on pressure monitors must be connected as shown in item 5.5.2.
Depending on the order specification and application, the flange pump may have been replaced by a
motor pump.
For operation and maintenance, always observe the operating instructions indicated in the
order-specific appendix.
The cooling effect is considerably reduced if the cooler or the gear housing are dirty (see section 10,
”Maintenance and repair”).
BA 5010 EN 06.03

5.9.4 Add-on water oil-cooling units
For types H1.., H2.. and B2.., a cooling unit with water oil-cooler may be applied if required in the order.
This oil-cooling unit is permanently mounted on the gear unit and consists of a flange pump, a coarse
filter, a pressure monitor, the actual water oil-cooler and the necessary pipework. For gear units of sizes
13 to 26, the coarse filter is replaced by a double change-over filter.
The flow direction of the flange pump used is independent of the direction of rotation, if nothing is
specified in the documentation to the contrary.
The required water connection must be provided by the user.

500005-10-19
2 2
5 4
3 5
6 6
1 1
H1.. / H2.. 12 H1.. / H2.. 13
500005-10-20
2 2
5 4
3 5
6 6
1 1
B2.. 12 B2.. 13
1 Flange pump 4 Double change-over filter

2 Pressure monitor (circuit diagram see item 5.5.2) 5 Water oil-cooler
3 Coarse filter 6 Water inlet and outlet
To ensure optimum cooling performance, the specified direction of flow in the

Caution! water oil-cooler must be observed. The cooling-water inlet and outlet must not
be reversed.
The pressure of the cooling water must not exceed 8 bars.
If the gear unit is being withdrawn from service for a longer period or if there
is a danger of freezing, the cooling water must be drained off. Remove any
remaining water with compressed air.
Add-on pressure monitors must be connected as shown in item 5.5.2.
Depending on the order specification and application, the flange pump may have been replaced by a
motor pump.
BA 5010 EN 06.03

5.10 Heating element
At low temperatures it may be necessary to heat the gear oil before switching on the drive unit or even
during operation. In such cases one or two such heating element may be provided if required. These
convert the electrical energy into heat which is conducted to the surrounding oil. The heating elements
are located in protective tubes inside the housing, thus making it possible to replace them without
draining off the oil.
Complete immersion of the heating elements in the oil bath must be guaranteed.
The heating elements are controlled by a temperature monitor which emits a signal when maximum and
minimum temperatures are reached; the signal requires amplification.
500005-10-22
1 2 1 2 1 2 1 2
H... / B... 12 H... / B... 13
1 Heating element 2 Temperature monitor
For a detailed illustration of the gear unit and the position of the add-on parts, please refer to the
drawings of the gear-unit documentation.
Never switch the heating element on unless complete immersion of the heating
Caution! elements in the oil bath is ensured. Fire hazard!
If heating elements are installed afterwards the max. heating capacity
of 0.8 W/cm2 on the outer surface of the heating elements must not be
exceeded.
BA 5010 EN 06.03

5.11 Oil-temperature measurement
Depending on the order specification, the gear unit may be fitted with a PT100 resistance thermometer
for monitoring the oil temperature in the sump. In order to measure the temperatures or temperature
differences, the PT100 resistance thermometer should be connected to a suitable instrument provided
by the customer. The thermometer has a connection head (protection type IP54) for the wiring. A
two-conductor circuit is fitted by the manufacturer. However, the customer may fit his own three- or
four-conductor circuit if required.
Note: A certain level of oil is necessary for reliable temperature measurement. For this
reason, the resistance thermometer is not suitable for use with labyrinth seals.
500005-10-23
1 1 1 1
H... / B... 12 H... / B... 13
1 PT100 resistance thermometer
5.12 Oil-level monitoring system
Depending on the order specification, the gear unit may be fitted with an oil-level monitor in the form
of a level limit switch. This monitoring is designed as a standstill monitoring (gear unit stop) and checks
the level of the oil before the unit is started up. When the signal ”oil level too low” is given, it should be
wired in such a way that the drive motor cannot start and an alarm is given. During operation, any signal
should be bridged.
500005-10-25
H... / B... 12 H... / B... 13
If an oil-level monitoring device is in use, it is very important that the gear unit is in a horizontal position.
BA 5010 EN 06.03

5.13 Bearing monitoring system
Depending on the order, the gear unit may be prepared for bearing monitoring by fitting measuring
nipples. These nipples are intended for attachment of the shock-pulse sensors with rapid-action
coupling and are located in the vicinity of the bearings to be monitored.
500005-10-26
X X ”X”
SW17
H... Measuring nipple
X 500005-10-27
X X ”X”
SW17
B... Measuring nipple
5.14 Speed transmitter
Depending on order specification, an incremental speed transmitter may be mounted on the second
last shaft. Wiring and evaluation instrument should be provided by the customer.
500005-10-28
A 3
”A”
2 1 3
1 Incremental transmitter 2 12-pole brass plug 3 Output
BA 5010 EN 06.03

6. Assembly
6.1 General information on installation
Assembly and installation work must be done with great care by trained and qualified personnel. The
manufacturer cannot be held liable for damage caused by incorrect assembly and installation.
During the planning phase sufficient space must be allowed around the gear unit for later care and
maintenance work.
Adequate lifting equipment must be available before beginning the installation and assembly work.
If the gear unit is fitted with a fan, there should be sufficient space for air intake.
When installing outdoors, direct sunlight should be avoided.

Caution! Protective features such as covers, roofing, etc. must be provided as required.
Do avoid a heat concentration.
The operator should ensure that no foreign bodies affect the proper function
of the gear unit (e.g. falling objects or heaping over).
No welding work must be done at all on the drive.

Caution! The drives must not be used as an earthing point for welding operations.
Toothed parts and bearings may be irreparably damaged by welding.
All the fastening points provided by the design of the unit must be used.
Caution! Screws which have been damaged during assembly or disassembly work must
be replaced with new ones of the same strength class and type.
To ensure proper lubrication, the installation position specified in the order must always be observed.
6.2 Installation of gear unit on housing base
6.2.1 Foundation
The foundation must be horizontal and level; the gear unit must not be excessively stressed when
tightening the fastening screws.
It must be designed in such a way that no resonance vibrations are set up and that no vibrations are
transmitted from adjacent foundations. Steel structures on which the unit is to be mounted must be rigid.
It must be designed according to the mass and torque, taking into account the forces acting on the gear
unit.
When fastening the gear unit to concrete foundations by means of stone bolts and/or foundation blocks,
suitable recesses should be made in the foundation.
Fastening bolts or nuts must be tightened to the prescribed torque. For the correct torque, refer to item
10.2.10. Bolts of the minimum strength class 8.8 must be used.
Slide rails should be correctly aligned and embedded in the concrete foundation.
Note: For dimensions, space requirement, arrangement of supply connections (e.g. with
separate oil-cooling units), refer to the drawings in the gear-unit documentation.
BA 5010 EN 06.03

6.2.2 Description of installation work
S Remove the anti-corrosion paint on the shafts with suitable cleaning agent such as benzine.
Caution! Do not allow the cleaning agent (e.g. benzine) to contact the shaft sealing rings.
Ensure adequate ventilation. Do not smoke!

Danger of explosion!
S Mount and secure input and output drive elements (e.g. coupling components) on shafts.
If these are to be heated before mounting, refer to the dimensioned drawings in the coupling
documentation for the correct joining temperatures.
Unless otherwise specified, the components may be heated inductively, with a burner or in a furnace.
Take precautions to avoid burns from hot components!
Protect shaft sealing rings from damage and heating to over + 100 _C (use
Caution! heat-protective screens to protect against radiant heat.)
The components must be pushed smartly onto the shaft up to the position specified in the order-specific
dimensioned drawing.
Fit the coupling with the aid of suitable fitting equipment. Never use force or
Caution! knock the couplings into position, as this may damage the gearwheels, rolling
bearings, locking rings, etc.
When fitting the components, care must be taken that the shaft sealing rings
and shaft running surface are not damaged.
When installing the drives, make absolutely certain that the individual
components are accurately aligned in relation to each other. Inadmissibly large
errors in the alignment of the shaft ends to be connected due to angular and
axial misalignments result in premature wear and material damage.
Insufficiently rigid base frames or sub-structures can also during operation
cause a radial or axial misalignment, which cannnot be measured when the unit
is at a standstill.
Note: Gear units whose weight requires the use of lifting gear must be attached as shown
in section 4, ”Transport, handling and storage”. When add-on parts are mounted on
the gear unit, appropriate additional attachment points must be provided in
accordance with the order-specific dimensioned drawing.
BA 5010 EN 06.03

6.2.2.1 Aligning surfaces, aligning thread
Initial alignment of the gear units (sizes 3 to 12) in a horizontal direction is done by the surfaces of the
inspection or assembly cover.
500006-10-1
1 1
Gear units of sizes 13 to 26 have special alignment surfaces on the top of the housing. To facilitate
alignment of gear units of these sizes, alignment threads are provided on the housing base.
500006-10-2
1 1
1
2 2
1 Alignment surfaces 2 Alignment thread
6.2.2.2 Mounting on a foundation frame
S Clean the undersurface of the gear-unit base.
S Using suitable lifting gear, place the gear unit on the foundation frame.
S Tighten the foundation bolts to the specified torque (see item 10.2.10). If necessary, use stops to
prevent displacement.
The gear unit must not be excessively stressed when tensioning the fastening
Caution! bolts.
The final fine alignment with the assemblies on the in- and output side must be carried out accurately
by the shaft axes, using:
S rulers
S spirit level
S dial gauge
S feeler gauge, etc.
Only then should the gear unit be fastened and the alignment checked once again.
Note: The accuracy of shaft axis alignment is an important factor in determining the life span
of shafts, bearings and couplings. If possible, the deviation should be zero. For
amongst others the special requirements for the couplings, refer to the specific
operating instructions.
Non-observance can cause shaft rupture, resulting in serious injury or danger

of live.
BA 5010 EN 06.03

6.2.2.3 Mounting on a concrete foundation by means of stone bolts or foundation blocks
S Hook the stone bolts with washers and hexagon nuts and/or foundation blocks with washers and
fastening bolts into the foundation fastening points on the housing and tighten the hexagon nuts
and/or fastening bolts to the specified torque (see item 10.2.10) (see figure below).
bild-stein
1
2
3
4
1 Hexagon nut 4 Stone bolt

2 Washer 5 Foundation
3 Gear-unit base
bild-fundament
1
2
3
4 7
5 8
1 Fastening bolt 6 Foundation

2 Washer 7 Final foundation height
3 Gear-unit base 8 Prepared foundation height
4 Set screw 9 Foundation block
5 Flat steel plate
S Using suitable lifting gear, place the gear unit on the concrete foundation.
S Align gear unit horizontally by in- and output shafts:
– if using stone bolts, with shims

– if using foundation blocks, with the aid of the set screws
S If applying considerable force, use stops to prevent the unit from displacement.
S Pour concrete into the recesses of the stone bolts or foundation blocks.
Note: Before pouring the concrete foundation, fill up the openings in the foundation blocks
with polystyrene.
When the concrete has set, tighten the hexagon nuts of the stone bolts or fastening
bolts to the specified torque (see Item 10.2.10).
With types H1 and H2, remove the air-conducting cowls before tightening the
foundation bolts and then bolt them back into position.
The gear unit must not be excessively stressed when tensioning the hexagon
Caution! nuts or fastening bolts.
BA 5010 EN 06.03

The final fine alignment with the assemblies on the in- and output side must be carried out accurately
by the shaft axes, using:
S rulers
S spirit level
S dial gauge
S feeler gauge, etc.
Only then should the gear unit be fastened and the alignment checked once again.
Note: The accuracy of shaft axis alignment is an important factor in determining the life span
of shafts, bearings and couplings. If possible, the deviation should be zero. For
amongst others the special requirements for the couplings, refer to the specific
operating instructions.
Non-observance can cause shaft rupture, resulting in serious injury.
6.2.2.4 Mounting on a concrete foundation by means of anchor bolts
S Place support on base plate.
S Insert anchor bolts.
S Place pressure plates in position and open hexagon nuts.
S Place wood under anchor bolts in such a way that the top edge is set back about 10 mm.
bild-anker-1
2
7
3
8
1
4
5
6
1 Anchor bolt 5 Hexagon nut

2 Support 6 Wood
3 Base plate 7 Fine-grained concrete
4 Pressure plate 8 Raw foundation
S Place gear unit on foundation
The carrying ropes must be attached only by the specified lifting eyes (see
Caution! Section 4, ”Handling and Storage”).
BA 5010 EN 06.03

S Pull anchor bolts up, fit washer and hexagon nut in place by giving it a few turns
A front-side thread is provided in the anchor bolts for this purpose.
S Align gear unit with supports
The values punched into the screeds must always be observed. Alignment tolerances in relation to the
units on the input and output sides are to be in accordance with the permissible angular and longitudinal
displacements of the couplings (see Coupling Drawings).
Record alignment dimensions.
Prior to tensioning the anchor bolts, the fine-grained concrete filling must have set for at least 28 days.
S Put anchor bolts under tension by tightening the hexagon nut with your fingers. Place hydraulic
tensioning device in position.
Tension bolts alternately to a tensioning force in accordance with Table 10.2.
The tensioning pressures and the initial tensioning forces should be recorded (see also item 7.2.4).
bild-anker-2
5
4 6
2
7
3
8
1
1 Anchor bolt 5 Hexagon nut

2 Support 6 Housing base
3 Base plate 7 Fine-grained concrete
4 Washer 8 Raw foundation
BA 5010 EN 06.03

6.3 Couplings
Generally speaking, flexible couplings or hydraulic couplings combined with flexible couplings should
be provided for the input drive.
Note: In the case of gear units with fan, the hydraulic unit of the hydraulic coupling should
be located on the motor shaft to ensure that sufficient space is available for intake of
cooling air (see item 5.9.1).
In the case of gear unit types with solid output shaft, flexible couplings are, likewise, ordinarily used for
the output shaft.
If rigid couplings or other input or output elements which generate additional radial and/or axial forces
(e.g. gear wheels, belt pulleys, disk flywheels, hydraulic couplings) are to be used, these must be
agreed by contract.
Couplings with peripheral velocities on the outer diameter of up to 30 m/s must

be statically balanced. Couplings with peripheral velocities over 30 m/s must
be dynamically balanced.
For maintenance and operation of the couplings, refer to the specific operating instructions for the
coupling.
When installing the drives, make absolutely certain that the individual
components are accurately aligned in relation to each other. Inadmissibly large
errors in the alignment of the shaft ends to be connected due to angular and
axial misalignments result in premature wear and material damage.
Insufficiently rigid base frames or sub-structures can also during operation
cause a radial or axial misalignment, which cannnot be measured when the unit
is at a standstill.
Note: For permissible alignment errors in the case of couplings supplied by FLENDER,
please refer to the operating manuals for the couplings.
If you use couplings by other manufacturers, ask which alignment errors are
permissible, stating the radial loads occurring.
Note: The smaller the radial and angular misalignment between coupling parts on the shaft
ends to be connected, the longer the service life and the higher the reliability of the
equipment and the quieter the operation.
Misalignments of the coupling parts in relation to each other can be caused by inaccurate alignment
during assembly, but also by actual operation of the equipment (expansion due to heat, shaft deflection,
insufficiently rigid machine frames, etc.).
Possible misalignments
500005-10-29
D Ka
D Kw
D Kr
Axial misalignment Angular misalignment Radial misalignment

(DKa) (DKw) (DKr)
BA 5010 EN 06.03

Alignment has to be done in two axial planes arranged perpendicular to each other. This can be done
by means of a ruler (radial misalignment) and feeler gauge (angular misalignment), as shown in the
illustration. The aligning accuracy can be increased by using a dial gauge or a laser alignment system.
500005-10-30
1 3
2 3
Example of alignment on a flexible coupling
1 Ruler 2 Feeler gauge 3 Measuring points
The maximum permissible misalignments must under no circumstances be

Caution! exceeded during operation.
For the exact values, please see operating instructions for the coupling.
Angular and radial misalignments may occur at the same time. The sum of both
misalignments must not exceed the maximum permissible value of the angular
or radial misalignment.
If using couplings by other manufacturers, always consult FLENDER.
Note: For alignment of the drive components (vertical direction), it is recommended to use
packing or foil plates underneath the mounting feet. The use of claws with set screws
on the foundation for lateral adjustment of the drive components is also
advantageous.
In the case of gear units with hollow output shafts or flange output shafts, the coupling on the output
side is not required. Gear units with hollow output shafts must be mounted on the shafts of the
customer’s machinery. Gear units with flanged output shafts must be mounted on the customer’s shaft
via a counterflange.
BA 5010 EN 06.03

6.4 Assembly of a shaft-mounting gear unit with hollow shaft and parallel keyway
The shaft end of the driven machine must be provided with a parallel key to DIN 6885 Part 1 Form A
(material C60+N or higher strength) and should have a centring means to DIN 332 Form DS (with
thread) in its end face (for connecting dimensions of the driven machine shaft, see dimensioned drawing
in the gear unit documentation).
6.4.1 Preparatory work
To assist demounting (see also item 6.4.3), we recommend providing a connection for pressure oil on
the end of the driven machine shaft. For this a hole must be drilled through to the hollow shaft bore (refer
to fig. 1).
500006-10-14
3
4
1
5
2
Fig. 1
1 Machine shaft 4 Bore for rust-releasing agent feed

2 Hollow shaft 5 Pressure oil connection
3 Parallel key
6.4.2 Assembly
S Remove the preservative agent from the hollow shaft and the machine shaft with a suitable cleaning
agent (such as benzine).

Danger of explosion.
S Check the hollow and machine shafts to ensure that seats and edges are not damaged. If necessary,
rework the parts with a suitable tool and clean them again.
Note: Coat with a suitable lubricant (e.g. Calypsol grease type H 443 HD88) to prevent
frictional corrosion of the contact surfaces.
BA 5010 EN 06.03

6.4.2.1 Fitting
S Fit the gear unit by means of nut and threaded spindle. The counterforce is provided by the hollow
shaft.
The hollow shaft must be exactly aligned with the machine shaft to avoid
Caution! canting.
500006-10-3
3
7
Fig. 2
1 Machine shaft 4 Nut 7 End plate

2 Hollow shaft 5 Threaded spindle
3 Parallel key 6 Nut
Instead of the nut and threaded spindle shown in the diagram, other types of equipment such as a
hydraulic lifting equipment (type Lucas) may be used.
The hollow shaft may be pulled against a machine shaft collar only on gear
Caution! arrangements with a torque arm or if supported with gear unit swing bases,
because with a different arrangement the bearings would be excessively
stressed.
6.4.2.2 Axial fastening
Depending on type, secure the hollow shaft axially on the machine shaft (e.g. with locking ring, end
plate, set screw etc.).
BA 5010 EN 06.03

6.4.3 Dismantling
S Remove the axial securing device from the hollow shaft.
S If frictional corrosion has occurred on the seating surfaces, inject rust-releasing or other agent (e.g.
with a pump) into the bore cavity to reach the seats in order to facilitate forcing off. The rust releaser
can be injected through a bore in the machine shaft (see fig. 1).
S Depending on the facilities available on site, the gear unit can be forced off the machine shaft using
forcing screws in an end plate (see fig. 4), a central threaded spindle or preferably a Lucas hydraulic
lifting unit.
S When the rust-releasing agent has taken effect, pull the gear unit off with the device as shown in
figs. 3 or 4.
Note: The end plate and the auxiliary plate for forcing off the gear unit are not included in
our delivery.
Each of the two end faces of the hollow shaft is provided with 2 tapped holes (for
dimensions, see fig. 5) to receive bolts for fastening the end plate to the hollow shaft.
500006-10-4
6
3
5 1
4
2
7
Fig. 3
1 Machine shaft 5 Threaded spindle

2 Hollow shaft 6 Bore for rust-releasing agent feed
3 Parallel key 7 Plate for forcing out
4 Hydraulic lifting unit
500006-10-5
5 1
4 2
Fig. 4
1 Machine shaft 4 End plate for forcing out

2 Hollow shaft 5 Screws
3 Parallel key 6 Forcing screws
Caution! Avoid canting when pulling the unit off.
Note: The plate for forcing out is not included in our delivery.
BA 5010 EN 06.03

500006-10-15
*) *)
m
s
s
t t
Fig. 5 *) 2 threads offset 180_
Gear-unit m s t Gear-unit m s t
size mm mm size mm mm
4 95 M8 14.5 12 215 M 12 19.5
5 115 M8 14.5 13 230 M 12 19.5
6 125 M8 14.5 14 250 M 12 19.5
7 140 M 10 17 15 270 M 16 24
8 150 M 10 17 16 280 M 16 24
9 160 M 10 17 17 300 M 16 24
10 180 M 12 19.5 18 320 M 16 24
11 195 M 12 19.5 19 ... 26 on request
Table 6.1: Threaded holes on the end faces of the gear unit hollow shafts
If the counterforce is provided not only by the hollow shaft, but also by the
Caution! housing, as shown in fig. 3, the forces used must not exceed the values given
in the following table.
Max. forcing Max. forcing

Gear-unit Gear-unit
pressure pressure
size size
N N
4 22600 12 113600
5 33000 13 140000
6 37500 14 160000
7 50000 15 193000
8 56000 16 215000
9 65000 17 240000
10 82000 18 266000
11 97200 19 ... 26 on request
Table 6.2: Maximum forcing pressures
If the above values are exceeded, the housing, the hollow-shaft bearings or
Caution! other gear components may be irreparably damaged. Before replacing the gear
unit on the machine shaft, always check the bearings for any signs of damage.
Note: When using forcing screws or threaded spindles, the head of the thread pressing
against the driven machine should be rounded and well greased to reduce the risk of
seizing at this point.
BA 5010 EN 06.03

6.5 Shaft-mounting gear unit with hollow shaft and internal spline to DIN 5480
The shaft end of the driven machine must be designed with involute splines to DIN 5480 and should
have a centring means to DIN 332 Form DS (with thread) in its end face (for connecting dimensions of
the driven machine shaft, see dimensioned drawing in the gear unit documentation).
6.5.1 Preparatory work
To facilitate demounting (see also item 6.4.3.), we recommend providing a connection for pressure oil
on the end of the driven machine shaft. Doing this a hole must be drilled through to the hollow shaft bore
(refer to fig. 6).
500006-10-16
3
4
1
5
2
Fig. 6
1 Machine shaft 4 Bore for rust-releasing agent feed

2 Hollow shaft 5 Pressure oil connection
3 DU bush
6.5.2 Assembly

S Check the hollow and machine shafts to ensure that seats, teeth or edges are not damaged. If
necessary, rework the parts with a suitable tool and clean them again.
Note: Coat with a suitable lubricant (e.g. Calypsol grease type H 443 HD88) to prevent
frictional corrosion of the contact surfaces.
BA 5010 EN 06.03

6.5.2.1 Fitting
S Fitting with integrated DU bush
shaft.
Caution! canting. When fitting, ensure that the position of the teeth between the machine
shaft and hollow shaft is correct. The correct position can be determined by
turning the input shaft or by swivelling the gear unit lightly around the hollow
shaft.
500006-10-6
3
7
1
Fig. 7

3 DU bush 6 Nut
S Fitting with loose DU bush
The loose DU bush is pushed onto the machine shaft, fixed rigidly in position with a locating tie and then
pulled into the hollow shaft along with the machine shaft (see fig. 7).
Caution! canting. When fitting, ensure that the position of the teeth between the machine
shaft and hollow shaft is correct. The correct position can be determined by
turning the input shaft or by swivelling the gear unit lightly around the hollow
shaft.
because with a different arrangement the bearings may be excessively
stressed.
Depending on type, secure the hollow shaft axially on the machine shaft (e.g. with locking ring, end
plate, set screw etc.).
BA 5010 EN 06.03

6.5.3 Dismantling
S Remove the axial securing device from the hollow shaft.
with a pump) into the bore cavity to reach the seats in order to facilitate forcing off. The rust releaser
can be injected through a bore in the machine shaft (see fig. 6).
S The end plate and the locking ring must first be removed.
S Depending on the facilities available on site, the gear unit can be forced off the machine shaft using
lifting unit.
figs. 8 or 9.
500006-10-7
6 3
1
5
4
2
7
Fig. 8

3 DU bush 7 Plate for forcing out
500006-10-8
5 1
4
2
Fig. 9
1 Machine shaft 4 End plate

3 DU bush 6 Forcing screws
Note: The plate for forcing out is not included in our delivery.
BA 5010 EN 06.03


Gear-unit Gear-unit
pressure pressure
size size
N N
4 22600 12 113600
5 33000 13 140000
6 37500 14 160000
7 50000 15 193000
8 56000 16 215000
9 65000 17 240000
10 82000 18 266000
11 97200 19 ... 26 on request
BA 5010 EN 06.03

6.6 Shaft-mounting gear unit with hollow shaft and shrink disk
The end of the driven machine shaft (material C60+N or higher strength) should have a centring means
to DIN 332 Form DS (with thread) in its end face (for connecting dimensions of the driven machine shaft,
see dimensioned drawing in the gear unit documentation).
6.6.1 Assembly

S Check the hollow and machine shafts to ensure that seats and edges are not damaged. If necessary,
rework the parts with a suitable tool and clean them again.
The bore of the hollow shaft and the machine shaft must be absolutely free of
Caution! grease in the area of the shrink disk seat.
This is essential for safe and reliable torque transmission.
Do not use contaminated solvents or dirty cloths for removing grease.
6.6.1.1 Fitting
S Fitting with integrated DU bush
shaft.
Caution! canting.
500006-10-9
3
7
1
Fig. 10

3 DU bush 6 Nut
S Fitting with loose DU bush
The loose DU bush is pushed onto the machine shaft, fixed rigidly in position with a locating tie and then
pulled into the hollow shaft along with the machine shaft (see fig. 10).
Caution! canting.
because with a different arrangement the bearings may be excessively
stressed.
BA 5010 EN 06.03

If the shrink disk is fitted according to instructions (see item 6.6.2.1), the gear unit is fixed securely in
the axial direction. Additional fastening is not required.
6.6.2 Shrink disk, type HSD
6.6.2.1 Assembly of shrink disk
The shrink disk is delivered ready for installation.
Caution! It must not be dismantled before tensioning for the first time.
The bore of the hollow shaft and the machine shaft must be absolutely free of
Caution! grease in the area of the shrink disk seat.
This is essential for safe and reliable torque transmission.
Do not use contaminated solvents or dirty cloths for removing grease.
bild-schrumpf-1
W
1 B
2
3
5
4
A Greased B Absolutely grease-free W Installation height
1 Machine shaft 3 Inner ring 5 Tensioning bolt

2 Hollow shaft 4 Outer ring
S Mounting the shaft or fitting the hub onto the shaft
For the exact installation height (W) of the shrink disk, refer to the dimensioned drawing (see section 1,
”Technical data”)
Note: The outer surface of the hollow shaft may be greased in the area of the shrink disk
seat.
Caution! Do not tighten the tensioning bolts until the machine shaft is installed.
The tensioning bolts must be tightened one after the other, in rotation and in several passes to the
tightening torque shown on the shrink disk.
Tighten all the tensioning bolts until the lateral surfaces of the inner and outer rings are aligned.
Note: This allows the tension condition to be checked visually. For safety the tensioning
bolts must then be tightened in 2 further passes.
BA 5010 EN 06.03

To avoid overloading the individual bolts, the maximum tensioning torque (see
Caution! table 6.4) must never be exceeded. The alignment of the front surfaces has
priority. If alignment cannot be achieved by tightening, consult FLENDER.
Max. tensioning torque

per bolt (with µ = 0.1)
Tensioning-bolt
Strength class Strength class
thread
10.9 12.9
Nm Nm
M 6 12 14.5
M 8 29 35
M 10 58 70
M 12 100 121
M 14 160 193
M 16 240 295
M 20 470 570
M 24 820 980
M 27 1210 1450
M 30 1640 1970
M 33 2210 2650
M 36 2850 3420
Table 6.4: Maximum torques for tensioning bolts
For safety reasons, a protective cover should be mounted above the shrink
disk.
6.6.2.2 Demounting and remounting the shrink disk
Disassemble the protective cover.
The loosening process is similar to that of tightening.
To enable the stored energy of the outer ring during disassembly to be lowered slowly via the bolts to
be loosened, the bolts must be loosened evenly and in sequence. Initially only by a quarter turn.
Caution! Under no circumstances must the bolts be unscrewed one after the other.
If after loosening all the bolts approx. one turn the outer ring does not come free of the inner ring of its
own accord, the outer ring can be detensioned with the forcing threads by screwing some of the adjacent
fastening bolts into the them. The now loosening outer ring is braced against the remaining bolts. This
operation must be carried out until the outer ring releases of its own accord.
Remove shaft or slip hub off the shaft. Rust deposits which may have formed on the shaft must be
removed from the hub before performing this operation.
Pull the shrink disk off the hollow shaft.
BA 5010 EN 06.03

6.6.2.3 Cleaning and greasing the shrink disk
Dismantled shrink disks do not have to be dismantled and re-greased before being re-installed.
The shrink disk should only be dismantled and cleaned if it is dirty.
Following cleaning, only the inner sliding surfaces of the shrink disk should be
Caution! re-greased.
Use a solid lubricant with a high MoS2-based molybdenum disulphide content and with a coefficient of
friction of m = 0.04 according to the following table.
Lubricant Form Manufacturer

Molykote 321 R (lubricating paint) Spray DOW Corning
Molykote Spray (powder spray) Spray DOW Corning
Molykote G Rapid Spray or Paste DOW Corning
Aemasol MO 19 P Spray or Paste A. C. Matthes
Unimoly P 5 Powder Klüber Lubrication
Table 6.5: Lubricants for shrink disk after cleaning
6.6.3 Dismantling
with a pump) into the bore cavity to reach the seats. The rust releaser can be injected through a bore
in the machine shaft (see fig. 11).
S Depending on the facilities availableon site, the gear unit can be forced off the machine shaft using
lifting unit.
figs. 11 or 12.
500006-10-10
6
3
1
5
4
2
7
Fig. 11

3 DU bush 7 Plate for forcing out
BA 5010 EN 06.03

500006-10-11
5 1
4
2
Fig. 12
1 Machine shaft 4 End plate

3 DU bush 6 Forcing screws
Note: The forcing-out plate is not included in our delivery.

Gear-unit Gear-unit
pressure pressure
size size
N N
4 22600 12 113600
5 33000 13 140000
6 37500 14 160000
7 50000 15 193000
8 56000 16 215000
9 65000 17 240000
10 82000 18 266000
11 97200 19 ... 26 on request
BA 5010 EN 06.03

6.7 Shaft-mounting gear unit with flanged shaft
The front area of the flanged shaft must be absolutely free of grease.
Caution! This is essential for safe and reliable torque transmission. Do not use
contaminated solvents or dirty cloths for removing grease.
Before tightening the tensioning bolts it must be ensured that the flange
Caution! centring means are inserted one inside the other.
Then tighten diametrically opposed tensioning bolts to full torque.
S Tightening torques of flange bolts for gear units:
Strength class
Gear-unit size Tightening
Bolt Nut torque
DIN 931 DIN 934
5 ... 6 10.9 10 610 Nm

7 ... 10 10.9 10 1050 Nm
11 ... 16 10.9 10 2100 Nm
17 ... 20 10.9 10 3560 Nm
21 ... 26 10.9 10 5720 Nm
Table 6.7: Tightening torques for flange connections
BA 5010 EN 06.03

6.8 Shaft mounting gear unit with block flange
The front area of the block flange must be absolutely free of grease.
Caution! This is essential for safe and reliable torque transmission. Do not use
contaminated solvents or dirty cloths for removing grease.
Tighten diametrically opposed tensioning bolts to full torque.

Caution!
The joint bolts must be tightened to the prescribed torque. For the correct
torque, refer to item 10.2.10. Bolts of the minimum strength class 8.8 must be
used. The transmittable tensioning torque is limited by the bolted joint on bolt
circle K1.
500006-11-11
ØK1
Configuration 1)
Type
B C
H2..
H3..
H4..
B2..
B3..
B4..
1) Configuration with hollow output shaft on request
BA 5010 EN 06.03

6.9 Mounting the torque arm for gear housing
6.9.1 Attaching the torque arm
Caution! The torque arm must be mounted stress-free on the machine side
On helical gear units with a motor bell housing the torque arm is located opposite the motor bell housing.
500006-10-12
1
1 Machine side 2 flexible support block
Max. standard-motor size

Gear-unit size Gear type Gear type
H2 H3 H4 B2 B3 B4
4 200 – – 200 200 –
5 ... 6 225 225 – 225 225 160
7 ... 8 280 280 180 280 280 200
9 ... 10 280 280 225 280 280 225
11 ... 12 315M 315M 250 315M 315M 280
13 ... 14 – 355 315M 355 355 315M
15 ... 16 – 355 315 – 355 355M
17 ... 18 – 355 355M – 355 355
19 ... 26 on request
Table 6.8: Motor types and torque arms
Note: Larger motors should be used only with FLENDER’s approval.
S Foundation type for fastening torque arm, see item 6.2.1 ”Foundation”.
S If the customer fits a torque arm, connection to the foundation must be by means of a flexible element.
BA 5010 EN 06.03

6.10 Mounting supports for gear-unit swing bases
6.10.1 Attaching the support
Caution! The support for the swing base must be mounted free of stress.
500006-10-13
2 1 2 1
4 3 5 3
1 Gear unit 4 Torque arm

2 Motor 5 flexible support block
3 Gear-unit swing base
Max. standard-motor size

Gear-unit size Gear type
B2 B3 B4
4 200 –
5 ... 6 225M 160
7 ... 8 280M 200
9 ... 10 315 225M
on
11 ... 12 request 355 280S
13 ... 14 400M 315M
15 ... 16 400M 315
17 ... 18 400M 355L
19 ... 26 on request
Table 6.9: Motor and gear-unit swing base
Note: Larger motors should be used only with FLENDER’s approval.
S Foundation type for fastening torque arm, see item 6.2.1 ”Foundation”.
S If the customer fits a torque arm, connection to the foundation must be by means of a flexible element.
BA 5010 EN 06.03

6.11 Gear unit with cooling coil
S Before connecting the cooling coil remove the plugs from the connection bush of the cooling coil and
flush the coil well to remove any dirt.
S Install the cooling-water in- and outflow pipes (for exact position of connections, see dimensionedl
drawing).
Note: Observe also item 5.9.2.
6.12 Gear unit with add-on components
S For the technical data to the add-on components, as stated in item 6.13 to 6.18, refer to the
order-specific equipment list.
S The electrical equipment for regulation and control must be wired in accordance with the equipment
suppliers’ instructions.
S For operation and maintenance the operating instructions provided specifically for the order and the
specifications in item 5.9.2 to 5.14 must be observed.
6.13 Gear unit with air oil-cooler
S Connect the indicator for double change-over filter (for gear sizes 13 only) and pressure monitor
electrically
S Connect the fan motor electrically
6.14 Gear unit with water oil-cooler
S Before connecting the water oil-cooler remove the plugs from the water connection and flush the
water oil-cooler well to remove any dirt.
S Install the cooling-water in- and outflow pipes. For the flow direction of the cooling water and the
location of the connections please refer to the dimensioned drawing.
S Connect pressure monitor electrically
6.15 Gear units with heating element
S Connect temperature monitor electrically
S Connect heating elements electrically
6.16 Gear units with oil-temperature measurement
S Connect resistance thermometer with evaluating instrument (to be provided by customer) electrically
6.17 Gear units with oil-level monitoring
S Connect oil-level monitor electrically
6.18 Gear units with speed transmitter
S Connect speed transmitter electrically
6.19 Final work
S After installation of the gear unit check all screw connections for tight fit.
S In addition, after tightening the fixings a check must be made to see that the alignment has not
changed.
S Check by means of the order specific equipment list as well as the associated drawings whether all
units which may have been removed for transport have been refitted.
S Rotating parts must be checked for correct seating. Contact with rotating parts is not permitted.
BA 5010 EN 06.03

7. Start-up
7.1 Procedure before start-up
7.1.1 Removal of preservative agent
S Unscrew the oil drain plug or open the draining valve, allow the preservative agent or run-in oil to drain
into a suitable container and dispose of it in accordance with regulations. Any residual-oil drain plugs
should also be opened (e.g. in the case of gear units with add-on backstop). The location of the oil
draining point is marked by an appropriate symbol in the dimensioned drawing in the unit
documentation.
Remove any oil spillage immediately with an oil-binding agent.
S Replace the oil drain plug.

500007-10-1
1 3
2
8
7
5
9
6
4
B... 12
500007-10-2
1
3
5
8
7
2
9
6
B... 13
1 Inspection or assembly cover 6 Backstop

2 Oil dipstick 7 Cover for backstop
3 Oil inlet 8 Screw plug for oil inlet backstop
4 Oil drain plug 9 Screw plug for residual-oil drainage backstop
5 Venting or screw plug
Before start-up, replace the yellow plastic plug with a breather screw with cap
Caution! (see also notice on gear unit).
BA 5010 EN 06.03

7.1.2 Charging with lubricant
S Release the fastening bolts on the inspection or assembly cover and remove the cover (including
seal) from the housing or use the marked oil filler plug. Do not discard the seal.
S In the case of gear units with add-on backstop, release the screw plug on the backstop cover and pour
in approx. 0.5 l fresh oil of the total oil quantity via a filter (max. filter mesh 25 mm)
S Replace the screw plug
Using a filter (max. mesh 25 mm), fill the gear unit with fresh oil up to the MAX
Caution! mark on the oil dipstick or oil sight glass.
Remember to fill the oil pockets above the bearings and (with bevel-gear units)
at the input shaft on the inside.
Caution! The sealing surfaces must not be contaminated nor damaged.
Note: For the correct type of oil (of various brands) to be used, refer to the BA 7300 EN
operating instructions supplied separately.
Information on the type, quantity and viscosity of the oil is given on the rating plate on
the gear unit.
The quantity of oil indicated on the rating plate is an approximation only. The marks
on the dipstick or oil sight glass are decisive for the amount of oil to be filled in.
Note: In the case of gear units fitted with forced lubrication or an oil-cooling system, the oil
circuit must also be charged with oil. To do this, briefly start up the gear unit with
add-on pump as described in section 8.
S Check the oil level in the gear unit housing with the oil dipstick or by means of the oil sight glass.
Note: The oil level must be at the upper mark on the oil dipstick or oil sight glass.
S Place the inspection or assembly cover (including seal) on the housing and replace and tighten the
fastening bolts (see item 10.2.10).
BA 5010 EN 06.03

7.1.2.1 Oil quantities
Oil quantity (approx.) in litres for size

Type
3 4 5 6 7 8 9 10 11 12 13 14
H1SH 7 – 22 – 42 – 68 – 120 – 175 –
H2.H – 10 15 16 27 30 42 45 71 76 135 140
H2.M – – – – – – – – – – 110 115
H3.H – – 15 17 28 30 45 46 85 90 160 165
H3.M – – – – – – – – – – 125 130
H4.H – – – – 25 27 48 50 80 87 130 140
H4.M – – – – – – – – – – 120 125
B2.H – 10 16 19 31 34 48 50 80 95 140 155
B2.M – – – – – – – – – – 120 130
B3.H – 9 14 15 25 28 40 42 66 72 130 140
B3.M – – – – – – – – – – 110 115
B4.H – – 16 18 30 33 48 50 80 90 145 150
B4.M – – – – – – – – – – 120 125

Type
15 16 17 18 19 20 21 22 23 24 25 26
H1SH 190 – 270 – 390 – – – – – – –
H2.H 210 215 290 300 320 340 320 340 430 450 600 640
H2.M 160 165 230 240 300 320 350 370 470 500 660 700
H3.H 235 245 305 315 420 450 470 490 620 650 880 935
H3.M 190 195 240 250 390 415 515 540 690 725 970 1030
H4.H 230 235 290 305 360 380 395 420 520 550 735 780
H4.M 170 175 225 230 310 330 430 450 500 600 800 850
B2.H 220 230 320 335 – – – – – – – –
B2.M 180 190 260 275 – – – – – – – –
B3.H 210 220 290 300 380 440 370 430 520 600 720 840
B3.M 160 165 230 235 360 420 420 490 560 650 790 920
B4.H 230 235 295 305 480 550 540 620 710 810 1000 1100
B4.M 170 175 230 235 440 510 590 680 790 910 1110 1200
Table 7.1: Approximate figures for required oil quantities in horizontal gear units
with radial shaft seals and Taconite seals

Type
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
H1SH 5.5 – 19 – 36 – 60 – 106 – 155 – 156 – 225 – 230
Table 7.2: Approximate figures for required oil quantities in horizontal gear units
with labyrinth seals
BA 5010 EN 06.03

7.2 Start-up
7.2.1 Oil level
The oil level must be monitored by means of the oil level monitoring equipment provided. The gear unit
must be shut down or FLENDER consulted.
When the oil is cool, the level should be at the upper mark on the oil dipstick or oil sight glass. When
the oil is warm it may slightly exceed this mark. It must in no case be allowed to fall below the mark. If
necessary, top up to the correct level.
7.2.2 Gear unit with cooling coil or external oil cooling or oil supply system
After starting up the external oil cooling or oil supply system for the first time the oil level must be once
more checked in accordance with item 7.2.1.
Fully open the stop valves in the coolant in- and outflow pipes.
7.2.3 Gear units with backstop
Before start-up, check whether the backstop can be turned manually in the free-wheeling direction
without exerting undue force. Observe the direction-of-rotation arrows on the housing.
To avoid damaging the backstop or the gear unit, the motor should not be run
Caution! in the stop direction of the gear unit.
Observe the notice fixed to the gear unit.
The minimum lifting speeds must not be exceeded during operation.
Before connecting the motor, determine the direction of rotation of the three-phase current supply using
a phase-sequence indicator, and connect the motor in accordance with the pre-determined direction
of rotation.
Note: The unit can be started up once the amount of oil indicated on the notice has been
poured in through the oil filler plug screw of the backstop. Always use oil of the same
type and viscosity as for the gear unit.
7.2.4 Checking procedure
The following visual checks must be conducted and recorded when starting up:
S Oil level
S Oiltightness of the oil cooling or oil supply lines
S Opening condition of the shut-off valves
S Effectiveness of the shaft seals
S Freedom of the rotating parts from contact
The tension pressures and pretensioning forces in accordance with item 6.2.2.4 must also be recorded
in this document.
Note: The document must be kept with the operating instructions.
7.3 Removal from service
S To take the gear unit out of service, first switch off the drive unit.
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch!
S In the case of gear units fitted with cooling coil or water oil-coolers, close the stop valve on the water
inflow and outflow pipes. To prevent freezing, drain the water from the cooling coil or the water
oil-cooler.
S During longer periods of disuse, start the unit up briefly at intervals of approx. 3 weeks. If the gear unit
is to remain out of service for longer than six months, it must be treated with preservative agent
(see item 7.3.1).
BA 5010 EN 06.03

7.3.1 Interior preservation during longer disuse
Depending on the type of lubrication or shaft sealing, the following types of internal preservative agent
can be used.
7.3.1.1 Interior preservation with gear oil
Gear units with dip lubrication systems and contacting shaft seals can be filled with the correct type of
oil up to a point just below the breather screw.
7.3.1.2 Interior preservation with preservative agent
Before longer periods of storage gear units with forced lubrication systems, oil circulation cooling or
non-contacting shaft seals should be filled with preservative agent and run without load.
Duration of protection Preservative agent Special measures
up to 6 months none
Castrol Alpha SP 220 S Close gear unit, replace breather screw or

up to 24 months air filter with a yellow plug screw
(replace the original parts before start-up)
For storage periods longer than 24 months, renew the preservative agent.
For storage periods over 36 months, FLENDER should be consulted before.
Table 7.3: Preservation procedure when using mineral oil or PAO-based synthetic oil
Duration of protection Preservative agent Special measures
up to 6 months none
Special anti-corrosion oil
Close gear unit, replace breather screw or
TRIBOL 1390 1)
up to 36 months air filter with a yellow plug screw
(replace the original parts before start-up)
For storage periods over 36 months, FLENDER should be consulted before.

Table 7.4: Preservation procedure when using PG-based synthetic oil
1) resistant to tropical conditions and sea water. Max. ambient temperature 50 _C
7.3.1.3 Interior preservation procedure
S Switch the gear unit off and drain the oil as described in section 10, ”Maintenance and repair”.
S Pour in the preservative agent specified in Table 7.3 or 7.4 through the venting hole or the opening
in the inspection or assembly cover until it reaches the top mark on the oil dipstick or oil sight glass.
S Close the venting hole or the opening in the inspection or assembly cover.
S Start the gear unit and allow it to idle for a short time.
S Unscrew the oil drain plug and allow the preservative agent to drain into a suitable container and
dispose of it according to regulations.
There is a risk of scalding from the hot preservative agent draining from the
gear unit. Wear protective gloves to avoid scalding.
S Replace the oil drain plug.
Before re-starting the gear unit replace the screw plug with the breather screw
Caution! or air filter.
See also item 7.1.1.
BA 5010 EN 06.03

7.3.2 Exterior preservation
Duration of Preservative
protection agent Layer thickness Remarks
Long-term wax-based preservative

up to 24 months Tectyl 846 K19 approx. 50 mm agent, resistant to sea water and
tropical conditions
(soluble with CH compounds)
Table 7.5: External preservation of shaft ends and other bright machined surfaces
7.3.2.1 Exterior preservation procedure
S Clean the surfaces
S For separation between the sealing lip of the shaft sealing ring and the preservative agent, the shaft
should be brushed with grease in way of the sealing lip
S Apply preservative agent
8. Operation
Observe the ”Safety instructions” in section 3, the instructions in section 9, ”Faults, causes and remedy”,
and in section 10, ”Maintenance and repair”!
S During operation the unit must be monitored for:
– Oil temperature (The gear unit is designed for a temperature of 90 °C

with mineral oil in continuous operation. For higher
temperatures, synthetic oils must be used. The
maximum short-term operating temperature is 100 °C;
see also section 10.)
– Changes in gear noise
– Possible oil leakage on the housing and shaft seals
– Bearing vibrations with present measuring sequence
– Correct oil level (see section 7, ”Start-up”)
If any irregularities are noticed during operation or if the pressure monitor in

Caution! the oil-cooling system (if installed) triggers the alarm, switch the drive unit off
at once. Determine the cause of the fault, using the table in section 9.
This table contains a list of possible faults, their causes and suggested
remedies.
If the cause cannot be found, a fitter from one of our customer service centres
should be called in (see section 11).
9. Faults, causes and remedy
Observe the ”Safety instructions” in section 3 and the instructions in section 10, ”Maintenance and
repair”!
9.1 General information on faults and malfunctions
Note: Faults and malfunctions occurring during the guarantee period and requiring repair
work on the gear unit must be carried out only by FLENDER Customer Service.
In the case of faults and malfunctions occurring after the guarantee period and whose
cause cannot be precisely identified, we advise our customers to contact our
customer service.
BA 5010 EN 06.03

FLENDER will not be bound by the terms of the guarantee or otherwise be
Caution! responsible in cases of improper use of the gear unit, modifications carried out
without FLENDER’s agreement or use of spare parts not supplied by FLENDER.
To remedy faults and malfunctions, the gear unit must always be taken out of
service.
Attach a warning notice to the start switch.
9.2 Possible faults
Loud noises in area of Fastening has worked loose Tighten bolts / nuts to prescribed
gear-unit fastening torque.
Replace damaged bolts / nuts.
Changes in gear noise Damage to gear teeth Contact Customer Service.
– Check all toothed components and
replace any damaged parts.
Excessive bearing play Contact Customer Service.

– Adjust bearing play.
Bearing defective Contact Customer Service.

– Replace defective bearings.
Operating temperature too Oil level in gear-unit housing too Check oil level and, if necessary,
high high adjust
Oil too old Contact Customer Service.

– Check date of last oil change.
Oil badly contaminated Contact Customer Service.

– Change oil.
On gear units with oil-cooling Fully set valves in inflow and outflow
system: pipes.
Coolant flow too low or too high Check for free flow through water
oil-cooler.
Coolant temperature too high Check temperature and, if necessary,

adjust
Oil flow through water oil-cooler Clean oil filter.

too low due to:
badly clogged oil filter
Oil pump defective Contact Customer Service.

– Check that oil pump is functioning
correctly
– Repair or replace oil pump
On gear units with fan: Clean fan cowl and gear-unit housing
Suction opening in fan cowl and/or
housing badly contaminated
Gear unit with cooling coil: Contact Customer Service.

Deposits in cooling coil – Clean or replace cooling coil
BA 5010 EN 06.03

Increased temperature at Oil level in gear-unit housing too Check oil level at room temperature
bearing points low or too high and, if necessary, top up oil
Oil too old Contact Customer Service.

– Check date of last oil change.
Mechanical oil pump defective Contact Customer Service.

– Check that oil pump is functioning
correctly
Repair or replace oil pump
Bearing defective Contact Customer Service.

– Consult values obtained during
vibration measurement by the
operator.
– Check and, if necessary, replace
bearings.
Increased vibration Bearing defective Contact Customer Service.
amplitudes at the bearing – Check and, if necessary, replace
points bearings.
Gears defective Contact Customer Service.

– Check gears and, if necessary,
replace.
Temperature at backstop too Damage to backstop Contact Customer Service.
high – Check backstop and replace, if
Locking function fails necessary.
Oil leakage from gear unit Inadequate sealing of housing Check and, if necessary, replace
covers or joints seals. Seal joints.
Radial shaft sealing rings defective Contact Customer Service.

–Replace radial shaft sealing rings
Water in oil Oil foams in sump Check state of oil by the test-tube
method for water contamination.
Have oil analysed by laboratory.
Defective oil cooler or cooling coil Contact Customer Service.

– Look for and repair any leaks.
– Replace oil cooler or cooling coil.
Gear unit exposed to cold air from Protect gear unit with suitable heat
machine-room ventilator: water insulation.
condensing Close air outlet or alter its direction by
structural measures.
Pressure monitor triggers Oil pressure < 0.5 bar Check oil level at room temperature
alarm and, if necessary, top up oil.
(gear units with pressurised Check oil filter, clean if necessary.
lubrication, water oil-cooler, Contact Customer Service.
air oil-cooler) – Check that oil pump is functioning
correctly
– Repair or replace oil pump
Indicator on double Double change-over filter clogged Change filter over as instructed,
change-over filter triggers remove clogged filter element and
alarm clean
Fault in oil supply system Consult operating instructions
for oil supply system
Table 9.1: Faults, causes and remedies
BA 5010 EN 06.03

10. Maintenance and repair
Observe the ”Safety instructions” in section 3 and the instructions in section 9, ”Faults, causes and
remedy”.
10.1 General notes on maintenance
Maintenance and repair work must be done with care by trained and qualified personnel only.
The following applies to all work in item 10.2:
Switch gear unit and add-on components off.

Attach a warning notice to the start switch.
The periods indicated in table 10.1 depend on the conditions under which the
Caution! gear unit is operated. Only average periods can therefore be stated here. These
refer to:
a daily operating time of 24 hours

a duty factor of 100 %
an input-drive speed of 1500 1/min
a maximum oil temperature of 90 °C (mineral oil only)
100 °C (synthetic oil only)
For operation and maintenance, always observe the instructions given in the order-specific appendix.
Measures Periods Remarks
Check oil temperature. daily
Check for unusual daily

gear-unit noise.
Check gear unit for leaks. monthly
Check oil level. each time before starting up the

gear unit
Test oil for water content. after approx. 400 operating hours see Item 10.2.1
once per year at least
First oil change 400 operating hours see Item 10.2.2

following start-up
subsequent oil changes every 2 years or after max. see Item 10.2.2
10 000 operating hours 1)
Clean the oil filter. every 3 months
Clean the breather screw. every 3 months see Item 10.2.3
Refill Taconite seals every 3 000 operating hours see Item 10.2.4
with grease. or every 6 months at least
Clean fan, fan cowl and depending on requirements or see Item 10.2.5
gear-unit housing. simultaneously with due oil change
Check cooling coil approx. every 2 years see Item 10.2.6

for deposits. simultaneously with due oil change
Check condition of simultaneously with oil change see Item 10.2.7

air oil-cooler.
Check condition of simultaneously with oil change see Item 10.2.8

water oil-cooler.
BA 5010 EN 06.03

Measures Periods Remarks
Check tightness of after first oil change, thereafter see Item 10.2.10
fastening bolts. after every second oil change
Carry out complete inspection approx. every 2 years see Item 10.3.1
of gear unit. simultaneously with due oil change
Table 10.1: Maintenance and repair work
1) When using synthetic oils, the periods can be doubled.
10.2 Description of maintenance and repair work
10.2.1 Test water-content of oil
For detailed information on testing the oil for water-content apply to the lubricant manufacturer.
10.2.2 Changing the oil
S The instructions in item 7.1 must be observed!
S Close the stop valves in the coolant in- and outflow pipes (gear units with cooling coil or water
oil-cooling systems)
S Drain the oil while it is still warm, i.e. immediately after shutting down the machinery.
When changing the oil, always re-fill the gear unit with the same type of oil.
Caution! Never mix different types of oil or oils made by different manufacturers. Never
mix synthetic oils with mineral-based oils or with other synthetic oils. When
changing from mineral-based oil to synthetic oil or from one type of synthetic
oil to another, flush the gear unit well with the new type of oil beforehand.
When changing the oil, the housing must be flushed with oil to remove sludge, metal particles and oil
residue. Use the same type of oil as is used for normal operation. High-viscosity oils must be heated
beforehand. Ensure that all residues have been removed before filling with fresh oil.
S Place a suitable container under the oil drain plug of the gear-unit housing
S Unscrew the breather screw on the top of the housing
S Unscrew the oil drain plug and allow the oil to drain into the container
There is a danger of scalding from the hot oil emerging from the housing.
Wear protective gloves to avoid scalding.
S Clean the permanent magnet of the oil drain plug thoroughly
S Replace the oil drain plug
Note: Check the condition of the sealing ring (the sealing ring is vulcanised onto the oil drain
plug). If necessary, use a new oil drain plug.
S Clean oil filter in oil-cooling system
S Fill with lubricant according to item 7.1.2
10.2.3 Cleaning the breather screw
If a layer of dust has built up, the breather screw must be cleaned, whether or not the minimum period
of 3 months has expired. To do this, the breather screw must be unscrewed, cleaned with benzine or
similar agent and dried. It can also be cleaned by blowing out with compressed air.
Caution! Foreign bodies must be prevented from entering the gear unit.
BA 5010 EN 06.03

10.2.4 Refilling Taconite seals with grease
S Inject approx. 30 g lithium-based bearing grease into each of the lubrication points of the Taconite
seal. The lubrication points are fitted with flat grease nipples type AM10x1 to DIN 3404.
Remove and dispose of any old grease escaping.
10.2.5 Cleaning the fan and gear unit
S The instructions in item 5.9.1 must be observed!
S Remove the fan cowl
S Using a stiff brush, remove any dirt adhering to the fan wheel, cowl and safety grid.
S Remove any corrosion.
S Screw safety grid back onto the fan cowl
Caution! The gear unit must not be cleaned with high-pressure cleaning equipment.
It must be ensured that the fan cowl is correctly fastened. The fan must not
Caution! come into contact with the fan cover.
10.2.6 Checking cooling coil
S Disconnect the water in- and outflow pipes from the cooling coil
S Check the inside walls of the cooling coil for deposits
If the cooling coil is dirty, heat is no longer withdrawn effectively from the gear
Caution! unit. Any dirt adhering to the inside of the coil should be removed by chemical
cleaning or the coil should replaced with a new one.
S If thick deposits have formed on the inside of the cooling coil, the cooling water (or the deposits
themselves) should be chemically analysed. These analyses are carried out by companies which
specialise in chemical cleaning. They also supply the special cleaning agents required.
Note: Before using these cleaning agents, ensure that they will not damage the coil
materials (contact FLENDER). Observe the manufacturer’s instructions at all times.
Avoid burns when working with corrosive cleaning agents. Always observe the
manufacturers’ instructions for safety and use.
S Seriously contaminated cooling coils must be replaced. Consult our Customer Service.
S Re-connect the water in- and outflow pipes.
10.2.7 Checking air oil-cooler
S The instructions in items 5.9.3, 7.1.2 and 10.1 must be observed!
S Remove dirt from the cooler block
S Check the condition of screw connections and, if necessary, replace.
BA 5010 EN 06.03

10.2.8 Checking water oil-cooler
S The instructions in items 5.9.4, 7.1.2 and 10.1 must be observed!
S Close the stop valves in the coolant in- and outflow pipes
S Inspect cooler for leaks in the piping.
S Check the condition of screw connections and, if necessary, replace.
10.2.9 Topping up oil
S The instructions in item 7.1.2 must be observed!
S Always top up with the same type of oil as already used in the gear unit (see also item 10.2.2).
10.2.10 Checking tightness of fastening bolts
S The instructions in item 10.1 must be observed!
S Close the stop valves in the coolant in- and outflow pipes (gear units with cooling coil or water
oil-cooling system)
S Check tightness of all fastening bolts with a torque wrench
Thread size Tightening torque Initial tensioning force

M 42 4070 Nm 526000 N
M 48 6140 Nm 693000 N
M 56 9840 Nm 959000 N
M 64 14300 Nm 1268000 N
M 72 x 6 20800 Nm 1600000 N
M 80 x 6 28900 Nm 1950000 N
M 90 x 6 41650 Nm 2550000 N
M 100 x 6 57800 Nm 3200000 N
Table 10.2: Tightening torques and initial tensioning forces of the foundation bolts
All other bolts on the gear unit should be checked for tightening torques according to the following table:
Tightening torque
Thread size (with µ = 0.14)
Strength class 8.8 Strength class 10.9

M 10 49 Nm 69 Nm
M 12 86 Nm 120 Nm
M 16 210 Nm 295 Nm
M 20 410 Nm 580 Nm
M 24 710 Nm 1000 Nm
M 30 1450 Nm 2000 Nm
M 36 2530 Nm 3560 Nm
M 42 4070 Nm 5720 Nm
M 48 6140 Nm 8640 Nm
M 56 9840 Nm 13850 Nm
M 64 14300 Nm 21000 Nm
Table 10.3: Tightening torques
Note: Damaged bolts must be replaced with new bolts of the same type and strength class.
BA 5010 EN 06.03

10.3 Final work
Note: Observe also item 6.19
10.3.1 General inspection of gear unit
The general inspection of the gear unit must be carried out by the FLENDER Customer Service, as our
engineers have the experience and training necessary to identify any components requiring
replacement.
10.4 Lubricants
The oil selected for use in the gear unit must be of the viscosity (VG class) indicated on the nameplate.
The viscosity class applies for the contractually agreed operating conditions.
FLENDER must be consulted for any change in operating conditions.
Note: For the correct type of oil (of various brands) to be used, refer to the BA 7300 EN
operating instructions supplied separately.
We are familiar with the composition of these lubricants and, as far as we are currently aware, they
possess the properties with regard to load-bearing capacity, corrosion resistance, resistance to grey
staining and compatibility with seals and internal paint coats which are necessary for the type of gear
unit concerned.
We therefore advise our customers to select one of the lubricants listed in the BA 7300 EN instructions,
taking into account the VG class specified on the rating plate.
Note: To avoid misunderstandings, we should like to point out that this recommendation is
in no way intended as a guarantee of the quality of the lubricant supplied. Each
lubricant manufacturer is responsible for the quality of his own product.
If for an important reason of your own you do not wish to follow our recommendation, you assume
responsibility for the technical suitability of the lubricant used.
11. Spare parts, customer-service addresses
11.1 Stocking spare parts
By stocking the most important spare and wearing parts on site you can ensure that the gear unit is
ready for use at any time.
To order spare parts, refer to the spare-parts list.
For further information refer to the spare-parts drawing stated in the list.
We guarantee only the original spare parts supplied by us.
Please note that spare parts and accessories not supplied by us have not been
Caution! tested or approved by us. The installation and/or use of such products may
therefore impair essential characteristics of the gear unit, thereby posing an
active or passive risk to safety. FLENDER will assume no liability or guarantee
for damage caused by spare parts and accessories not supplied by FLENDER.
Please note that certain components often have special production and supply specifications and that
we supply you with spare parts which comply fully with the current state of technical development as
well as current legislation.
When ordering spare parts, always state the following:
Order no. / Item Type / Size Part no. Quantity
BA 5010 EN 06.03

11.2 Spare-part and customer service addresses
When ordering spare parts or the services of our specialist engineers, apply first to FLENDER AG.
FLENDER Germany
46393 Bocholt - Tel.: (0 28 71) 92-0 - Fax: (0 28 71) 92 25 96
Shipping address: Alfred - Flender - Strasse 77 - 46395 Bocholt
A. FRIEDR. FLENDER AG - Kupplungswerk Mussum

Industriepark Bocholt - Schlavenhorst 100 - 46395 Bocholt - Tel.: (0 28 71) 92 28 68 - Fax: (0 28 71) 92 25 79
E-mail: couplings@flender.com S www.flender.com
A. FRIEDR. FLENDER AG - Werk Friedrichsfeld
Am Industriepark 2 - 46562 Voerde - Tel.: (0 28 71) 92-0 - Fax: (0 28 71) 92 25 96
Winergy AG
Am Industriepark 2 - 46562 Voerde - Tel.: (0 28 71) 924 - Fax: (0 28 71) 92 24 87
E-mail: info@winergy-ag.com S www.winergy-ag.com
A. FRIEDR. FLENDER AG - Getriebewerk Penig
Thierbacher Strasse 24 - 09322 Penig - Tel.: (03 73 81) 60 - Fax: (03 73 81) 8 02 86
E-mail: ute.tappert@flender.com S www.flender.com
FLENDER - TÜBINGEN GMBH
72007 Tübingen - Tel.: (0 70 71) 7 07-0 - Fax: (0 70 71) 70 74 00
E-mail: sales-motox@flender-motox.com S www.flender.com
Shipping address: Bahnhofstrasse 40 - 72072 Tübingen
LOHER GMBH
94095 Ruhstorf - Tel.: (0 85 31) 3 90 - Fax: (0 85 31) 3 94 37
E-mail: info@loher.de S www.loher.de
Shipping address: Hans-Loher-Strasse 32 - 94099 Ruhstorf
FLENDER SERVICE GMBH

44607 Herne - Tel.: (0 23 23) 940-0 - Fax: (0 23 23) 940 333
E-mail: infos@flender-service.com S www.flender-service.com
Shipping address: Südstrasse 111 - 44625 Herne
A. FRIEDR. FLENDER AG - FLENDER GUSS

Obere Hauptstrasse 228-230 - 09228 Chemnitz / Wittgensdorf - Tel.: (0 37 22) 64-0 - Fax: (0 37 22) 64 21 89
E-mail: flender.guss@flender-guss.com S www.flender-guss.de
BA 5010 EN 06.03

Germany
46393 BOCHOLT - TEL.: (0 28 71) 92 - 0 - FAX: (0 28 71) 92 25 96
SHIPPING ADDRESS: ALFRED - FLENDER - STRASSE 77 - 46395 BOCHOLT
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
VERTRIEBSZENTRUM BOCHOLT 46393 Bocholt
Alfred-Flender-Strasse 77, 46395 Bocholt
Tel.: (0 28 71) 92 - 0
Fax: (0 28 71) 92 - 14 35
E-mail: vz.bocholt@flender.com
___________________________________________________________________________________________________________
VERTRIEBSZENTRUM STUTTGART 70472 Stuttgart

Friolzheimer Strasse 3, 70499 Stuttgart
Tel.: (07 11) 7 80 54 - 51
Fax: (07 11) 7 80 54 - 50
E-mail: vz.stuttgart@flender.com
___________________________________________________________________________________________________________
VERTRIEBSZENTRUM MÜNCHEN 85750 Karlsfeld

Liebigstrasse 14, 85757 Karlsfeld
Tel.: (0 81 31) 90 03 - 0
Fax: (0 81 31) 90 03 - 33
E-mail: vz.muenchen@flender.com
___________________________________________________________________________________________________________
VERTRIEBSZENTRUM BERLIN Schlossallee 8, 13156 Berlin

Tel.: (0 30) 91 42 50 58
Fax: (0 30) 47 48 79 30
E-mail: vz.berlin@flender.com
___________________________________________________________________________________________________________
BA 5010 EN 06.03

FLENDER International (2003-12-01)
EUROPE Flender - Graffenstaden SA PORTUGAL

1, rue du Vieux Moulin Rodamientos FEYC, S.A
67400 Illkirch-Graffenstaden R. Jaime Lopes Dias, 1668 CV
AUSTRIA B.P. 84 1750 - 124 Lissabon
Flender Ges.m.b.H. Phone: +351 (0) 21 - 7 54 24 10
67402 Illkirch - Graffenstaden
Industriezentrum Nö-Süd Fax: +351 (0) 21 - 7 54 24 19
Phone: +33 (0) 3 - 88 67 60 00
Strasse 4, Objekt 14, Postfach 132 E-mail: info@rfportugal.com
Fax: +33 (0) 3 - 88 67 06 17
2355 Wiener Neudorf
E-mail: flencomm@flender-graff.com
Phone: +43 (0) 22 36 6 45 70 ROMANIA
Fax: +43 (0) 22 36 6 45 70 10 A. Friedr. Flender AG
E-mail: office@flender.at GREECE
Flender Hellas Ltd. Branch Office
www.flender.at 98 - 106, Soseaua Mihai Bravu
2, Delfon str., 11146 Athens
Phone: +30 210 - 2 91 72 80 Sector 2, Bloc D 16, Sc 1, Apartament 4
BELGIUM & LUXEMBOURG 021331 Bucuresti - 2
N.V. Flender Belge S.A. Fax: +30 210 - 2 91 71 02
E-mail: flender@otenet.gr Phone: +40 (0) 21 - 4 91 10 08
Cyriel Buyssestraat 130 Fax: +40 (0) 21 - 4 91 10 08
1800 Vilvoorde Mangrinox S.A. E-mail: flender@fx.ro
Phone: +32 (0) 2 - 2 53 10 30 14, Grevenon str., 11855 Athens
Fax: +32 (0) 2 - 2 53 09 66 Phone: +30 210 - 3 42 32 01 RUSSIA
E-mail: sales@flender.be Fax: +30 210 - 3 45 99 28 F & F GmbH
E-mail: mangrinox@otenet.gr Tjuschina 4-6
BULGARIA 191119 St. Petersburg
A. Friedr. Flender AG HUNGARY Phone: +7 (0) 8 12 - 3 20 90 34
Branch Office A. Friedr. Flender AG Fax: +7 (0) 8 12 - 3 40 27 60
c/o Auto - Profi GmbH Branch Office E-mail: flendergus@mail.spbnit.ru
Alabin Str. 52, 1000 Sofia Bécsi Út 3-5, 1023 Budapest
Phone: +359 (0) 2 - 9 80 66 06 Phone: +36 (0) 1 - 3 45 07 90 / 91 SLOVAKIA
Fax: +359 (0) 2 - 9 80 33 01 Fax: +36 (0) 1 - 3 45 07 92 A. Friedr. Flender AG
E-mail: sofia@auto-profi.com E-mail: jambor.laszlo@axelero.hu Branch Office
Vajanského 49
P.O. Box 286, 08001 Presov
CROATIA / SLOVENIA ITALY Phone: +421 (0) 51 - 7 70 32 67
BOSNIA-HERZEGOVINA Flender Cigala S.p.A. Fax: +421 (0) 51 - 7 70 32 67
A. Friedr. Flender AG Parco Tecnologico Manzoni E-mail: micenko.flender@nextra.sk
Branch Office Palazzina G
c/o HUM - Naklada d.o.o. Viale delle industrie, 17 SPAIN
Mandroviceva 3, 10000 Zagreb 20040 Caponago (MI) Flender Ibérica S.A.
Phone: +385 (0) 1 - 2 30 60 25 Phone: +39 (0) 02 - 95 96 31 Poligono Industrial San Marcos
Fax: +385 (0) 1 - 2 30 60 24 Fax: +39 (0) 02 -95 74 39 30 Calle Morse, 31 (Parcela D-15)
E-mail: flender@hi.hinet.hr E-mail: info@flendercigala.it 28906 Getafe - Madrid
Phone: +34 (0) 91 - 6 83 61 86
CZECH REPUBLIC THE NETHERLANDS Fax: +34 (0) 91 - 6 83 46 50
A. Friedr. Flender AG Flender Nederland B.V. E-mail: f-iberica@flender.es
Branch Office Industrieterrein Lansinghage www.flender.es
Hotel DUO, Teplicka 17 Platinastraat 133
19000 Praha 9 2718 ST Zoetermeer SWEDEN
Phone: +420 (0) 2 - 83 88 23 00 Postbus 725 Flender Scandinavia
Fax: +420 (0) 2 - 83 88 22 05 2700 AS Zoetermeer Äsenvägen 2
E-mail: flender_pumprla@hotelduo.cz Phone: +31 (0) 79 - 3 61 54 70 44339 Lerum
Fax: +31 (0) 79 - 3 61 54 69 Phone: +46 (0) 302 - 1 25 90
DENMARK E-mail: sales@flender.nl Fax: +46 (0) 302 - 1 25 56
Flender Scandinavia A/S www.flender.nl E-mail: kontakt@flenderscandinavia.com
Rugmarken 35 B, 3520 Farum www.flenderscandinavia.com
SALES OFFICES:
Phone: +45 - 70 22 60 03 Flender Nederland B.V.
Fax: +45 - 44 99 16 62 SWITZERLAND
Lage Brink 5-7 Flender AG
E-mail: kontakt@flenderscandinavia.com 7317 BD Apeldoorn
www.flenderscandinavia.com Zeughausstr. 48
Postbus 1073 5600 Lenzburg
7301 BH Apeldoorn Phone: +41 (0) 62 8 85 76 00
ESTHONIA / LATVIA / LITHUANIA Phone: +31 (0) 55 - 5 27 50 00 Fax: +41 (0) 62 8 85 76 76
Flender Branch Office Fax: +31 (0) 55 - 5 21 80 11 E-mail: info@flender.ch
Addinol Mineralöl Marketing OÜ E-mail: tom.alberts@flender-group.com www.flender.ch
Suur-Söjamäe 32 Bruinhof B.V.
11415 Tallinn / Esthonia Boterdiep 37 TURKEY
Phone: +372 (0) 6 - 27 99 99 3077 AW Rotterdam Flender Güc Aktarma Sistemleri
Fax: +372 (0) 6 - 27 99 90 Postbus 9607 Sanayi ve Ticaret Ltd. Sti.
E-mail: flender@addinol.ee 3007 AP Rotterdam IMES Sanayi, Sitesi
www.addinol.ee Phone: +31 (0) 10 - 4 97 08 08 E Blok 502. Sokak No. 22
Fax: +31 (0) 10 - 4 82 43 50 81260 Dudullu - Istanbul
FINLAND E-mail: info@bruinhof.nl Phone: +90 (0) 2 16 - 4 66 51 41
Flender Oy www.bruinhof.nl Fax: +90 (0) 2 16 3 64 59 13
Ruosilantie 2 B, 00390 Helsinki E-mail: cuzkan@flendertr.com
Phone: +358 (0) 9 - 4 77 84 10 www.flendertr.com
NORWAY
Fax: +358 (0) 9 - 4 36 14 10 Elektroprosess AS
E-mail: webmaster@flender.fi UKRAINE
Frysjaveien 40, 0884 Oslo A. Friedr. Flender AG
www.flender.fi Postboks 165, Kjelsås Branch Office, c/o DIV - Deutsche Industrie-
0411 Oslo vertretung, Prospect Pobedy 44
FRANCE Phone: +47 (0) 2 - 2 02 10 30 252057 Kiev
Flender s.a.r.l. Fax: +47 (0) 2 - 2 02 10 50 / 51 Phone: +380 (0) 44 - 4 46 80 49
3, rue Jean Monnet - B.P. 5 E-mail: post@elektroprosess.no Fax: +380 (0) 44 - 2 30 29 30
78996 Elancourt Cedex E-mail: flender@div.kiev.ua
Phone: +33 (0) 1 - 30 66 39 00 POLAND
Fax: +33 (0) 1 - 30 66 35 13 A. Friedr. Flender AG UNITED KINGDOM & EIRE
E-mail: sales@flender.fr Branch Office Flender Power Transmission Ltd.
SALES OFFICES: Przedstawicielstwo w Polsce Thornbury Works, Leeds Road
Flender s.a.r.l. ul. Wyzwolenia 27 Bradford
36, rue Jean Broquin 43 - 190 Mikolów West Yorkshire BD3 7EB
69006 Lyon Phone: +48 (0) 32 - 2 26 45 61 Phone: +44 (0) 12 74 65 77 00
Phone: +33 (0) 4 - 72 83 95 20 Fax: +48 (0) 32 - 2 26 45 62 Fax: +44 (0) 12 74 66 98 36
Fax: +33 (0) 4 - 72 83 95 39 E-mail: flender@pro.onet.pl E-mail: flenders@flender-power.co.uk
E-mail: sales@flender.fr www.flender.pl www.flender-power.co.uk
BA 5010 EN 06.03

SERBIA-MONTENEGRO SALES OFFICES: USA
ALBANIA / MACEDONIA Flender Brasil Ltda. Flender Corporation
A. Friedr. Flender AG Rua James Watt, 142 950 Tollgate Road
Branch Office conj. 142 - Brooklin Novo P.O. Box 1449, Elgin, IL. 60123
c/o G.P.Inzenjering d.o.o. 04576 - 050, São Paulo - SP Phone: +1 (0) 8 47 - 9 31 19 90
III Bulevar 54 / 19 Phone: +55 (0) 11 - 55 05 99 33 Fax: +1 (0) 8 47 - 9 31 07 11
11070 Novi Beograd Fax: +55 (0) 11 - 55 05 30 10 E-mail: flender@flenderusa.com
Phone: +381 (0) 11 - 60 44 73 E-mail: flesao@uol.com.br www.flenderusa.com
Fax: +381 (0) 11 - 3 11 67 91 Flender Corporation
E-mail: flender@eunet.yu Flender Brasil Ltda. Service Centers West
Rua Campos Salles, 1095 4234 Foster Ave.
sala 04 - Centro 14015 - 110, Bakersfield, CA. 93308
Ribeirão Preto - SP
AFRICA Phone: +55 (0) 16 - 6 35 15 90
Phone: +1 (0) 6 61 - 3 25 44 78
Fax: +1 (0) 6 61 - 3 25 44 70
Fax: +55 (0) 16 - 6 35 11 05 E-mail: flender1@lightspeed.net
NORTH AFRICAN COUNTRIES E-mail: flender.ribpreto@uol.com.br
Please refer to Flender s.a.r.l. VENEZUELA
3, rue Jean Monnet - B.P. 5 F. H. Transmisiones S.A.
78996 Elancourt Cedex CANADA Urbanización Buena Vista
Phone: +33 (0) 1 - 30 66 39 00 Flender Power Transmission Inc. Calle Johan Schafer o Segunda Calle
Fax: +33 (0) 1 - 30 66 35 13 215 Shields Court, Units 4 - 6 Municipio Sucre, Petare
E-mail: sales@flender.fr Markham, Ontario L3R 8V2 Caracas
Phone: +1 (0) 9 05 - 3 05 10 21 Phone: +58 (0) 2 - 21 52 61
Fax: +1 (0) 9 05 - 3 05 10 23 Fax: +58 (0) 2 - 21 18 38
EGYPT E-mail: flender@ca.inter.net E-mail: fhtransm@telcel.net.ve
Sons of Farid Hassanen www.flenderpti.com www.fhtransmisiones.com
81 Matbaa Ahlia Street
Boulac 11221, Cairo SALES OFFICE: ASIA
Phone: +20 (0) 2 - 5 75 15 44 Flender Power Transmission Inc.
Fax: +20 (0) 2 - 5 75 17 02 34992 Bemina Court BANGLADESH / SRI LANKA
E-mail: hussein@sonfarid.com Abbotsford - Vancouver Please refer to Flender Limited
B.C. V3G 1C2 No. 2 St. George’s Gate Road
Phone: +1 (0) 6 04 - 8 59 66 75 5th Floor, Hastings
SOUTH AFRICA Fax: +1 (0) 6 04 - 8 59 68 78 Kolkata - 700 022
Flender Power Transmission (Pty.) Ltd. E-mail: tvickers@rapidnet.net Phone: +91 (0) 33 - 2 23 05 45
Cnr. Furnace St & Quality Rd. Fax: +91 (0) 33 - 2 23 18 57
P.O. Box 131, Isando 1600 E-mail: flender@flenderindia.com
Johannesburg CHILE / ARGENTINA / BOLIVIA
Phone: +27 (0) 11 - 5 71 20 00 ECUADOR / PARAGUAY / URUGUAY PEOPLE’S REPUBLIC OF CHINA
Fax: +27 (0) 11 - 3 92 24 34 Flender Cono Sur Limitada Flender Power Transmission
E-mail: sales@flender.co.za Avda. Galvarino Gallardo 1534 (Tianjin) Co. Ltd.
www.flender.co.za Providencia, Santiago ShuangHu Rd.- Shuangchen Rd. West
Phone: +56 (0) 2 - 2 35 32 49 Beichen Economic Development
SALES OFFICES: Area (BEDA)
Flender Power Transmission (Pty.) Ltd. Fax: +56 (0) 2 - 2 64 20 25
E-mail: flender@flender.cl Tianjin 300400
Unit 3 Marconi Park Phone: +86 (0) 22 - 26 97 20 63
9 Marconi Crescent, Montague Gardens www.flender.cl
Fax: +86 (0) 22 - 26 97 20 61
P.O. Box 37291 E-mail: flender@flendertj.com
Chempet 7442, Cape Town www.flendertj.com
Phone: +27 (0) 21 - 5 51 50 03 COLOMBIA
Fax: +27 (0) 21 - 5 52 38 24 A.G.P. Representaciones Ltda. Flender Power Transmission
E-mail: sales@flender.co.za Flender Liaison Office Colombia (Tianjin) Co. Ltd.
Av Boyaca No 23A Beijing Office
Flender Power Transmission (Pty.) Ltd. 50 Bodega UA 7-1, Bogotá C-415, Lufthansa Center
Unit 3 Goshawk Park Phone: +57 (0) 1 - 5 70 63 53 50 Liangmaqiao Road, Chaoyang District
Falcon Industrial Estate Fax: +57 (0) 1 - 5 70 73 35 Beijing 100016
P.O. Box 1608 E-mail: aguerrero@agp.com.co Phone: +86 (0) 10 - 64 62 21 51
New Germany 3620, Durban www.agp.com.co Fax: +86 (0) 10 - 64 62 21 43
Phone: +27 (0) 31 - 7 05 38 92 E-mail: beijing@flenderprc.com.cn
Fax: +27 (0) 31 - 7 05 38 72 Flender Power Transmission
E-mail: sales@flender.co.za MEXICO (Tianjin) Co. Ltd.
Flender Power Transmission (Pty.) Ltd. Flender de Mexico S.A. de C.V. Shanghai Office
9 Industrial Crescent, Ext. 25 17, Pte, 713 Centro 1101-1102 Harbour Ring Plaza
P.O. Box 17609, Witbank 1035 72000 Puebla 18 Xizang Zhong Rd.
Phone: +27 (0) 13 - 6 92 34 38 Phone: +52 (0) 2 22 - 2 37 19 00 Shanghai 200 001
Fax: +27 (0) 13 - 6 92 34 52 Fax: +52 (0) 2 22 - 2 37 11 33 Phone: +86 (0) 21 - 53 85 31 48
E-mail: sales@flender.co.za E-mail: szugasti@flendermexico.com Fax: +86 (0) 21 - 53 85 31 46
www.flendermexico.com E-mail: shanghai@flenderprc.com.cn
Flender Power Transmission (Pty.) Ltd. Flender Power Transmission
Unit 14 King Fisher Park, Alton SALES OFFICES: (Tianjin) Co. Ltd.
Cnr. Ceramic Curve & Alumina Allee Flender de Mexico S.A. de C.V. Wuhan Office
P.O. Box 101995 Lago Nargis No. 38 Rm. 1503, Jianyin Building,
Meerensee 3901, Richards Bay Col. Granada, 709 Jianshedadao
Phone: +27 (0) 35 - 7 51 15 63 11520 Mexico, D.F. Wuhan 430 015
Fax: +27 (0) 35 - 7 51 15 64 Phone: +52 (0) 55 - 52 54 30 37 Phone: +86 (0) 27 - 85 48 67 15
E-mail: sales@flender.co.za Fax: +52 (0) 55 - 55 31 69 39 Fax: +86 (0) 27 - 85 48 68 36
E-mail: info@flendermexico.com E-mail: wuhan@flenderprc.com.cn
Flender de Mexico S.A. de C.V. Flender Power Transmission
AMERICA Ave. San Pedro No. 231-5 (Tianjin) Co. Ltd.
Col. Miravalle Guangzhou Office
64660 Monterrey, N.L. Rm. 2802, Guangzhou International
ARGENTINA Electronics Tower
Chilicote S.A. Phone: +52 (0) 81 - 83 63 82 82
Fax: +52 (0) 81 - 83 63 82 83 403 Huanshi Rd. East
Avda. Julio A. Roca 546
E-mail: info@flendermexico.com Guangzhou 510 095
C 1067 ABN Buenos Aires
Phone: +86 (0) 20 - 87 32 60 42
Phone: +54 (0) 11 - 43 31 66 10 Fax: +86 (0) 20 - 87 32 60 45
Fax: +54 (0) 11 - 43 31 42 78 E-mail: guangzhou@flenderprc.com.cn
E-mail: chilicote@chilicote.com.ar PERU
Potencia Industrial E.I.R.L. Flender Power Transmission
Calle Victor González Olaechea N° 110 (Tianjin) Co. Ltd.
BRASIL Urb. La Aurora - Miraflores, Chengdu Office
Flender Brasil Ltda. P.O.Box: Av. 2 de Mayo N° 679 G-6 / F Guoxin Mansion,
Rua Quatorze, 60 - Cidade Industrial Of.108-Miraflores 77 Xiyu Street
32211 - 970, Contagem - MG Casilla N° 392, Lima 18 Chengdu 610 015
Phone: +55 (0) 31 - 33 69 21 00 Phone: +51 (0) 1 - 2 42 84 68 Phone: +86 (0) 28 - 86 19 83 72
Fax: +55 (0) 31 - 33 69 21 66 Fax: +51 (0) 1 - 2 42 08 62 Fax: +86 (0) 28 - 86 19 88 10
E-mail: vendas@flenderbrasil.com E-mail: cesarzam@chavin.rcp.net.pe E-mail: chengdu@flenderprc.com.cn
BA 5010 EN 06.03

Flender Power Transmission ISRAEL SINGAPORE
(Tianjin) Co. Ltd. Greenshpon Engineering Works Ltd. Flender Singapore Pte. Ltd.
Shenyang Office Haamelim Street 20 13 A, Tech Park Crescent
Rm. 2-163, Tower I, City Plaza Shenyan P.O. Box 10108, 26110 Haifa Singapore 637843
206 Nanjing Street (N), Heping District Phone: +972 (0) 4 - 8 72 11 87 Phone: +65 (0) - 68 97 94 66
Shenyang 110 001 Fax: +972 (0) 4 - 8 72 62 31 Fax: +65 (0) - 68 97 94 11
Phone: +86 (0) 24 - 23 34 20 48 E-mail: sales@greenshpon.com E-mail: flender@singnet.com.sg
Fax: +86 (0) 24 - 23 34 20 46 www.greenshpon.com www.flender.com.sg
E-mail: shenyang@flenderprc.com.cn
JAPAN SYRIA
Flender Power Transmission Flender Japan Co., Ltd. Misrabi Co & Trading
(Tianjin) Co. Ltd. WBG Marive East 21F Mezzeh Autostrade Transportation
Xi’an Office Nakasa 2 - 6 Building 4/A, 5th Floor
Rm. 302, Shaanzi Zhong Da Mihama-ku, Chiba-shi P.O. Box 12450, Damascus
International Mansion Chiba 261-7121 Phone: +963 (0) 11 - 6 11 67 94
30 Southern Rd. Phone: +81 (0) 43 - 2 13 39 30 Fax: +963 (0) 11 - 6 11 09 08
Xi’an 710 002 Fax: +81 (0) 43 - 2 13 39 55 E-mail: ismael.misrabi@gmx.net
Phone: +86 (0) 29 - 7 20 32 68 E-mail: contact@flender-japan.com
Fax: +86 (0) 29 - 7 20 32 04
E-mail: xian@flenderprc.com.cn TAIWAN
KOREA A. Friedr. Flender AG
Flender Ltd. Taiwan Branch Company
INDIA 7th Fl. Dorim Bldg. 1F, No. 5, Lane 240
Flender Limited 1823 Bangbae-Dong, Seocho-Ku, Nan Yang Street, Hsichih
Head Office: Seoul 137-060 Taipei Hsien 221
No. 2 St. George’s Gate Road Phone: +82 (0) 2 - 34 78 63 37 Phone: +886 (0) 2 - 26 93 24 41
5th Floor, Hastings Fax: +82 (0) 2 - 34 78 63 45 Fax: +886 (0) 2 - 26 94 36 11
Kolkata - 700 022 E-mail: flender@unitel.co.kr E-mail: flender_tw@flender.com.tw
Phone: +91 (0) 33 - 22 23 05 45
Fax: +91 (0) 33 - 22 23 08 30 KUWAIT THAILAND
E-mail: flender@flenderindia.com South Gulf Company Flender Singapore Pte. Ltd.
Al-Reqai, Plot 1, Block 96 Representative Office
Flender Limited P.O. Box 26229, Safat 13123 23/F M Thai Tower, All Seasons Place
Industrial Growth Centre Phone: +965 (0) - 4 88 39 15 87 Wireless Road, Phatumwan
Rakhajungle, Nimpura Fax: +965 (0) - 4 88 39 14 Bangkok 10330
Kharagpur - 721 302 E-mail: adelameen@hotmail.com Phone: +66 (0) 2 - 6 27 91 09
Phone: +91 (0) 3222 - 23 33 07 Fax: +66 (0) 2 - 6 27 90 01
Fax: +91 (0) 3222 - 23 33 64 LEBANON E-mail: christian.beckers@flender.th.com
E-mail: works@flenderindia.com Gabriel Acar & Fils s.a.r.l.
Dahr-el-Jamal VIETNAM
SALES OFFICES: Zone Industrielle, Sin-el-Fil Flender Singapore Pte. Ltd.
Flender Limited B.P. 80484, Beyrouth Representative Office
Eastern Regional Sales Office Phone: +961 (0) 1 - 49 82 72 Suite 6/6A, 16F Saigon Tower
No. 2 St. George’s Gate Road Fax: +961 (0) 1 - 49 49 71 29 Le Duan Street, District 1
5th Floor, Hastings E-mail: gacar@beirut.com Ho Chi Minh City, Vietnam
Kolkata - 700 022
Phone: +84 (0) 8 - 8 23 62 97
Phone: +91 (0) 33 - 22 23 05 45
MALAYSIA Fax: +84 (0) 8 - 8 23 62 88
Fax: +91 (0) 33 - 22 23 08 30 E-mail: flender@hcm.vnn.vn
Flender Singapore Pte. Ltd.
E-mail: ero@flenderindia.com
Flender Limited 37 A - 2, Jalan PJU 1/39
Western Regional Sales Office Dataran Prima AUSTRALIA
Plot No. 23, Sector 19 - C 47301 Petaling Jaya
Vashi, Navi Mumbai - 400 705 Selangor Darul Ehsan
Phone: +91 (0) 22 - 27 65 72 27 Phone: +60 (0) 3 - 78 80 42 63
Fax: +60 (0) 3 - 78 80 42 73 Flender (Australia) Pty. Ltd.
Fax: +91 (0) 22 - 27 65 72 28 9 Nello Place, P.O. Box 6047
E-mail: wro@flenderindia.com E-mail: flender@tm.net.my
Wetherill Park
Flender Limited N.S.W. 2164, Sydney
PAKISTAN Phone: +61 (0) 2 - 97 56 23 22
Southern Regional Sales Office Please refer to
41 Nelson Manickam Road Fax: +61 (0) 2 - 97 56 48 92, 97 56 14 92
A. Friedr. Flender AG
Aminjikarai, E-mail: sales@flender.com.au
46393 Bocholt
Chennai - 600 029 www.flender.com.au
Phone: +49 (0) 28 71 - 92 22 59
Phone: +91 (0) 44 - 23 74 39 21 Fax: +49 (0) 28 71 - 92 15 16 SALES OFFICES:
Fax: +91 (0) 44 - 23 74 39 19 E-mail: ludger.wittag@flender.com Flender (Australia) Pty. Ltd.
E-mail: sro@flenderindia.com Suite 3, 261 Centre Rd.
PHILIPPINES Bentleigh, VIC 3204 Melbourne
Flender Limited Phone: +61 (0) 3 - 95 57 08 11
Northern Regional Sales Office Flender Singapore Pte. Ltd.
Representative Office Fax: +61 (0) 3 - 95 57 08 22
209-A, Masjid Moth, 2nd Floor E-mail: sales@flender.com.au
(Behind South Extension II) 28/F, Unit 2814
New Delhi - 110 049 The Enterprise Centre Flender (Australia) Pty. Ltd.
Phone: +91 (0) 11 - 26 25 02 21 6766 Ayala Avenue corner Suite 5, 1407 Logan Rd.
Fax: +91 (0) 11 - 26 25 63 72 Paeso de Roxas, Makati City Mt. Gravatt
E-mail: nro@flenderindia.com Phone: +63 (0) 2 - 8 49 39 93 QLD 4122, Brisbane
Fax: +63 (0) 2 - 8 49 39 17 Phone: +61 (0) 7 - 34 22 23 89
E-mail: roman@flender.com.ph Fax: +61 (0) 7 - 34 22 24 03
INDONESIA E-mail: sales@flender.com.au
Flender Singapore Pte. Ltd. BAHRAIN / IRAQ / JORDAN / LYBIA Flender (Australia) Pty. Ltd.
Representative Office OMAN / QATAR / U.A.E. / YEMEN
Please refer to A. Friedr. Flender AG Suite 2 403 Great Eastern Highway
Perkantoran Puri Niaga II W.A. 6104, Redcliffe - Perth
Jalan Puri Kencana Blok J1 Middle East Sales Office
IMES Sanayi Sitesi Phone: +61 (0) 8 - 94 77 41 66
No. 2i, Kembangan Fax: +61 (0) 8 - 94 77 65 11
Jakarta Barat 11610 E Blok 502, Sokak No. 22
81260 Dudullu - Istanbul E-mail: sales@flender.com.au
Phone: +62 (0) 21 - 5 82 86 24
Fax: +62 (0) 21 - 5 82 86 23 Phone: +90 (0) 2 16 - 4 99 66 23
Fax: +90 (0) 2 16 - 3 64 59 13 NEW ZEALAND
E-mail: bobwall@cbn.net.id Please refer to Flender (Australia) Pty. Ltd.
E-mail: meso@flendertr.com
9 Nello Place, P.O. Box 6047
IRAN SAUDI ARABIA Wetherill Park
Cimaghand Co. Ltd. South Gulf Co. N.S.W. 2164, Sydney
P.O. Box 15745-493 Al-Khobar, Dahran Str. Phone: +61 (0) 2 - 97 56 23 22
No. 13, 16th East Street Middle East Trade Center Fax: +61 (0) 2 - 97 56 48 92
Beyhaghi Ave., Argentina Sq. 3rd floor, Flat # 23 E-mail: sales@flender.com.au
Tehran 15156 P.O. Box 20434 31952 Al-Khobar
Phone: +98 (0) 21 - 8 73 02 14 Phone: +966 (0) 3 - 8 87 53 32
Fax: +98 (0) 21 - 8 73 39 70 Fax: +966 (0) 3 - 8 87 53 31
E-mail: info@cimaghand.com E-mail: adelameen@hotmail.com
BA 5010 EN 06.03

12. Declaration by the manufacturer

in accordance with EC Engineering Guideline 98/37/EC, Appendix II B
We hereby declare that the
Gear Unit Types

H.SH, H.VH, H.HH, H.DH, H.KH, H.FH, H.HM, H.DM, H.KM, H.FM, H.PH
B.SH, B.VH, B.HH, B.DH, B.KH, B.FH, B.HM, B.DM, B.KM, B.FM
Sizes 3 to 26
described in these Operating Instructions are intended for incorporation in a machine, and that
it is prohibited to put them into service before verifying that the machine into which they are
incorporated complies with the EC Guidelines (original edition 98/37/EC including any subse-
quent amendments thereto).
This Manufacturer’s Declaration takes into account all the unified standards (inasmuch as
they apply to our products) published by the European Commission in the Official Journal of
the European Community.
Penig, 2003-06-20
Signature (Director ZGE Engineering) Sizes 3 to 16
Bocholt, 2003-06-20
Signature (Director IDE Engineering) Sizes 17 to 26
BA 5010 EN 06.03

BA 7300 EN 01.05
Recommended Lubricants
TEXACO

Contents
1. Lubricants for gear units 3

1.1 Required quality of gear oils 3
1.1.1 Oil groups 4
1.1.2 Oil temperatures 4
1.1.3 General oil service lives 4
1.1.4 Oil change 4
Table A : Lubricating oils for FLENDER helical-gear, bevel helical-gear and planetary-gear units 5
Table B : Lubricating oils for FLENDER worm-gear units 14
Table C : Lubricating oils for FLENDER gear motors 18
1.2 Lubricating greases for gear units and rolling bearings 23
Table D : Lubricating greases for FLENDER gear units and rolling bearings 23
2. Lubricants for ZAPEX couplings 25

2.1 Required oil and grease quality 25
2.1.1 Oil and grease types 25
2.1.2 Oil and grease change 25
Table E : Lubricating oils and lubricating greases for FLENDER ZAPEX couplings 26
BA 7300 EN 01.05

1. Lubricants for gear units
This lubricant recommendation does not apply to WINERGY AG gear units.

Caution!
For axle drives, marine gearboxes and turbo gear units also special lubricant
recommendations apply.
According to manufacturer’s information the gear oils listed in these operating instructions are
manufactured and supplied world-wide in the above-mentioned quality as required by FLENDER
(Exceptions: Observe footnotes in the following tables).
1.1 Required quality of gear oils
For FLENDER gear units, only CLP-quality oils containing active agents to DIN 51 517-3 for increasing
corrosion protection and resistance to ageing and for reducing wear in mixed-friction areas are
approved. The scuffing resistance in the FZG test to DIN 51354-2 must comply with stage 12 or higher
under A/8,3/90 test conditions. In the FE-8 rolling bearing test to DIN 51 819-3 rolling element wear must
be under 30 mg and cage wear under 100 mg under test conditions D-7,5/80-80.
In addition, the gear oils must meet the following quality requirements demanded by FLENDER:
S Sufficiently high grey-staining resistance in accordance with FVA 54 grey-staining test

a) for helical-gear, bevel-gear and planetary-gear units in table A, GS-criteria stage 10
or higher applies, and high grey-staining resistance GST = high
b) for all other gear units in tables B and C, GS-criteria stage 9 or higher applies
S Low degree of foaming with less than 15 % foam formation in the FLENDER foam test
S Compatibility with elastomer materials of the radial shaft-sealing rings applied in FLENDER gear units
S Compatibility with residues of corrosion-protection agent and run-in oils used by FLENDER
S Compatibility with the paints used by FLENDER in its gear-unit interiors
S Compatibility with liquid seals between bolted-joint surfaces.
For use in worm-gear units moreover:
S Low wear, high pitting resistance and high efficiency (low temperature) in the cylindrical worm-gear
unit test
Note: The use of gear oils which do not comply with the above quality requirements
invalidate the FLENDER product guarantee obligation. Please note that every oil
manufacturer or supplier is responsible for the quality of his product.
Always select the gear oil in accordance with the oil group and viscosity class indicated on the rating
plate on the gear unit. If a different viscosity is selected, or oil of a type other than those recommended
in these instructions, the operator assumes the responsibility for its technical suitability. In order to
minimise the technical risk in such a case, the oil applied must be at least CLP oil quality to
DIN 51 517-3, which should be confirmed by the oil manufacturer.
The oil group and oil viscosity indicated on the rating plates as well as the
Caution! instructions in the gear-unit operating instructions must be adhered to.
Deviations are permitted only after consultation with FLENDER!
BA 7300 EN 01.05

1.1.1 Oil groups
In tables A, B and C five oil groups are distinguished:
S Mineral oils (MIN oil)
S Polyglycol (PG oil)
S Poly-a olefin (PAO oil)
S Biologically degradable oils (BIO oil)
S Physiologically safe oils approved in accordance with USDA H1 (PHY oil).
1.1.2 Oil temperatures
The synthetic oils have a wider temperature range and a higher viscosity index (i.e. a flatter
viscosity-temperature gradient) than the mineral oils. Guideline values for temperature range:
mineral oils approx. –10 °C to +90 °C (short term +100 °C);

polyglycols and poly-a olefins approx. –20 °C to +100 °C (short term +110 °C);
bio-degradable oils (synthetic Ester) approx. –15 to +90 °C.
Note: The upper and lower operating temperatures of certain gear oils may deviate widely
from the values indicated. For operating conditions outside the above mentioned
temperature ranges, the flash point and pour point of the oils must be observed. For
these and other data and properties of the gear oils, refer to the oil manufacturers’
technical data sheets (to this purpose Flender must be consulted).
1.1.3 General oil service lives
According to the manufacturers, the following are the minimum periods during which the oils can be
used without undergoing any significant change in quality. They are calculated on the basis of an
average oil temperature of 80 °C:
– mineral oils, bio-degradable oils and physiologically safe oils: 2 years or 10 000 hours of service
– for poly-a olefins and polyglycols: 4 years or 20 000 hours of service.
Note: The actual service lives may be higher or lower (for temperatures over 80 °C). The
general rule is that an increase in temperature of 10 K will halve the service life.
1.1.4 Oil change
The degree of purity of the oil affects the operating reliability and life span of the oil and the gear unit.
It should therefore be ensured that the oil in the gear unit is clean. For the first oil change after start-up
and for subsequent oil changes, the specifications in the gear-unit operating instructions must be
observed. In the case of larger oil quantities, an analysis should be carried out before cleaning or
changing the oil.
When changing oil of the same type, the quantity of oil remaining in the gear unit should be kept as low
as possible. Generally speaking, a small remaining quantity will cause no particular problems. Gear oils
of different types and manufacturers must not be mixed. If necessary, the manufacturer should confirm
that the new oil is compatible with residues of the old oil. When changing to very different types of oil
or oils with very different additives, especially when changing from polyglycols to another gear oil or vice
versa, the gear unit must always be well flushed out with the new oil. Residues of old oil must be
completely removed from the gear unit.
Gear oils must never be mixed with other substances. Flushing with paraffin or
Caution! other solvents is not permitted, as traces of these substances always remain
inside the unit.
BA 7300 EN 01.05

Table A Lubricating oils for FLENDER helical-gear, bevel helical-gear and planetary-gear units
Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
A11 VG 1000
CLP 680 S Degol BG 680 Plus

A12 VG 680 ECO GEAR 680 M Degol BMB 680 1)
GEAR RSX 680

GEAR RSX 460
Mineral oils CLP 320 S Degol BG 320 Plus
GEAR RSX 320
(MIN oil)
GEAR RSX 220

GEAR RSX 150
Degol BG 100 Plus

A17 VG 100 ECO GEAR 100 M
Degol BMB 100 1)
GEAR RSX 100
A21 VG 1000 Degol GS 1000
A22 VG 680 Degol GS 680 GEAR VSG 680

Polyglycol
(PG oil)
A27 VG 100 GEAR VSG 100
4111 XEP
A31 VG 1000 5999 XEP
SYNTOGEAR PE 1000
4680 XEP SYNTOGEAR PE 680

A32 VG 680 ECO GEAR 680 S
5680 XEP EVOGEAR SX 680
5460 XEP
Degol PAS 460
EVOGEAR SX 460
Poly-a-
olefin A34 VG 320 ECO GEAR 320 S
4320 XEP
Degol PAS 320
SYNTOGEAR PE 320
(PAO oil) 4220 XEP SYNTOGEAR PE 220
5220 XEP
Degol PAS 220
EVOGEAR SX 220
4150 XEP
5150 XEP
Degol PAS 150 SYNTOGEAR PE 150
A37 VG 100 ECO GEAR 100 S 4100 XEP SYNTOGEAR PE 100
A41 VG 1000
A42 VG 680
Biologically A43 VG 460

degradable
oils A44 VG 320
(BIO oil) A45 VG 220
A46 VG 150
A47 VG 100
A51 VG 1000
A52 VG 680
A53 VG 460
Physiologically
safe oils A54 VG 320
(PHY oil)
A55 VG 220
A56 VG 150
A57 VG 100
1) with solid content MoS2
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
A11 VG 1000 Beslux Gear XP 1000
A12 VG 680 Energol GR-XF 680 Beslux Gear XP 680

Mineral oils
(MIN oil)
A16 VG 150 Energol GR-XF 150
A17 VG 100
A21 VG 1000 Beslux Sincart W 1000
BERUSYNTH
A22 VG 680 EP 680
Enersyn SG-XP 680 Beslux Sincart W 680
BERUSYNTH
A23 VG 460 EP 460
Polyglycol BERUSYNTH
A24 VG 320 EP 320
(PG oil)
BERUSYNTH
A25 VG 220 EP 220
BERUSYNTH
A26 VG 150 EP 150
BERUSYNTH
A27 VG 100 EP 100
Enersyn SG-XP 100
Bel-Ray Beslux Gearsint

A31 VG 1000 Synth. Gear Oil 6698 XP 1000
A32 VG 680 Synth. Gear Oil 6696 XP 680
A33 VG 460 Synth. Gear Oil 6694
Enersyn EP-XF 460
XP 460
Poly-a-
olefin A34 VG 320
Bel-Ray
Enersyn EP-XF 320
Beslux Gearsint
Synth. Gear Oil 6692 XP 320
(PAO oil) Bel-Ray Beslux Gearsint
Enersyn EP-XF 220
XP 220
Enersyn EP-XF 150
XP 150
A37 VG 100 Enersyn EP-XF 100
A41 VG 1000
A42 VG 680

degradable
oils A44 VG 320
A46 VG 150
A47 VG 100
A51 VG 1000
A52 VG 680
A53 VG 460
Physiologically
(PHY oil)
A55 VG 220
A56 VG 150
A57 VG 100
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s) classic performance
Optigear BM 1000 CEPSA
A11 VG 1000 Alpha SP 1000
Tribol 1100 / 1000 AEROGEAR 1000
Optigear BM 680 CEPSA
A12 VG 680 Alpha SP 680
Tribol 1100 / 680 AEROGEAR 680
Alpha SP 460 Optigear BM 460 CEPSA
A13 VG 460 Alpha MAX 460 Tribol 1100 / 460 AEROGEAR 460
Mineral oils Alpha SP 320 Optigear BM 320 CEPSA
(MIN oil)
Alpha SP 150 Optigear BM 150
A16 VG 150 Alpha MAX 150 Tribol 1100 / 150
A17 VG 100 Alpha MAX 100 Tribol 1100 / 100
A21 VG 1000 Tribol 800 / 1000
A22 VG 680 Tribol 800 / 680
A23 VG 460 Tribol 800 / 460

Polyglycol
A24 VG 320 Tribol 800 / 320
(PG oil)
A25 VG 220 Tribol 800 / 220
A26 VG 150 Tribol 800 / 150
A27 VG 100 Tribol 800 / 100
A31 VG 1000
AEROGEAR
A32 VG 680 Alphasyn EP 680
SYNT 680
Optigear Synth. A 460 Optigear Synth. X 460 AEROGEAR
A33 VG 460 Alphasyn EP 460 Tribol 1710 / 460 SYNT 460
Poly-a-
olefin A34 VG 320
Alphasyn EP 320 Tribol 1710 / 320 SYNT 320
(PAO oil) Optigear Synth. A 220 Optigear Synth. X 220 AEROGEAR
A35 VG 220 Alphasyn EP 220 Tribol 1710 / 220 SYNT 220
A36 VG 150 Alphasyn EP 150
A37 VG 100
A41 VG 1000
RIVOLTA
A42 VG 680 S.G.L. 680
Tribol BioTop
Biologically A43 VG 460 1418 / 460
degradable RIVOLTA Tribol BioTop
oils A44 VG 320 S.G.L. 320 1418 / 320
RIVOLTA Tribol BioTop
(BIO oil) A45 VG 220 S.G.L. 220 1418 / 220
Tribol BioTop
A46 VG 150 1418 / 150
RIVOLTA
A47 VG 100 S.G.L. 100
A51 VG 1000
A52 VG 680 Optileb GT 680

Physiologically
safe oils A54 VG 320 Optileb GT 320
(PHY oil)
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
A11 VG 1000 RENOLIN CLP1000 PLUS
RENOLIN CLP 680

A12 VG 680 SPARTAN EP 680 3)
RENOLIN CLP 680 PLUS
RENOLIN CLP 460
A13 VG 460 EP Industrial G 460 SPARTAN EP 460 3)
Mineral oils RENOLIN CLP 320
(MIN oil)
RENOLIN CLP 220
RENOLIN CLP 150
RENOLIN CLP 100
A21 VG 1000 Breox SL 1000 RENOLIN PG 1000

Polyglycol
(PG oil)
A27 VG 100 RENOLIN PG 100
A31 VG 1000
A32 VG 680 RENOLIN UNISYN

CLP 680

Poly-a- CLP 460
olefin A34 VG 320 RENOLIN UNISYN
CLP 320
(PAO oil) RENOLIN UNISYN
A35 VG 220 CLP 220

CLP 150

CLP 100
A41 VG 1000 PLANTOGEAR

1000 S

680 S

Biologically 460 S
degradable PLANTOGEAR
oils A44 VG 320 320 S
PLANTOGEAR
(BIO oil) A45 VG 220 220 S

150 S

100 S
A51 VG 1000 Breox FGL 1000 2)
A52 VG 680 Breox FGL 680 2)

Physiologically
safe oils A54 VG 320 Breox FGL 320 2)
(PHY oil)
A57 VG 100
2) PG oil
3) ESSO guarantees the qualities required by FLENDER only for products from Europe
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
GEARMASTER
A11 VG 1000 CLP 1000
GEARMASTER Klüberoil
A12 VG 680 CLP 680 GEM 1 - 680 N
A13 VG 460 CLP 460 GEM 1 - 460 N
Mineral oils GEARMASTER Klüberoil
A14 VG 320 CLP 320 GEM 1 - 320 N
(MIN oil)
A15 VG 220 CLP 220 GEM 1 - 220 N
A16 VG 150 CLP 150 GEM 1 - 150 N
A17 VG 100 CLP 100 GEM 1 - 100 N
GEARMASTER Klübersynth.
A21 VG 1000 PGP 1000
Ucolub BSL-IG 1000
GH 6 - 1000
A22 VG 680 PGP 680
Ucolub BSL-IG 680
GH 6 - 680
A23 VG 460 PGP 460
Ucolub BSL-IG 460
GH 6 - 460
Polyglycol GEARMASTER Klübersynth.
A24 VG 320 PGP 320
Ucolub BSL-IG 320
GH 6 - 320
(PG oil)
A25 VG 220 PGP 220
Ucolub BSL-IG 220
GH 6 - 220
A26 VG 150 PGP 150
Ucolub BSL-IG 150
GH 6 - 150
GEARMASTER
A27 VG 100 PGP 100
Ucolub BSL-IG 100
GEARMASTER
A31 VG 1000 SYN 1000
A32 VG 680 SYN 680 GEM 4 - 680 N
GEARMASTER Galp Transgear Klübersynth.
A33 VG 460 SYN 460
Ucolub N-PA 460
SMP 460 GEM 4 - 460 N
Poly-a-
olefin A34 VG 320
GEARMASTER
Ucolub N-PA 320 Galp Transgear Klübersynth.
SYN 320 SMP 320 GEM 4 - 320 N
(PAO oil) GEARMASTER Galp Transgear Klübersynth.
A35 VG 220 SYN 220
Ucolub N-PA 220
SMP 220 GEM 4 - 220 N
A36 VG 150 SYN 150 SMP 150 GEM 4 - 150 N
GEARMASTER
A37 VG 100 SYN 100
GEARMASTER
A41 VG 1000 ECO 1000
GEARMASTER
A42 VG 680 ECO 680
GEARMASTER
Biologically A43 VG 460 ECO 460
degradable GEARMASTER Klübersynth.
oils A44 VG 320 ECO 320 GEM 2 - 320
(BIO oil) A45 VG 220 ECO 220 GEM 2 - 220
GEARMASTER
A46 VG 150 ECO 150
GEARMASTER
A47 VG 100 ECO 100
A51 VG 1000 Ucolub BSL 1000 4)

Physiologically
safe oils A54 VG 320 Ucolub BSL 320 4)
(PHY oil)
A57 VG 100
4) PG oil
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
GEAR COMPOUND
A11 VG 1000 PLUS 1000
609 ALMASOL Vari- GEAR COMPOUND
A12 VG 680 Purpose Gear Lubricant
Mobilgear XMP 680
PLUS 680
Mobilgear XMP 460
PLUS 460
Mineral oils 605 ALMASOL Vari- GEAR COMPOUND
Mobilgear XMP 320
PLUS 320
(MIN oil)
Mobilgear XMP 220
PLUS 220
Mobilgear XMP 150
PLUS 150
Mobilgear XMP 100
PLUS 100
A21 VG 1000
A22 VG 680
A23 VG 460
Polyglycol
A24 VG 320
(PG oil)
A25 VG 220
A26 VG 150
A27 VG 100
GEAR SINTEC
A31 VG 1000 Mobil SHC 639
CLP 1000
megol Gearoil Synth GEAR SINTEC
A32 VG 680 680
Mobilgear SHC XMP680
CLP 680
megol Gearoil Synth Mobil SHC 634 GEAR SINTEC
A33 VG 460 460 Mobilgear SHC XMP460 CLP 460
Poly-a-
olefin A34 VG 320
320 Mobilgear SHC XMP320 CLP 320
(PAO oil) megol Gearoil Synth Mobil SHC 630 GEAR SINTEC
A35 VG 220 220 Mobilgear SHC XMP220 CLP 220
Mobil SHC 629 GEAR SINTEC
A36 VG 150 Mobilgear SHC XMP150 CLP 150
GEAR SINTEC
A37 VG 100 CLP 100
A41 VG 1000
A42 VG 680

degradable
oils A44 VG 320
A46 VG 150
A47 VG 100
A51 VG 1000
A52 VG 680
A53 VG 460
Physiologically
(PHY oil)
A55 VG 220
A56 VG 150
A57 VG 100
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
A11 VG 1000 OMV gear HST 1000 PO Gravis MP 1000
TRANSOL
A12 VG 680 OMV gear HST 680
PREMIUM 680 PO Gravis MP 680
TRANSOL
PREMIUM 460 PO Gravis MP 460
Mineral oils TRANSOL
PREMIUM 320 PO Gravis MP 320 Q8 Goya NT 320
(MIN oil)
TRANSOL
PREMIUM 220 PO Gravis MP 220 Q8 Goya NT 220
A16 VG 150 OMV gear HST 150 PO Gravis MP 150 Q8 Goya NT 150
A17 VG 100 OMV gear HST 100 PO Gravis MP 100
A21 VG 1000
A22 VG 680
A23 VG 460
Polyglycol
A24 VG 320
(PG oil)
A25 VG 220
A26 VG 150
A27 VG 100
TRANSGEAR
A31 VG 1000 PE 1000 PO Gravis SP 1000
TRANSGEAR
A32 VG 680 PE 680 PO Gravis SP 680
TRANSGEAR
A33 VG 460 PE 460 PO Gravis SP 460 Q8 El Greco 460
Poly-a-
olefin A34 VG 320
TRANSGEAR
PO Gravis SP 320 Q8 El Greco 320
PE 320
(PAO oil) TRANSGEAR
A35 VG 220 PE 220 PO Gravis SP 220 Q8 El Greco 220
A36 VG 150 Q8 El Greco 150
A37 VG 100
A41 VG 1000
A42 VG 680

degradable
oils A44 VG 320
A46 VG 150
A47 VG 100
A51 VG 1000
A52 VG 680
A53 VG 460
Physiologically
(PHY oil)
A55 VG 220
A56 VG 150
A57 VG 100
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s) TEXACO
KASSILLA GMP 1000
A11 VG 1000 CARTER EP 1000
KASSILLA GMP 680
A12 VG 680 LoadWay EP 680
CARTER EP 680
Meropa WM 460 KASSILLA GMP 460
A13 VG 460 Shell Omala F 460 LoadWay EP 460
Auriga EP 460 CARTER EP 460
Mineral oils Meropa WM 320 KASSILLA GMP 320
(MIN oil)
Meropa WM 220 KASSILLA GMP 220
A16 VG 150 Meropa WM 150

Auriga EP 150
A17 VG 100 Meropa WM 100

Auriga EP 100
Shell Tivela S 1000
A21 VG 1000 Shell Cassida WG 1000
Shell Tivela S 680
Shell Tivela S 460
Polyglycol Shell Tivela S 320
(PG oil)
Shell Tivela S 220
Shell Tivela S 150
A27 VG 100
A31 VG 1000 CARTER SH 1000
A32 VG 680 Shell Omala HD 680 CARTER SH 680
A33 VG 460 Shell Omala HD 460 CARTER SH 460

Poly-a-
olefin A34 VG 320 Shell Omala HD 320 MERETA 320 CARTER SH 320
(PAO oil)
A35 VG 220 Shell Omala HD 220 MERETA 220 CARTER SH 220
A36 VG 150 Shell Omala HD 150 MERETA 150 CARTER SH 150
A37 VG 100
A41 VG 1000
A42 VG 680
Biologically A43 VG 460 Shell Omala EPB 460

degradable
oils A44 VG 320 Shell Omala EPB 320
(BIO oil) A45 VG 220 Shell Omala EPB 220
A46 VG 150 Shell Omala EPB 150
A47 VG 100 Shell Omala EPB 100
Shell Cassida WG 1000

A51 VG 1000 5)

A52 VG 680 5)
Shell Cassida WG 460 Keystone Nevastane

A53 VG 460 5) SY 460 5)
Physiologically
Shell Cassida WG 320 Keystone Nevastane
5) SY 320 5)
(PHY oil) Shell Cassida WG 220 Keystone Nevastane
A55 VG 220 5) SY 220 5)
A56 VG 150
A57 VG 100
5) PG oil
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
VECO MATRANOL
A11 VG 1000 XP 1000
VECO MATRANOL
A12 VG 680 TUNGEAR 680 6) COMPOUND MP 680
XP 680
VECO MATRANOL
XP 460
Mineral oils VECO MATRANOL
XP 320
(MIN oil)
VECO MATRANOL
XP 220
A16 VG 150 COMPOUND MP 150
A17 VG 100
A21 VG 1000
A22 VG 680
A23 VG 460
Polyglycol
A24 VG 320
(PG oil)
A25 VG 220
A26 VG 150
A27 VG 100
A31 VG 1000
A32 VG 680
A33 VG 460
Poly-a-
olefin A34 VG 320
(PAO oil)
A35 VG 220
A36 VG 150
A37 VG 100
A41 VG 1000
A42 VG 680

degradable
oils A44 VG 320
A46 VG 150
A47 VG 100
A51 VG 1000
A52 VG 680
A53 VG 460
Physiologically
(PHY oil)
A55 VG 220
A56 VG 150
A57 VG 100
6) TUNGEAR is approved for Brazil under the name of GEAROIL in VG 220, 320, 460 and 680. Distributor: TRIBOTECHNICA Lubrificantes Sinteticos Sao Paulo.
TUNGEAR is approved for India under the name of Mox-Active Gear oil in VG 220, 320 and 460. Distributor: OKS Speciality Lubricants Bombay.
BA 7300 EN 01.05

Table B Lubricating oils for FLENDER worm-gear units
Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
B11 VG 1000 Energol GR-XP 1000
B12 VG 680 Degol BG 680 Energol GR-XP 680

Mineral oils
(MIN oil)
B21 VG 1000 Degol GS 1000
B22 VG 680 Degol GS 680 GEAR VSG 680 BERUSYNTH Enersyn SG-XP 680
EP 680
EP 460
B24 VG 320 Degol GS 320 GEAR VSG 320
EP 320
Enersyn SG-XP 320
(PG oil)
EP 220
EP 150
B27 VG 100 GEAR VSG 100 BERUSYNTH Enersyn SG-XP 100

EP 100
B31 VG 1000
B32 VG 680
B33 VG 460
Poly-a-
olefin B34 VG 320
(PAO oil)
B35 VG 220
B36 VG 150
B37 VG 100
B41 VG 1000
B42 VG 680
Biologically B43 VG 460

degradable
oils B44 VG 320
(BIO oil) B45 VG 220
B46 VG 150
B47 VG 100
B51 VG 1000
B52 VG 680
B53 VG 460
Physiologically
safe oils B54 VG 320
(PHY oil)
B55 VG 220
B56 VG 150
B57 VG 100
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s) performance
Optigear BM 1000
B11 VG 1000 Tribol 1100 / 1000
Optigear BM 680
B12 VG 680 SPARTAN EP 680 1)
Tribol 1100 / 680
Optigear BM 460
Tribol 1100 / 460
Mineral oils Optigear BM 320
Tribol 1100 / 320
(MIN oil)
Optigear BM 220
Tribol 1100 / 220
Optigear BM 150
Tribol 1100 / 150
Optigear BM 100
Tribol 1100 / 100
Optiflex A 1000
B21 VG 1000 Tribol 800 / 1000
Breox SL 1000 RENOLIN PG 1000
Optiflex A 680
B22 VG 680 Tribol 800 / 680
Optiflex A 460
B23 VG 460 Tribol 800 / 460
Polyglycol Optiflex A 320
B24 VG 320 Tribol 800 / 320
(PG oil)
Optiflex A 220
B25 VG 220 Tribol 800 / 220
Optiflex A 150
B26 VG 150 Tribol 800 / 150
Optiflex A 100
B27 VG 100 Tribol 800 / 100
RENOLIN PG 100
B31 VG 1000
B32 VG 680
B33 VG 460
Poly-a-
olefin B34 VG 320
(PAO oil)
B35 VG 220
B36 VG 150
B37 VG 100
B41 VG 1000
B42 VG 680

degradable
oils B44 VG 320
B46 VG 150
B47 VG 100
B51 VG 1000 Breox FGL 1000 2)
Tribol FoodProof
B52 VG 680 Breox FGL 680 2)
1800 / 680 2)
Tribol FoodProof
Physiologically 1800 / 460 2)
Tribol FoodProof
Breox FGL 320 2)
1800 / 320 2)
(PHY oil) Tribol FoodProof
1800 / 220 2)
B57 VG 100
2) PG oil
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
B11 VG 1000
B12 VG 680 Klüberoil Mobilgear 636

GEM 1 - 680 N Mobilgear XMP 680

Mineral oils Klüberoil Mobilgear 632
B14 VG 320 GEM 1 - 320 N Mobilgear XMP 320
(MIN oil)


GEARMASTER SYNTHESO Shell Tivela S 1000
B21 VG 1000 PGP 1000 D 1000 EP Shell Cassida WG 1000
Polyglycol GEARMASTER SYNTHESO Shell Tivela S 320
(PG oil)
GEARMASTER SYNTHESO
B26 VG 150 PGP 150 D 150 EP
Shell Tivela S 150
GEARMASTER SYNTHESO
B27 VG 100 PGP 100 D 100 EP
B31 VG 1000
B32 VG 680
B33 VG 460
Poly-a-
olefin B34 VG 320
(PAO oil)
B35 VG 220
B36 VG 150
B37 VG 100
B41 VG 1000
B42 VG 680

degradable
oils B44 VG 320
B46 VG 150
B47 VG 100

B51 VG 1000 3)

B52 VG 680 3)

B53 VG 460 3)
Physiologically
3)
(PHY oil) Shell Cassida WG 220

B55 VG 220 3)
B56 VG 150
B57 VG 100
3) PG oil
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
B11 VG 1000
B12 VG 680 Ersolan 680

Mineral oils
(MIN oil)
B21 VG 1000
B22 VG 680
B23 VG 460
Polyglycol
B24 VG 320
(PG oil)
B25 VG 220
B26 VG 150
B27 VG 100
B31 VG 1000
B32 VG 680
B33 VG 460
Poly-a-
olefin B34 VG 320
(PAO oil)
B35 VG 220
B36 VG 150
B37 VG 100
B41 VG 1000
B42 VG 680

degradable
oils B44 VG 320
B46 VG 150
B47 VG 100
B51 VG 1000
B52 VG 680
B53 VG 460
Physiologically
(PHY oil)
B55 VG 220
B56 VG 150
B57 VG 100
BA 7300 EN 01.05

Table C Lubricating oils for FLENDER gear motors
Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
C15 VG 220 ECO GEAR 220 M Degol BG 220 1) GEAR RSX 220
Mineral oils CLP 150 S Degol BG 150 Plus
(MIN oil)
Degol BG 100 Plus
C23 VG 460 Degol GS 460 GEAR VSG 460

Polyglycol
(PG oil)

C33 VG 460 ECO GEAR 460 S 5460 XEP Degol PAS 460 EVOGEAR SX 460
Poly-a-
olefin C34 VG 320 ECO GEAR 320 S
4320 XEP
Degol PAS 320
SYNTOGEAR PE 320
(PAO oil) 4220 XEP SYNTOGEAR PE 220
C35 VG 220 ECO GEAR 220 S 5220 XEP Degol PAS 220 EVOGEAR SX 220
Biologically C44 VG 320

degradable
oils C45 VG 220
(BIO oil) C46 VG 150
C53 VG 460
Physiologically
safe oils C54 VG 320
(PHY oil)
C55 VG 220

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
Energol GR-XF 220 Beslux Gear
C15 VG 220 Energol GR-XP 220 XP 220
Mineral oils
C16 VG 150 Energol GR-XF 150
(MIN oil)
C17 VG 100
BERUSYNTH
C23 VG 460 EP 460 Enersyn SG-XP 460 Beslux Sincart W 460
(PG oil)
BERUSYNTH

C33 VG 460 Synth. Gear Oil 6694
Enersyn EP-XF 460 XP 460
Poly-a-
olefin C34 VG 320
Bel-Ray
Enersyn EP-XF 320
Beslux Gearsint
Synth. Gear Oil 6692 XP 320
(PAO oil) Bel-Ray Beslux Gearsint
C35 VG 220 Synth. Gear Oil 6690
Enersyn EP-XF 220 XP 220

degradable
oils C45 VG 220
C53 VG 460
Physiologically
(PHY oil)
C55 VG 220
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s) classic performance
C15 VG 220 Alpha MAX 220 Tribol 1100 / 220 AEROGEAR 220
Mineral oils Alpha SP 150 Optigear BM 150
C16 VG 150 Alpha MAX 150 Tribol 1100 / 150
(MIN oil)
C17 VG 100 Alpha MAX 100 Tribol 1100 / 100
Optiflex A 460
C23 VG 460 Tribol 800 / 460
Polyglycol Optiflex A 320
C24 VG 320 Tribol 800 / 320
(PG oil)
Optiflex A 220
C25 VG 220 Tribol 800 / 220
C33 VG 460 Alphasyn EP 460 Tribol 1710 / 460 SYNT 460
Poly-a-
olefin C34 VG 320
Alphasyn EP 320 Tribol 1710 / 320 SYNT 320
(PAO oil) Optigear Synth. A 220 Optigear Synth. X 220 AEROGEAR
C35 VG 220 Alphasyn EP 220 Tribol 1710 / 220 SYNT 220
RIVOLTA Tribol BioTop
Biologically C44 VG 320 S.G.L. 320 1418 / 320
degradable RIVOLTA Tribol BioTop
oils C45 VG 220 S.G.L. 220 1418 / 220
Tribol BioTop
(BIO oil) C46 VG 150 1418 / 150
Optileb GT 460
C53 VG 460 FoodProof 1800/460 2)
Physiologically
Optileb GT 320
FoodProof 1800/320 2)
(PHY oil) Optileb GT 220
C55 VG 220 FoodProof 1800/220 2)
2) PG oil

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
RENOLIN CLP 220
C15 VG 220 EP Industrial G 220 SPARTAN EP 220 3) RENOLIN CLP 220 PLUS
Mineral oils RENOLIN CLP 150
C16 VG 150 SPARTAN EP 150 3) RENOLIN CLP 150 PLUS
(MIN oil)
RENOLIN CLP 100
C17 VG 100 SPARTAN EP 100 3) RENOLIN CLP 100 PLUS
C23 VG 460 Breox SL 460 RENOLIN PG 460

Polyglycol
(PG oil)
C33 VG 460 RENOLIN UNISYN

Poly-a- CLP 460
olefin C34 VG 320 RENOLIN UNISYN
CLP 320
(PAO oil) RENOLIN UNISYN
C35 VG 220 CLP 220
C44 VG 320 PLANTOGEAR

Biologically 320 S
degradable PLANTOGEAR
oils C45 VG 220 220 S
PLANTOGEAR
(BIO oil) C46 VG 150 150 S
C53 VG 460 Breox FGL 460 4)

Physiologically
safe oils C54 VG 320 Breox FGL 320 4)
(PHY oil)
C55 VG 220 Breox FGL 220 4)
4) PG oil
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
C15 VG 220 CLP 220 GEM 1 - 220 N
Mineral oils GEARMASTER Klüberoil
C16 VG 150 CLP 150 GEM 1 - 150 N
(MIN oil)
C17 VG 100 CLP 100 GEM 1 - 100 N
GEARMASTER SYNTHESO
C23 VG 460 PGP 460 Ucolub BSL-IG 460
D 460 EP
Polyglycol GEARMASTER SYNTHESO
D 320 EP
(PG oil)
GEARMASTER SYNTHESO
D 220 EP
C33 VG 460 SYN 460 Ucolub N-PA 460
SMP 460 GEM 4 - 460 N
Poly-a-
olefin C34 VG 320
GEARMASTER
Ucolub N-PA 320 Galp Transgear Klübersynth.
SYN 320 SMP 320 GEM 4 - 320 N
(PAO oil) GEARMASTER Galp Transgear Klübersynth.
C35 VG 220 SYN 220 Ucolub N-PA 220
SMP 220 GEM 4 - 220 N
Biologically C44 VG 320 ECO 320 GEM 2 - 320
degradable GEARMASTER Klübersynth.
oils C45 VG 220 ECO 220 GEM 2 - 220
GEARMASTER
(BIO oil) C46 VG 150 ECO 150
C53 VG 460 Ucolub BSL 460 5)

Physiologically
safe oils C54 VG 320 Ucolub BSL 320 5)
(PHY oil)
C55 VG 220 Ucolub BSL 220 5)
5) PG oil

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
607 ALMASOL Vari- Mobilgear 630 GEAR COMPOUND
C15 VG 220 Purpose Gear Lubricant Mobilgear XMP 220 PLUS 220
Mineral oils 604 ALMASOL Vari- Mobilgear 629 GEAR COMPOUND
(MIN oil)
606 ALMASOL Vari- Mobilgear 627 GEAR COMPOUND
C23 VG 460
Polyglycol
C24 VG 320
(PG oil)
C25 VG 220

C33 VG 460 460 Mobilgear SHC XMP460 CLP 460
Poly-a-
olefin C34 VG 320
320 Mobilgear SHC XMP320 CLP 320
(PAO oil) megol Gearoil Synth Mobil SHC 630 GEAR SINTEC
C35 VG 220 220 Mobilgear SHC XMP220 CLP 220

degradable
oils C45 VG 220
C53 VG 460
Physiologically
(PHY oil)
C55 VG 220
BA 7300 EN 01.05

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s)
TRANSOL
C15 VG 220 OMV gear HST 220 PREMIUM 220 PO Gravis MP 220 Q8 Goya NT 220
Mineral oils
C16 VG 150 OMV gear HST 150 PO Gravis MP 150 Q8 Goya NT 150
(MIN oil)
C17 VG 100 OMV gear HST 100 PO Gravis MP 100
C23 VG 460
Polyglycol
C24 VG 320
(PG oil)
C25 VG 220
TRANSGEAR
C33 VG 460 PE 460 PO Gravis SP 460 Q8 El Greco 460
Poly-a-
olefin C34 VG 320
TRANSGEAR
PO Gravis SP 320 Q8 El Greco 320
PE 320
(PAO oil) TRANSGEAR
C35 VG 220 PE 220 PO Gravis SP 220 Q8 El Greco 220

degradable
oils C45 VG 220
C53 VG 460
Physiologically
(PHY oil)
C55 VG 220

Viscosity
Code ISO-VG
no. DIN 51519
Lubricant at 40 °C
(mm2/s) TEXACO
Shell Omala F 220 Meropa WM 220
C15 VG 220 Shell Omala 220
Ersolan 220 LoadWay EP 220 Auriga EP 220
Mineral oils Shell Omala F 150 Meropa WM 150
Ersolan 150 Auriga EP 150
(MIN oil)
Shell Omala F 100 Meropa WM 100
Ersolan 100 Auriga EP 100
Shell Tivela S 460
C23 VG 460 Shell Cassida WG 460
Polyglycol Shell Tivela S 320
(PG oil)
Shell Tivela S 220
C33 VG 460 Shell Omala HD 460

Poly-a-
olefin C34 VG 320 Shell Omala HD 320 MERETA 320
(PAO oil)
C35 VG 220 Shell Omala HD 220 MERETA 220
Biologically C44 VG 320 Shell Omala EPB 320

degradable
oils C45 VG 220 Shell Omala EPB 220
(BIO oil) C46 VG 150 Shell Omala EPB 150
Shell Cassida
C53 VG 460 WG 460 6)
Physiologically
Shell Cassida
WG 320 6)
(PHY oil) Shell Cassida
C55 VG 220 WG 220 6)
6) PG oil
BA 7300 EN 01.05

Viscosity
Kenn- ISO-VG
ziffer DIN 51519
Lubricant at 40 °C
(mm2/s)
KASSILLA GMP 220 VECO MATRANOL
C15 VG 220 CARTER EP 220
TUNGEAR 220 7) XP 220
COMPOUND MP 220
Mineral oils
C16 VG 150 COMPOUND MP 150
(MIN oil)
C17 VG 100
C23 VG 460
Polyglycol
C24 VG 320
(PG oil)
C25 VG 220
C33 VG 460 CARTER SH 460

Poly-a-
olefin C34 VG 320 CARTER SH 320
(PAO oil)
C35 VG 220 CARTER SH 220

degradable
oils C45 VG 220
Kestone Nevastane
C53 VG 460 SY 460 8)
Physiologically
Kestone Nevastane
SY 320 8)
(PHY oil) Kestone Nevastane
C55 VG 220 SY 220 8)
7) TUNGEAR is approved for Brazil under the name of GEAROIL in VG 220. Distributor: TRIBOTECHNICA Lubrificantes Sinteticos Sao Paulo.
TUNGEAR is approved for India under the name of Mox-Active Gear oil in VG 220. Distributor: OKS Speciality Lubricants Bombay.
8) PG oil
BA 7300 EN 01.05

1.2 Lubricating greases for gear units and rolling bearings
For special gear unit applications, grease lubrication of the gears and/or bearings may be necessary.
Note: Greases may be used only if their use is specified in the operating instructions for the
gear unit. The relubrication periods must be adhered to.
Gear greases are suitable for the lubrication of gears and bearings with closed gear units (e.g. small
gear units) and open drives with low peripheral speeds (e.g. for girth gears, racks).
As well as lubrication, rolling bearing greases are used for the special sealing of bearing points, e.g.
with vertical gear-unit connection shafts or against environmental action such as dust or water spray.
Note: In closed gear units with internal oil lubrication the gear oils must not be allowed to
mix with bearing greases.
Table D Lubricating greases for FLENDER gear units and rolling bearings
Consistency
Code
Lubricant no. NLGI class
DIN 51818
classic performance
G13 3 Viscogen 1)
G14 2
Gear greases
G15 1
(MIN-GF)
G16 0
Mineral oil base
Tribol 5000
G17 00 Optitemp OG 0
Aralub FDP 00 CLS Grease Longtime PD 00
G18 000 MA Mehrzweckfett 00
Rolling bearing H12 4

greases Energrease
(MIN-WF) H13 3 Aralub HL3 LS 3 Spheerol AP 3
Energrease Spheerol AP 2 Tribol 4020 / 220-2

Mineral oil base H14 2 Aralub HL2 LS 2 Spheerol EPL 2 Longtime PD 2
Lithium
saponification H15 1 Tribol 3785 2)

2) Mixture of mineral oil and PAO
Consistency
Code
DIN 51818
G13 3
G14 2
Gear greases
G15 1
(MIN-GF)
G16 0
Mineral oil base
MICROLUBE
G17 00 GB 00
G18 000

greases Renolit FWA 220
(MIN-WF) H13 3 Renolit H 443-HD 88
Renolit H 443-HD 88 LAGERMEISTER CENTOPLEX
Mineral oil base H14 2 Arcanol L 186 V 3) Renolit FWA 160 EP 2 GLP 402
Lithium
saponification H15 1
3) Li, Ca saponification
BA 7300 EN 01.05

Consistency
Code
DIN 51818
TEXACO
G13 3 Glissando FG 30 EP
G14 2
Gear greases
G15 1
(MIN-GF)
G16 0 Mobilux EP 004 Wiolub GFW
Mineral oil base
G17 00 Alvania GL 00 Marfak 00
G18 000

greases Alvania RL 3
(MIN-WF) H13 3 Mobilux EP 3
Alvania EP / LF 3
Alvania RL 2 Multifak 2
Mineral oil base H14 2 Mobilux EP 2
Alvania EP / LF 2 Wiolub LFK 2 Multifak 20
Lithium
saponification H15 1
Consistency
Code
DIN 51818
G13 3
G14 2
Gear greases
G15 1
(MIN-GF)
G16 0 Multis EP 0
Mineral oil base
G17 00 Multis EP 00
G18 000

greases Multis 3
(MIN-WF) H13 3 Multis EP 3
Multis 2
Mineral oil base H14 2 Multis EP 2
Lithium
saponification Multis 1
H15 1 Multis EP 1
BA 7300 EN 01.05

2. Lubricants for ZAPEX couplings
Note: For FLUDEX couplings, special lubricant recommendations apply.
According to manufacturer’s information the oils and greases listed in these operating instructions are
manufactured and supplied world-wide in the above-mentioned quality as required by FLENDER
(Exceptions: Observe footnotes in the tables).
2.1 Required oil and grease quality
For FLENDER ZAPEX couplings, only oils and greases containing active agents to DIN 51 517-3 for
increasing corrosion protection and resistance to ageing and for reducing wear in mixed-friction areas
are approved. The scuffing resistance of the oils in the FZG test to DIN 51 354-2 must comply with stage
12 or higher under A/8,3/90 test conditions.
In addition, the oils and greases must meet the following quality requirements specified by FLENDER:
S Compatibility with elastomer materials of the shaft-sealing rings
S Compatibility with liquid seals between bolted-joint surfaces.
Note: The use of lubricants which do not comply with the above quality requirements may
invalidate our product guarantee. Please note that every lubricant manufacturer or
supplier is responsible for the quality of his product.
Which lubricant to select always depends on the viscosity or NLGI class indicated in these operating
instructions. If a different viscosity or NLGI class or a lubricant of a type other than those recommended
in these instructions is used, the operator is responsible for its technical suitability. To minimise the
technical risk in such cases, we recommend using a lubricant of the above indicated quality, which
should be accompanied by a statement of suitability by the lubricant manufacturer.
The instructions given in the operating instructions for the couplings must be
Caution! observed!
Deviations are permitted only after consultation with FLENDER!
2.1.1 Oil and grease types
Note: The upper and lower limits for the operating temperatures (flash point, pour point) of
individual oils and greases may vary considerably. For these and other data and
properties of oils and greases, refer to the lubricant manufacturers’ technical data
sheets.
According to the manufacturers, the following are the minimum periods during which the oils or greases
can be used without undergoing any significant change in quality:
– with use at up to 70 °C after approx. 8 000 operating hours, max. 2 years,

with use at over 70 °C after approx. 3 000 operating hours, max. 1 year.
2.1.2 Oil and grease change
The degree of purity of the lubricant affects the operating reliability and life span of the lubricant and
the coupling. Care must always be taken that the oil or grease in the coupling is clean. For the first
lubricant change after start-up of the coupling and for subsequent lubricant changes, the specifications
in the operating instructions for the coupling must be observed. With larger lubricant quantities, an
anlysis should be carried out to find out whether cleaning or changing is required.
When changing lubricant of the same type, the quantity of lubricant remaining in the coupling should
be kept as low as possible. Generally speaking, a small remaining quantity will cause no particular
problems. Lubricants of different types and manufacturers must not be mixed together. If necessary,
confirmation that the new lubricant is compatible with residues of the old lubricant should be obtained
from the manufacturer.
Caution! Lubricants must never be mixed with other substances.
BA 7300 EN 01.05

Table E Oil: Viscosity Lubricating oils and lubricating greases for FLENDER ZAPEX couplings
in cSt at 40 °C
Code DIN 51519
Lubricant no. Grease:
Consistency
DIN 51818
I11 VG 1000
class
s
CLP 680 S
Mineral oils I12 VG 680 ECO GEAR 680 M Degol BG 680 Plus GEAR RSX 680 Energol GR-XF 680
ISO cla
CLP 460 S
(MIN oil) I13 VG 460 ECO GEAR 460 M Degol BG 460 Plus GEAR RSX 460 Energol GR-XF 460
IS
I14 VG 320
Liquefied J15 1
greases
NLGII class
cl ss
J16 0 Aralub Fließfett AN 0

(MIN-FLF)
Energrease
J17 00 LS-EP 00
NL
Mineral oil
base J18 000
in cSt at 40 °C
Code DIN 51519
Consistency
DIN 51818 classic performance
CEPSA
I11 VG 1000 AEROGEAR 1000
class
s
Beslux gear Tribol 1100 / 680 CEPSA

Mineral oils I12 VG 680 XP 680 Alpha SP 680 Optigear BM 680 AEROGEAR 680
ISO cla
Beslux gear Alpha SP 460 Tribol 1100 / 460 CEPSA

(MIN oil) I13 VG 460 XP 460 Alpha MAX 460 Optigear BM 460 AEROGEAR 460
IS
I14 VG 320
Liquefied J15 1
greases
ss
class
J16 0
NLGII cl
(MIN-FLF)
Tribol 3020/1000-00
J17 00 Longtime PD 00
NL
Mineral oil CLS Grease

base J18 000
in cSt at 40 °C
Code DIN 51519
Consistency
DIN 51818
I11 VG 1000
ISO class
cla s
Renolin EPX 680

Mineral oils I12 VG 680 SPARTAN EP 680 1) Renolin CLP 680 PLUS
Renolin EPX 460
(MIN oil) I13 VG 460 EP Industrial 460 SPARTAN EP 460 1) Renolin CLP 460 PLUS
IS
I14 VG 320
Liquefied J15 1
greases
class
ss
J16 0
NLGII cl
(MIN-FLF) FLENDER
Hochleistungsfett RENOLIT
J17 00 SO-D 6024
NL
Mineral oil
base J18 000
BA 7300 EN 01.05

in cSt at 40 °C
Code DIN 51519
Consistency
DIN 51818
I11 VG 1000
class
s
GEARMASTER STRUCTOVIS 609 ALMASOL Vari- Mobilgear 636
Mineral oils I12 VG 680 CLP 680 BHD-MF Purpose Gear Lubricant Mobilgear XMP 680
ISO cla
GEARMASTER 608 ALMASOL Vari- Mobilgear 634
(MIN oil) I13 VG 460 CLP 460 Purpose Gear Lubricant Mobilgear XMP 460
IS
I14 VG 320
Liquefied J15 1
greases
NLGII class
cl ss
J16 0
GRAFLOSKON
(MIN-FLF) C-SG 500 Plus
J17 00 Mobilux EP 004
NL
Mineral oil
base J18 000
in cSt at 40 °C
Code DIN 51519
Consistency
DIN 51818
I11 VG 1000 PO Gravis MP 1000

class
s
I12 VG 680 GEAR COMPOUND OMV gear HST 680 PO Gravis MP 680 Shell Omala 680
Mineral oils PLUS 680
ISO cla
GEAR COMPOUND Shell Omala 460

(MIN oil) I13 VG 460 PLUS 460
OMV gear HST 460 PO Gravis MP 460 Shell Omala F 460
IS
I14 VG 320 PO Gravis MP 320
Liquefied J15 1
greases
ss
class
J16 0
NLGII cl
(MIN-FLF)
J17 00 Alvina GL 00
NL
Mineral oil
base J18 000
in cSt at 40 °C
Code DIN 51519
Consistency
DIN 51818 TEXACO
VECO MATRANOL
I11 VG 1000 XP 1000
ISO class
cla s
VECO MATRANOL
Mineral oils I12 VG 680 TUNGEAR 680 2) XP 680
Meropa WM 460 VECO MATRANOL
(MIN oil) I13 VG 460 Auriga EP 460 TUNGEAR 460 2) XP 460
IS
I14 VG 320 LoadWay EP 320
Liquefied J15 1
greases
class
ss
J16 0
NLGII cl
(MIN-FLF)
J17 00
NL
Mineral oil
base J18 000
2) TUNGEAR is approved for Brazil under the name of GEAROIL in VG 460 and 680. Distributor: TRIBOTECHNICA Lubrificantes Sinteticos Sao Paulo.
TUNGEAR is approved for India under the name of Mox-Active Gear oil in VG 460. Distributor: OKS Speciality Lubricants Bombay.
BA 7300 EN 01.05

in cSt at 40 °C
Code DIN 51519
Consistency
DIN 51818
I11 VG 1000
class
s
Mineral oils I12 VG 680
ISO cla
(MIN oil) I13 VG 460
IS
COMPOUND
I14 VG 320 MP 320
Liquefied J15 1
greases
NLGII class
cl ss
J16 0
(MIN-FLF)
J17 00
NL
Mineral oil
base J18 000
BA 7300 EN 01.05

Edition: March 2002
Oil drain cock B 5100 EN
(ball valve with full straightway) Page 1 of 2
These operating instructions are binding for oil drain plugs (ball valves with full straightway) to Flender Works
Standard W 5100.
Double nipple N8
to DIN EN 10242
Plug T9
to DIN EN 10242
Double parallel nipple and plug with thread sealed with hemp and Fermit.
Fig. 1: Ball valve, complete with double nipple and plug

Fig. 2: Component in sectional view
Nominal width Pipe Rated Threaded Weigh

of connection thread LW pressure d3 h1 h2 l1 l2 length l8 R SW t
DN d2 PN bar l3 kg
max. approx.
8 G 1/4 9 25 23,5 21 26 44,5 36 9,7 10 86 20,0 0,16
10 G 3/8 10 25 23,5 25 31 44,5 38 10,1 10 86 20,0 0,17
15 G 1/2 14 25 30,0 27 33 50,0 44 13,2 12 86 25,0 0,19
20 G 3/4 19 25 37,0 31 37 55,0 47 14,5 12 106 30,5 0,37
25 G1 25 25 45,0 35 41 66,0 53 16,8 14 106 37,5 0,58
32 G 1 1/4 32 25 56,5 45 51 80,0 57 19,1 17 148 46,5 0,92
40 G 1 1/2 40 25 70,0 53 60 90,0 59 19,1 17 148 54,0 1,35
50 G2 50 25 85,0 63 70 108,0 68 23,4 21 152 65,0 2,32
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Hesselmann ENDD

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 2002-03-04 Rev.:
Edition: March 2002
Oil drain cock B 5100 EN
(ball valve with full straightway) Page 2 of 2
Material: Housing: nickel-plated brass

Ball: chromium-plated brass
Valve key: galvanized steel with red plastic sheathing
Ball seal: Teflon (PTFE)
Double nipple: GTW35-V
Plug: GTW35-V
Operable temperature range: from -20 °C to max. +170 °C
If oil drain plugs are combined with screw connections, a suitable ring must be provided. This ring bridges the
too short thread in the oil drain plug and brings the screw connection into contact on the end face (see Fig. 3).
Oil drain cock
Double nipple
Ring e.g Cast iron screw connection
Fig. 3: Oil drain plug with double nipple, ring and cast iron screw connection

Edition: May 1995
B 5122 EN
Breather Page 1 of 1
These operating instructions are binding for breathers according to FLENDER works standard W 5122.
Mounting
The thread of the filter has to be coated with sealing compound LOCTITE 572 before screwing it into the female
thread.
∅F
H
SW
D
S
∅R
D SW L K H A F R S
R 1/4 22 8 23 35 19 28 8 16.5
R 1/2 22 12 26 38 19 28 10 17
R 3/4 27 14 32 46 25 32 18 23
Material: Stainless steel

Tubes made out of oil-resistant plastics
Temperature resistance: up to 120 °C
Design: Tapered thread acc. to DIN 2999 (Taper 1 : 16)
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Paul DOA

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 24.05.1995 Rev.:
Edition: March 2002
B 5926 EN

Page 1 of 2

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Edition: March 2002
B 5926 EN

Page 2 of 2

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Edition: March 2002
B 6100 EN
Resistance Thermometer Pt 100 Page 1 of 5
General
The electric resistance in the resistance thermometer sensor changes as the temperature fluctuates. This
change of resistance on the PT 100 or the converted output signal of the measuring transducer (4 to 20 mA)
can be used to measure temperature with an evaluating instrument or to define a switch point by means of limit
switches.
Operation
Pt 100 measuring thermometer sensor
The electrical conductivity of metal (here platinum) is based on the mobility of conduction electrons. As the
temperature rises, the movement of the atoms in the metal lattice about their rest position intensifies and so
obstructs the electrons flowing to the plus pole of a power source. This obstruction sets up a resistance in linear
proportion to the temperature.
To generate the output signal a constant test current (approx. 1 mA) is applied to the Pt 100. The resistance
in the Pt 100 causes a drop in voltage (U = R · l), which can be evaluated.
Measuring transducer
The two-wire measuring transducer is mounted in the J-head only if requested by the customer. It should be
noted that here only a single connection is possible.
The measuring transducer converts the temperature-dependent resistance to a standard uniform signal
of 4 to 20 mA. This signal can be transmitted over long distances without interference.
Technical Date - Pt 100

– Type of protection Terminal head: IP 65
– Tolerance class: DIN IEC 60751 Class B
(at 0 °C ±0.3 K, at 100 °C ±0.8 K)
– Ambient temperature range for J head: –20 °C to +100 °C
– Ambient temperature range for protective tube: –50 °C to +200 °C
– Test temperature range: –50 °C to +150 °C
Material
– Terminal head: GD-AlSi9Cu3
– Protective sleeve for measuring thermometer sensor: 1.4571
– Spring: wire DIN 2076-A-0.8 (stainless steel)
– Guide tube: 1.4571
– Terminal base: ceramic

– Adapter: 1.4301
– Gasket NBR (Perbunan)

Edition: March 2002
B 6100 EN
Technical data - Measuring transducer

– Measuring input: Pt 100 (DIN EN 60751)
– Measuring range: –50 °C to +150 °C
– Ambient temperature: –20 °C to +85 °C
– Terminal type: two-wire
– Minimum measuring range: 25 K
– Maximum measuring range: 1050 K
– Sensor line resistance with three-wire connection: ≤ 11 W per line
– Sensor line resistance with two-wire connection: 0 W per line resistance
– Sensor current: ≤ 0,5 mA
– Measuring rate: continuous measurement, as signal path analog
Measuring circuit monitoring system
– Drop below range: falling to ≤ 3.6 mA
– Rise over range: rising to ≥ 22 mA ... < 28 mA (typical 24 mA)
– Probe short circuit: ≤ 3,6 mA
– Probe and line break: positive: ≥ 22 mA ... < 28 mA (typical 24 mA)
negative: ≤ 3,6 mA
Output
– Output signal: impressed DC 4 ... 20 mA
– Transient response: temperature-linear
– Transmission accuracy: ≤ ± 0.1 %
– Attenuation of residual ripple of feed voltage: 40 dB
– Working resistance (Rb): RB =

– Influence of working resistance: ≤ ± 0,02 % / 100 W

relative to measuring range final value of 20 mA
– Adjustment time with temperature change: ≤ 10 ms
– Balancing conditions: DC 24 V / approx. 22 °C
– Balancing accuracy: ≤ ± 0.2 %
Voltage supply
– Voltage supply (Ub): DC 7.5 ... 30 V
– Pole confusion protection: yes
– Voltage supply influence: ≤ 0.01 % / V deviation of 24 V
Environmental influences
– Operating temperature range: –40 to +85 °C
– Temperature influence: ≤ 0.01 % / K deviation of 22 °C
– Climate resistance: rel. humidity ≤ 95 % on annual average without dew contact
– Vibration strength: acc. to GL characteristic 2
– EMV: EN 61326
Housing
– Material: Polycarbonate (encapsulated)
– Screw connection: ≤ 1.5 mm2
– Assembly: in terminal head Form J
– Mounting position: any
– Weight: approx. 12 g

Edition: March 2002
B 6100 EN
Connection
The customer can minimise measuring inaccuracies by using multiple wires. At Flender, as a rule, a 3- or 4-wire
arrangement from an additional terminal box is provided for (Fig. 1, 2). At the customer’s specific request, the
3/4-wire arrangement can be used from the J-head (Figure 4, 5). Through lack of space, however, the 4-wire
arrangement is possible only with a single connection (Fig. 5).
Customer Customer
Terminal box Terminal box
Resistance thermometer Resistance thermometer

Fig. 1: 3-wire arrangement Fig. 2: 4-wire arrangement
from terminal box from terminal box
Customer Customer Customer
Terminal Terminal Terminal

box box box
Resistance thermometer Resistance thermometer Resistance thermometer

Fig. 3: 2-wire circuit from Fig. 4: 3-wire circuit from Fig. 5: 4-wire circuit from
terminal head of Pt 100 terminal head of Pt 100 terminal head of Pt 100
Connection for measuring transducer
Connection for Connection values

Voltage supply

Current output Working resistance

Voltage supply
Analog inputs

Resistance thermometer
series W
in two-wire circuit
í

Edition: March 2002
B 6100 EN
Types
EL = Installation length ≈ 61
40 14 3
∅ 49
G 1/2A
∅8
25 SW 27
∅ 5.8
crimped in
O-rings
≈ 33
Guide tube
∅ 26.9-0.2
0
Measuring resistance Adapter
Pt 100 doubled SW 17
!et t" D#$ 3%&' M16 x 1.5
Terminal head IP 65
e(t)*e t+e,m"mete, - &1001
+5
EL-10 = Installation length ≈ 61
+5
25-10 50 14 3
10+5 Spring travel ∅ 49

SW 27
G 1/2A
∅8
Guide tube
∅ 5.8
Spring
crimped in
≈ 33
∅ 26.9-0.2
0

Pt 100 doubled
SW 17
!et t" D#$ 3%&'
M16 x 1.5
Terminal head IP 65
e(t)*e t+e,m"mete, - &1002
122
100 ≈ 61
14 3
G 1/2A
SW 27 SW 27 ∅ 49
∅ 9.5
Guide tube
Protective tube
≈ 33
26.9-0.2
0

Pt 100 doubled
∅
SW 17
!et t" D#$ 3%&'
Terminal head IP 65 M16 x 1.5
e(t)*e t+e,m"mete, - &1003

Edition: March 2002
B 6100 EN
NL = Nominal length
EL = Installation length 73 ≈ 74
40 14 62 8 Spring travel for clamp on
25 3
crimped in
SW 27 SW 18 SW 27
∅ 49
∅ 5.8
∅8
O-rings
≈ 33
∅ 26.9-0.2
Guide tube Adapter
G 1/2A
0 28
sprung
Measuring resistance screw connection
!et t" D#$ 3%&' Terminal head IP 65 M16 x 1.5
e(t)*e t+e,m"mete, - &1004
Adjustment by means of sprung screw connection
Housing
Terminal head
≈5
Measuring tip
Anti-friction bearing
A B C D
a) Insert guide tube ”A” into hole in housing until the measuring tip of the resistance thermometer makes
contact.
b) Screw screw connection ”B” into the housing as far as it will go.
c) Pull out screw connection ”C” approx. 5 mm towards the terminal head. Then lock nut ”D” with screw
connection ”C”. This ensures that the pretensioned spring keeps the measuring tip permanently in contact
with the part to be measured.

BA HYC.ANZ.000 EN
FLUTEC
Fluid Level Gauge
Fluid Level Sensor
Temperature Switch
FSA / FSK / TSE
up to size 381
up to PN 1 bar
up to T = 80 °C
1. DESCRIPTION 1.2. FUNCTION OF THE FSA 1.3. APPLICATION
1.1. GENERAL By using a FLUTEC FSA, the fluid FLUTEC fluid level gauges FSA,
level can be easily seen on the fluid level sensors FSK and
FLUTEC fluid level gauges FSA, outside of the tank. The fluid temperature switches TSE are
fluid level sensors FSK and enters the unit via the lower used to monitor and control levels
temperature switches TSE are connection bore and is clearly of operating fluid.
units which serve to monitor and visible in the tube. Selection of
control the level of operating fluid. Areas of application are
the correct size allows the for example:
The flexible product range means respective level of the fluid to be
that many combinations are Machine tools, system
monitored.
possible: engineering, hydraulic oil,
FUNCTION OF THE FSK lubricating oil and cutting oil tanks
– FSA: five sizes. By using a FLUTEC FSK, the fluid as well as gearboxes.
Visual thermometer with level is monitored via an electrical 1.4. NOTES
°C and °F scale. switching signal. This switching
signal can be used as an warning The upper viscosity limit is
Temperature gauge which records 2,000 mm²/s.
the temperature of the operating message or to regulate the fluid
fluid in the tank; display in °C. level. The fluid enters the unit via It is not possible to combine a
Dual scale in °C and °F is the lower connection bore and temperature switch TSE with an
available on request. pushes up a float in the tube. The FT temperature gauge.
float now shows the level of the FSA/FSK
Simple, standardised mounting
fluid in the tank. If the level of Not suitable for use with glycol or
conditions (FSA/K).
fluid drops again, the float fluids containing glycol.
– FSK: four sizes. activates a switching contact. To ensure correct functioning,
Switching contact can be either On type C the circuit is then pressure, viscosity and
type O (opens when fluid is at low closed and on type O the circuit temperature specifications must
level) or type C (closes when is then open. be observed.
fluid is at low level) or type W
The special dual switching model FSK
(dual switching unit)
(type W) offers two possibilities. Depending on the fluid level of the
Temperature gauge which records It can either be used to close on tank the following switching logic
the temperature of the operating contact or to open on contact. applies.
fluid in the tank; display in °C.
FUNCTION OF THE TSE
Dual scale in °C and °F is
available on request. The FLUTEC TSE is a very useful
additional option to the FSA and
Simple, standardised mounting Tank fluid level
FSK products. However, it also
conditions (FSA/K).
has a useful application as a
– TSE: three nominal temperatures separate build-on unit on
possible: 60 °C, 70 °C and 80 °C. systems.
Can be easily fitted into the FSA The temperature sensor of the
and FSK. (opens on
TSE, when fitted, is surrounded
contact)
Simple, standardised mounting by operating fluid. When the
conditions (FSA/K). nominal temperature is reached,
Non-corroding surfaces. a contact opens and the circuit is
broken. Tank fluid level
This switching process can be

used either as a warning
message or to monitor the
temperature.
When the temperature of the fluid (closes on
contact)
drops by approx. 20K, the circuit
closes again.
In the FSK type O the switching

contact opens when the fluid level
drops below the switching level.
Correspondingly, in the FSK type
C, the switching contact closes
when the fluid level drops below
the switching level.
2
2. TECHNICAL 2.1.2 Model code for FSA
SPECIFICATIONS (also order example)
2.1. GENERAL FSA - 076 - 2 . X / FT200 / 12
2.1.1 Designation and symbol
Fluid level gauge
Fluid level gauge FSA
Size
@ centre distance of bolts
076
127
176
254
381
Material of seals
2 = Viton (FKM)
1 = Perbunan (NBR)
Series
(determined by manufacturer)
Additional thermometer function
Fluid level sensor FSK
= no additional function
T = thermometer in display tube
FT 200 = temperature gauge 200 mm
TSE 60 = temperature switch nominal temperature 60 °C
Mounting
O - N/C contact
Banjo bolt thread
M 12 (standard)
M 10 (not on TSE)
Model code for FSK

(also order example)
FSK - 127 - 2 . X / C / FT200 / 12
C - N/O contact
Fluid level sensor

Size
@ centre distance of bolts
127
176
254
W - N/O or 381
N/C contact Material of seals
2 = Viton (FKM)
Temperature switch TSE
Series
(determined by manufacturer)
Switching function
O = opens at the switching level
C = closes at the switching level
W = opens or closes at the switching level
(form B plug)
Additional thermometer function

= no additional function
Mounting
Banjo bolt thread
M 12 (standard)
M 10 (not on TSE )
3
2.1.4 Type of construction
Model code for TSE
The units are designed to be
(also order example)
mounted directly on to the
TSE - 70 / X / 12 operating fluid tank.
2.1.5 Type of connection
Temperature switch FSA / FSK
TSE (with earth connection) The unit is mounted using two
banjo bolts. The connection
Nominal temperature
bores can either be threaded
60 °C
holes or clearance holes
70 °C
(Ø 13, Ø 11).
80 °C
TSE
Series The temperature switch can be
(determined by manufacturer) fitted to the FSA / FSK in place
of the lower banjo bolt.
Banjo bolt thread
M 12 2.1.6 Mounting position
FSA vertically
on the tank wall
2.1.3 Standard models FSK vertically
Type Size Order no. = Weight on the tank wall
@ centre distance of bolts stock no. [kg] (connection plug at
the bottom of the tank)
FSA-076-1.X/-/12 076 700 000 0.17
TSE optional
FSA-076-2.X/-/12 076 700 002 0.17
2.1.7 Weight
FSA-127-1.X/-/12 127 700 036 0.19 (See table 2.1.3)
FSA-127-2.X/-/12 127 700 038 0.19
2.1.8 Flow direction
FSA-254-1.X/-/12 254 700 072 0.22 Optional
FSA-254-2.X/-/12 254 700 074 0.22 2.1.9 Ambient temperature
FSK-127-2.X/C/-/12 127 718 030 0.22 - 20 °C to + 80 °C
FSK-127-2.X/O/-/12 127 718 031 0.22 2.1.10 Materials
FSK-254-2.X/C/-/12 254 718 050 0.28 FSA / FSK
FSK-254-2.X/O/-/12 254 718 051 0.28 End caps and tube in high quality
TSE-60/X/12 703 724 0.11 synthetic material
TSE-70/X/12 703 714 0.11 Housing in aluminium
TSE-80/X/12 551 481 0.11 Soft seals in Viton (FKM) or
Perbunan (NBR)
FT 200 0 - 100 °C / M12 200 700 154 0.03
Bolts, nuts and washers in steel
FT 300 0 - 100 °C / M12 300 700 155 0.04 (plated)
Plug connections in high quality
synthetic material (FSK)
TSE
Housing with temperature sensor,
washer and nut in steel
(zinc-plated)
Plug connections in high quality
synthetic material
4
2.2. HYDRAULIC DETAILS
2.3. ELECTRICAL DETAILS 2.4. ELECTRICAL DETAILS
2.2.1 Nominal pressure OF FSK OF TSE
Max. 1 bar
2.3.1 Electrical functions 2.4.1 Electrical function
2.2.2 Operating fluids
Mineral oil to DIN 51524, Part 1 Type O opens on contact
and 2, water-oil emulsions and when fluid is at low level,
synthetic fluids, such as hydraulic contact opens
fluids based on phosphate ester when supplied, contact is open
(NOT water glycol).
For other fluids, please contact
our technical sales department.
2.2.3 Temperature of operating fluid
- 20 °C to + 80 °C
2.2.4 Scale range of thermometer
FSA / FSK
Thermometer T for FSA: when fluid is at working level,
+ 20 °C to + 80 °C contact is closed 2.4.2 Switching power
2.5 A/50 V -
Thermometer FT for FSA / FSK:
0 °C to + 100 °C 10,000 switching operations
0.5 A/50 V -
100,000 switching operations
2.4.3 Minimum switching current
50 mA
2.4.4 Switching tolerance
Terminal 3 is not connected
±5K
Type C
when fluid is at low level,
contact closes
when supplied, contact is closed
when fluid is at working level,

contact is open
Terminal 3 is not connected

Type W / form B plug
Dual switching unit
When supplied, switching points
correspond to the diagram below
2.3.2 Contact load

Max. 8 W
2.3.3 Switching voltage
50 V AC / DC
2.3.4 Switching current
0.2 A
5
3. DIMENSIONS
3.1. FLUID LEVEL GAUGE FSA
Standard FSA FSA with thermometer max. 8
tank bore
SW18, 16
torque rating 10 +2 Nm
FSA with temperature gauge
SW18, 16
FSA with temperature switch

can be turned through 360°
SW 18
Size
≅ centre distance of bolts L0 L1 L2
076 108 34 76
127 159 76 127
176 208 125 176
254 286 203 254
381 413 330 381
6
3.2. FLUID LEVEL SENSOR FSK
Standard FSK FSK form B plug

max. 8
plug socket can be turned through 4 x 90°

switching level
tank bore
SW18, 16
Size
≅ centre distance of bolts L0 L2
127 201 127
176 250 176
254 328 254
381 455 381
7
3.3. SCALE RANGE FSA / FSK
sight glass
Size 76 Size 127 Size 176 Size 254 Size 381
3.4. TEMPERATURE SWITCH TSE

See FSA with TSE fitted
4. SPARE PARTS 5. NOTE

All details in this
4.1. SEAL KIT brochure are subject
to technical
modifications.
Seal kit Order no. = stock no.

FSA-076/127-1.X/ 704 616
FSA-076/127-2.X/ 704 627
FSA-176-1.X/ 555 599
FSA-176-2.X/ 555 600
FSA-254-1.X/ 700 037
FSA-254-2.X/ 704 649
FSA-381-1.X/ 860 008
FSA-381-2.X/ 860 009
8
BA HEL.PAT.000 EN
Einbau, Bedienung, Wartung

Mounting, Operating Instructions, Maintenance
Installation, Mode D’Emploi, Entrétien
D GB F
Einschraub-Heizkörper Screw-in heating element Elément de chauffage à visser
Die technischen Daten entnehmen For the technical data, please refer Pou les données techniques,
Sie bitte der betreffenden to the list of equipment. veuillez consulter la list des
Geräteliste. appareils.
Heizkörper waagerecht montieren. Install heating element horizontally. Monter horizontalement l’élément de chauffage.
Flüssigkeit in den Behälter füllen und Pour liquid into the container until the level Remplir le réservoir de liquide et cela
zwar so weit, daß der Spiegel is at least 20 mm above the heating jusqu‘ à ce que le niveau soit au moins 20
wenigstens 20 mm oberhalb des element. Appropriate measures must be mm au-dessus de l’élément de chauffage.
Heizgerätes steht. Dieser Mindest- taken to assure that this minimum level is Ce niveau minimum de remplissage doit
flüssigkeitsstand ist durch geeignete maintained. être garanti par des mésures adéquates.
Maßnahmen sicherzustellen.
Für eine ausreichende Wärmeabgabe Please take care of a good heat emission. Il faut veiller à une transmission suffisante
muß gesorgt werden. de chaleur.
Der elektrische Anschluß erfolgt nach Connection according to wiring scheme. Le branchement èlectrique est effectué
Schaltbild. selon le schéma.
WS (AC) DS (3~)
Wechselstrom Drehstrom
single-phase three-phase
L1 L1 L2 L3
L2/N
Schutzhaube aufsetzen. Apply protective cap. Poser le capot.
Bei Verschmutzung empfiehlt es sich, The tube protection jacket has to be En cas de salissure, nous recommandons
den Heizkörper zu reinigen, damit eine cleaned from time to time in order to de nettoyer le radiateur pour garantir une
einwandfreie Wärmeabgabe warrant constant unrestraint heat emission. parfaite transmission de la chaleur.
gewährleistet ist.
Telefon (02392) 69 08-0 . Telefax (02392) 69 08-88

BA TUR.SEN.032 EN
1/1
Subject to change without notice • © Hans Turck GmbH & Co.KG 2002 • Edition:
Hans Turck GmbH & Co.KG • Postfach • D-45466 Mülheim an der Ruhr • Telefon 02 08/49 52-0 • Telefax 02 08/49 52-264
Inductive sensor
Bi5-G18-Y1
● threaded barrel, M18 x 1

● chrome-plated brass
● 2-wire DC, nom. 8.2 VDC
● output according to DIN EN 60947-
M18 x 1 5-6 (NAMUR)
● cable connection
24/4
30 Wiring diagram
4
BN
+
BU

Function principles
Inductive proximity switches are designed
Type Bi5-G18-Y1 for wear-free non-contact detection of me-
Ident-No. 10060 tal objects. For this they use a high-fre-
quency electro-magnetic AC field that
Rated operating distance Sn 5 mm interacts with the target. With inductive
Mounting mode flush sensors, this field is generated by an LC re-
Hysteresis (switching distance) 1... 10 % sonant circuit with a ferrite core coil.
Min. repeat accuracy ≤2 %
Temperature drift ≤ ± 10 %
Operating temperature -25 ...+ 70 °C
Voltage nom. 8,2 VDC

Current consumption (off-state) ≥ 2,1 mA
Current consumption (on-state) ≤ 1,2 mA
Max. switching frequency ≤ 1 kHz
Output function 2-wire, NAMUR
Approval according to KEMA 02 ATEX 1090X

Internal inductivity (Li) / capacitivity (Ci) 150 nF / 150 µH *
* Value for pre-fixed cable up to 30m
Marking of device É II 2 G EEx ia IIC T6
(max. Ui = 15 V, Ii = 60 mA, Pi = 200 mW)
Housing style threaded barrel; M18 x 1

Dimensions 34 mm
Housing material metal, CuZn, chrome-plated
Active face plastic, PA12-GF30
Max. fixing torque of coupling nut 25 Nm
Wiring cable
Cable Ø 5,2, LiYY, PVC, 2 m
Cable cross section 2 x 0,5 mm2
Vibration resistance 55 Hz (1 mm)
Shock resistance 30 x g (11 ms)
Degree of protection IP67
Subject to change without notice • © Hans Turck GmbH & Co.KG 2002 • Edition: • 15.04.2004
Hans Turck GmbH & Co.KG • Postfach • D-45466 Mülheim an der Ruhr • Telefon 02 08/49 52-0 • Telefax 02 08/49 52-264
Bauart B3FH Seite
Ersatzteilliste (EL) Type Page
Spare parts list Größe 28,0 1/1
Size
Übersetzung 22,432
ratio
Please quote in correspondence EL 4214492-040 DE/EN
G 0097 1 ST KEGELRADSATZ HP 780/1,81 1.6587 000.001.328.607 0,0

PAIR OF MATING BEVEL WHEELS ZY
E* 0100 1 ST KEGELRADW L HP 780/1,81 1.6587 6105895/A 000.001.312.245 445,0
BEVEL PINION SHAFT R HP 780/1,81 1.6587
G* 0102 1 ST KEGELRAD R HP 780/1,81 1.6587 6105275/- 000.001.310.736 456,0
BEVEL GEAR R HP 780/1,81 1.6587
E 0128 1 ST RING-PASS 585X461X12 ST 6107143/- 000.001.312.529 8,5
RING
E 0133 3 ST RING,AS 230/08,0X1,5 W 5730 FED-ST 000.000.347.217 0,1
LAMELLAR RING, AS (FEY) 230/08,0X1,5 W 5
E 0135 1 ST RING-LABYR A 201X230 ST 5882183/C 000.000.562.183 0,1
LABYRINTH RING A 201X230 ST
E 0136 1 ST RING-LABYR I 200X220 ST 5882133/A 000.000.562.133 0,1
LABYRINTH RING I 200X220 ST
E 0150 1 ST EINBAUS 32244 J2/DF C560 SKF/FAG 000.001.156.799 60,0
PAIRED TAPER ROLLER BEARINGS 32244 J2/DF
E 0151 1 ST WAELZL192344 LSL C3 INA 000.000.782.185 108,0
ROLLING CONTACT BEARING192344 LSL C3 INA
G 0200 1 ST WELLE-FLANSCH B3FH 28 42CrMo4V 6105291/D 000.001.310.780 3.448,0
FLANGED SHAFT B3FH 28 42CrMo4V
E 0250 1 ST WAELZL 230/530 CA/W33 D 635 SKF/FAG 000.000.781.384 310,0
ROLLING CONTACT BEARING 230/530 CA/W33 D
E 0251 1 ST WAELZL 24084 ECA/W33 D 635 SKF 000.001.156.797 210,0
ROLLING CONTACT BEARING 24084 ECA/W33
E 0300 1 ST STRDWELLE LP 955,0/3,38 1.6587 6105561/B 000.001.312.243 882,0
PINION SHAFT RP 955,0/3,38 1.6587
G 0302 1 ST STIRNRAD RP 955,0/3,38 1.6587 6105243/B 000.001.310.699 4.490,0
GEAR WHEEL RP 955,0/3,38 1.6587
E 0350 1 ST WAELZL192348 LSL C3 000.000.782.186 138,6
ROLLING CONTACT BEARING192348 LSL C3
E 0351 1 ST WAELZL192348 LSL C3 000.000.782.186 138,6
E 0400 1 ST STRDWELLE RP 690,0/3,67 1.6587 6105615/A 000.001.312.244 409,0
PINION SHAFT LP 690,0/3,67 1.6587
G 0402 1 ST STIRNRAD LP 690,0/3,67 1.6587 6105260/C 000.001.310.734 1.819,0
GEAR WHEEL LP 690,0/3,67 1.6587
RING
E 0709 5 ST DICHTUNG 80 PN16 W3960 BELPA 000.001.228.304 0,1
SEAL 80 PN16 W3960 BELPA
A. Friedr.Flender AG, D 46393 Bocholt, Datum Date THIELE, MARKUS 1571

Bauart B3FH Seite
Ersatzteilliste (EL) Type Page
Spare parts list Größe 28,0 1/1
Size
Übersetzung 22,432
ratio
Please quote in correspondence EL 4214492-185 DE/EN
G 0097 1 ST KEGELRADSATZ HP 780/1,81 1.6587 000.001.328.607 0,0

PAIR OF MATING BEVEL WHEELS ZY
E* 0100 1 ST KEGELRADW L HP 780/1,81 1.6587 6105895/A 000.001.312.245 445,0
BEVEL PINION SHAFT R HP 780/1,81 1.6587
G* 0102 1 ST KEGELRAD R HP 780/1,81 1.6587 6105275/- 000.001.310.736 456,0
BEVEL GEAR R HP 780/1,81 1.6587
RING
E 0135 1 ST RING-LABYR A 201X230 ST 5882183/C 000.000.562.183 0,1
LABYRINTH RING A 201X230 ST
E 0136 1 ST RING-LABYR I 200X220 ST 5882133/A 000.000.562.133 0,1
LABYRINTH RING I 200X220 ST
G 0200 1 ST WELLE-FLANSCH B3FH 28 42CrMo4V 6105291/D 000.001.310.780 3.448,0
FLANGED SHAFT B3FH 28 42CrMo4V
E 0250 1 ST WAELZL 230/530 CA/W33 D 635 SKF/FAG 000.000.781.384 310,0
ROLLING CONTACT BEARING 230/530 CA/W33 D
E 0251 1 ST WAELZL 24084 ECA/W33 D 635 SKF 000.001.156.797 210,0
ROLLING CONTACT BEARING 24084 ECA/W33
E 0300 1 ST STRDWELLE LP 955,0/3,38 1.6587 6105561/B 000.001.312.243 882,0
PINION SHAFT RP 955,0/3,38 1.6587
G 0302 1 ST STIRNRAD RP 955,0/3,38 1.6587 6105243/B 000.001.310.699 4.490,0
GEAR WHEEL RP 955,0/3,38 1.6587
E 0350 1 ST WAELZL192348 LSL C3 000.000.782.186 138,6
E 0351 1 ST WAELZL192348 LSL C3 000.000.782.186 138,6
E 0400 1 ST STRDWELLE RP 690,0/3,67 1.6587 6105615/A 000.001.312.244 409,0
PINION SHAFT LP 690,0/3,67 1.6587
G 0402 1 ST STIRNRAD LP 690,0/3,67 1.6587 6105260/C 000.001.310.734 1.819,0
GEAR WHEEL LP 690,0/3,67 1.6587
RING
E 0709 5 ST DICHTUNG 80 PN16 W3960 BELPA 000.001.228.304 0,1
SEAL 80 PN16 W3960 BELPA
A. Friedr.Flender AG, D 46393 Bocholt, Datum Date THIELE, MARKUS 1571

List of equipment Type B3FH Page
1 of 2
Project: LOS PELAMBRES Size 28
Please quote in correspondence GL 4214492-040/170/185 EN
Part No. Qty. Description Manufacturer
45 1 Oil drain valve ARGUS

as per Flender Works Standard W 5100 B 5100 EN
Nominal width DN 50
Screw connection G 2
822 1 Breather filter FLENDER

Screw connection G 1/2
54 1 Breather filter MANN

803 1 Temperature monitor FLENDER

Type ATHs-SW-22 B 5926 EN
as per Flender Works Standard W 5926
Immersion tube length 100 mm
Connection immersion tube G 1/2
Quantity of switching contacts: 2
Contact loading:
2 A / 230 V AC / 460 VA
0.25 A / 230 V DC / 58 W
Degree of protection: IP 65
804 1 Resistance thermometer JUMO

as per Flender Works Standard F 6100-3 B 6100 EN
for measuring oil sump temperature
Length of immersion tube = Mounting length EL 100 mm
Precision resistor 2 x PT 100 DIN IEC Kl. B
Two wire circuit
Connection immersion tube G 1/2 thread
801 1 Resistance thermometer FLENDER


for measurement of bearing temperature
Mounting length EL 230 mm
Precision resistor 2 x PT 100 DIN IEC Cl. B
Two-wire circuit

for measurement of bearing temperature
Mounting length EL 265 mm
Precision resistor 2 x PT 100 DIN IEC Cl. B
Two-wire circuit

List of equipment Type B3FH Page
2 of 2
Project: LOS PELAMBRES Size 28
Please quote in correspondence GL 4214492-040/170/185 EN
Part No. Qty. Description Manufacturer
821 1 Oil level control BÜHLER

Type Nivotemp M-0-VA-M3 with SK 161 BA ...
883 6 Cartridge heater HELIOS

Type O 52 BA HEL.PAT.000 EN
Tension 230 V
Supply frequency 50 Hz
Heating power 1215 W
Mounting length 1000 mm
Surface loading: 0.75 W/cm2
43 2 Oil level control FLUTEC

Type FSA 254-2.0 SO BA HYC.ANZ.000 EN
as per Flender Works Standard W 5302
800 1 Vibration switch METRIX

Type PMC/BETA 440 SR - 2200 - 0100 BA ...
173 1 Pulse transmitter TURCK

Type BI5-G18-Y1 BA TUR.SEN.032 EN

CAD-DRAWING TO BE MODIFIED ON THE MONITOR ONLY THIS TECHNICAL DOCUMENT IS REGISTERED (DIN 34)
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 1 2 3 4 5 6 7
A Zeile Änd. Benennung Blatt Planart Anlage Gruppe Ort Zeile Änd. Benennung Blatt Planart Anlage Gruppe Ort A
Line Rev. Description Sheet Plantyp Unit Group Place Line Rev. Description Sheet Plantyp Unit Group Place
1 c Inhaltsverzeichnis INH
1 INH 21 *
Table of contents *
2 b Überwachung UEW
1 SSL +TB01 22 *
Monitoring *
3 Überwachung UEW
2 SSL +TB02 23 *
Monitoring *
4 c Überwachung UEW
1 STR +TB01 24 *
Monitoring *
B 5 c Überwachung UEW
2 STR +TB01 25 * B
Monitoring *
6 c Heizungen HEI
3 STR +TB02 26 *
Heating *
7 Klemmenplan 1283
1 VKL +TB01-X53 +TB01 27 *
Connection plan *
8 Klemmenplan 1283
1 VKL +TB01-X63 +TB01 28 *
Connection plan *
9 Klemmenplan 1283
1 VKL +TB01-X73 +TB01 29 *
Connection plan *
C 10 Klemmenplan 1283
1 VKL +TB01-X93 +TB01 30 * C
Connection plan *
11 Klemmenplan 1283
1 VKL +TB02-X13 +TB02 31 *
Connection plan *
12 * 32 *
* *
13 * 33 *
* *
14 * 34 *
* *
D 15 * 35 * D
* *
16 * 36 *
* *
17 * 37 *
* *
18 * 38 *
* *
19 * 39 *
* *
E 20 * 40 * E
* *
Order No. = 5
7
. 6
+
2
1 3
4
Rev. Description Sh.
F Date19.10.06 120-CV-005-21 Order No. F

TBK
Drawn
Inhaltsverzeichnis 6 123 673
c index c 19.10.06 TBK Checked TBK 120-CV-006-21 Klemmenplan - Getriebe B3FH 1
Rev Description Date Name Norm DIN Made from In exchange for exchanged thru
Table of contents Terminal diagram - Gearbox B3FH INH 1 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
Typ: 1515.510 (300x150x80)
B-Seite
B-Side
150
B B
+TB01
C C
300
C-Seite D-Seite
C-Side D-Side
D D
A-Seite B-Seite C-Seite D-Seite Größe

A-Side B-Side C-Side D-Side Size
Verschraubungen / Cable glands

M12
4 3 M16
M20
E M25 E
M32
Verschlußstopfen / Plugs
M12
A-Seite
M16 A-Side
2 M20
2 M25
1:2
M32

TBK
Drawn
Überwachung 6 123 673 +TB01
b revised 27.07.06 TBK Checked TBK 120-CV-006-21 Klemmenplan - Getriebe B3FH 1
Monitoring Terminal diagram - Gearbox B3FH SSL 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
Typ: 1515.510 (300x150x80)
B-Seite
B-Side
150
B B
+TB02
C C
300
C-Seite D-Seite
C-Side D-Side
D D
A-Seite B-Seite C-Seite D-Seite Größe

A-Side B-Side C-Side D-Side Size
Verschraubungen / Cable glands

M12
6 M16
M20
E M25 E
M32
Verschlußstopfen / Plugs
M12
A-Seite
M16 A-Side
M20
1 M25
1:2
M32

TBK
Drawn
Checked TBK 120-CV-006-21 Klemmenplan - Getriebe B3FH 2
Monitoring Terminal diagram - Gearbox B3FH SSL 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
B B
-X73 1 2 -X73 5 6 -X73 9 10 -X93 1 2 3 -X93 8 9 10 11

+EXT +EXT +EXT +EXT +EXT PE
C C
-X73 1 2 -X73 3 4 -X73 5 6 -X73 7 8 -X73 9 10 -X73 11 12 -X93 1 2 3 -X93 4 5 6 7 -X93 8 9 10 11
PE PE
D D
RD RD WH WH RD RD WH WH RD RD WH WH 2 4 1 2 4 1 PE 1 2 3 PE
-B801.1 -B801.2 -B802.1 -B802.2 -B804.1 -B804.2 -S803.1 -S803.2 -S821
Q
E Bearing 1 Spare Bearing 2 Spare Oilsump Spare Heater control Spare E
Widerstandsthermometer Widerstandsthermometer Widerstandsthermometer Temperaturwächter Niveauwächter

Resistance thermometer Resistance thermometer Resistance thermometer Temperature monitor Level monitor
F Date 23.06.06 120-CV-005-21 Order No. F

Drawn TBK
c revised 19.10.06 TBK Checked TBK 120-CV-006-21 Klemmenplan - Getriebe B3FH 1
Monitoring Terminal diagram - Gearbox B3FH STR 3 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
B B
-X63 1 2 3 4 PE -X53 1 2
+EXT +EXT
C C
-X63 1 2 3 4 PE -X53 1 2
D D
1 2 3 4 PE 5 6 7 PE 8 9 10 11 12 13 14 +BN -BU
-B800 -B1
PMC / 440S
NAMUR
E E
Schwingungsmessung Näherungsschalter
Vibration measurement Proximity switch
F Date
30.06.06 120-CV-005-21 Order No. F
TBK
Drawn
Monitoring Terminal diagram - Gearbox B3FH STR 3 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
B B
-X13 L1 L2 L3 PE
+EXT
C C
-X13 1 4 5 -X13 2 4 5 -X13 3 4 5 -X13 1 6 7 -X13 2 6 7 -X13 3 6 7
PE PE PE PE PE PE
D D
L1 N PE L1 N PE L1 N PE L1 N PE L1 N PE L1 N PE
-E883/1 -E883/2 -E883/3 -E883/4 -E883/5 -E883/6
E 230V / 50Hz 230V / 50Hz 230V / 50Hz 230V / 50Hz 230V / 50Hz 230V / 50Hz E
1215W 1215W 1215W 1215W 1215W 1215W
Heizstab Heizstab Heizstab Heizstab Heizstab Heizstab

Heating cartridge Heating cartridge Heating cartridge Heating cartridge Heating cartridge Heating cartridge
F Date 23.06.06 120-CV-005-21 Order No. F

Drawn TBK
Heizungen 6 123 673 +TB02
Heating Terminal diagram - Gearbox B3FH STR 3 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
Verbindungsleitungen Zielbezeichnung Richtung Maschine Klemmenleiste Zielbezeichnung Richtung Schaltschrank
A Conecting lines Target description maschine direction Terminal strip
+TB01 -X53 Target description cabinet direction A
Kennzeichen Anschl. Typ Brücke Klemme A mm² Schaltplanposition Kennzeichen Anschl.

Designation Connec. Typ Jumper Terminal A mm² Wiring diagram pos. Designation Connec.
= + - : max. STR = + - :
+EXT -X53 1 UK5N 1 4.0 STR/2.3 +TB01 -B1 +BN
+EXT -X53 2 UK5N 2 4.0 STR/2.4 +TB01 -B1 -BU
USLKG 5 3 4.0 R
B B
C C
D D
E E
F Date 19.10.06 120-CV-005-21 Order No. .+TB01-X53 F

Drawn TBK
Klemmenplan 6 123 673 +TB01
Connection plan Terminal diagram - Gearbox B3FH VKL 1 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
+EXT -X63 1 UK5N 1 4.0 STR/2.1 +TB01 -B800 1
+EXT -X63 2 UK5N 2 4.0 STR/2.1 +TB01 -B800 2
+EXT -X63 3 UK5N 3 4.0 STR/2.1 +TB01 -B800 3
+EXT -X63 4 UK5N 4 4.0 STR/2.2 +TB01 -B800 4
B B
+EXT -X63 PE USLKG 5 PE 4.0 STR/2.2 +TB01 -B800 PE
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
+EXT -X73 1 UK5N 1 4.0 STR/1.1 +TB01 -B801.1 RD
UK5N 3 4.0 STR/1.2 +TB01 -B801.2 WH
UK5N 4 4.0 STR/1.2 +TB01 -B801.2 WH
B B
UK5N 7 4.0 STR/1.3 +TB01 -B802.2 WH
UK5N 8 4.0 STR/1.4 +TB01 -B802.2 WH
UK5N 11 4.0 STR/1.5 +TB01 -B804.2 WH
UK5N 12 4.0 STR/1.5 +TB01 -B804.2 WH
USLKG 5 13 4.0 R
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
+EXT -X93 1 UK5N 1 4.0 STR/1.6 +TB01 -S803.1 2
+EXT -X93 2 UK5N 2 4.0 STR/1.6 +TB01 -S803.1 4
+EXT -X93 3 UK5N 3 4.0 STR/1.6 +TB01 -S803.1 1
UK5N 4 4.0 STR/1.7 +TB01 -S803.2 2
B B
UK5N 5 4.0 STR/1.7 +TB01 -S803.2 4
UK5N 6 4.0 STR/1.7 +TB01 -S803.2 1
USLKG 5 7 4.0 STR/1.7 +TB01 -S803.2 PE
+EXT -X93 8 UK5N 8 4.0 STR/1.8 +TB01 -S821 1
+EXT -X93 9 UK5N 9 4.0 STR/1.8 +TB01 -S821 2
+EXT -X93 10 UK5N 10 4.0 STR/1.8 +TB01 -S821 3
+EXT -X93 11 USLKG 5 11 4.0 STR/1.8 +TB01 -S821 PE
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
+EXT -X13 L1 UK5N 1 4.0 STR/3.1 +TB02 -E883/1 L1
UK5N 1 4.0 STR/3.4 +TB02 -E883/4 L1
UK5N 2 4.0 STR/3.5 +TB02 -E883/5 L1
B B
UK5N 3 4.0 STR/3.5 +TB02 -E883/6 L1
UK5N 4 4.0 STR/3.1 +TB02 -E883/1 N
UK5N 4 4.0 STR/3.2 +TB02 -E883/2 N
UK5N 4 4.0 STR/3.3 +TB02 -E883/3 N
USLKG 5 5 4.0 STR/3.1 +TB02 -E883/1 PE
USLKG 5 5 4.0 STR/3.2 +TB02 -E883/2 PE
+EXT -X13 PE USLKG 5 5 4.0 STR/3.3 +TB02 -E883/3 PE
UK5N 6 4.0 STR/3.4 +TB02 -E883/4 N
C UK5N 6 4.0 STR/3.5 +TB02 -E883/5 N C
UK5N 6 4.0 STR/3.5 +TB02 -E883/6 N
USLKG 5 7 4.0 STR/3.4 +TB02 -E883/4 PE
USLKG 5 7 4.0 STR/3.5 +TB02 -E883/5 PE
USLKG 5 7 4.0 STR/3.6 +TB02 -E883/6 PE
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
Betriebsanleitung
Operating instructions
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Material- no. 1.319.555
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Description Oil supply system

OLGS 11
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
A. Friedr. Flender AG ⋅ D 46393 Bocholt ⋅ Tel. 02871/92-0 ⋅ Telefax 02871/92-2596 ⋅ http://www.flender.com

Type OLGS Page
Operating Instructions 1 of 1
Size 11
Please quote in correspondence BA 1.319.555 EN
Contents
1. Technical data TD 1.319.555 EN Rev.

Technical data
Drawings
List of equipment
2. General notes BA 73 00 02 0000 EN Rev.

Introduction
General scope of application
Use as specified
Copyright
3. Safety notes BA 73 00 03 0003 EN Rev.

Explanation of symbols and instructions
Industrial Safety instructions
4. Handling and storage BA 97 00 04 0000 EN Rev. a

Packing
Extent of Disassembly
Handling
Storage
Scope of supply
5. Technical description BA 97 00 05 0006 EN Rev.

General configuration
6. Assembly BA 97 00 06 0000 EN Rev.

General Notes
Installation conditions
Installation
Final operations
7. Startup BA 97 00 07 0001 EN Rev.
Filling with oil
Oil pump
Oil cooler
Startup
8. Operation BA 97 11 08 1004 EN Rev.

Control notes
Response to malfunctions
Shutdown
9. Disturbances, reasons and remedy BA 97 00 09 0010 EN Rev. a

General
Possible malfunctions
10. Maintenance and repair BA 97 00 10 0002 EN Rev. a

Safety
Oils
Oil pump
Filter
Oil cooler
Preservation
11. Spare parts stock, service facility addresses BA 73 00 11 0000 EN Rev. a

Spare parts stock
Addresses of replacement part suppliers and service organizations
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: OK/OK TFAE

Operating Instructions Type OLGS Page
Section 1 1 of 1
Technical Data Size 11
Please quote in correspondence TD 1.319.555 EN
Material- no. : 1.319.555
Type : OLGS
Size : 11
Weight (without oil filling) : 950 kg

Overall dimensions l x b x h : 1650 x 1650 x 1500 mm
Pump delivery : 335 l/min
Oil quantity : see operating instructions or

rating plate of the ”gear unit”
Oil viscosity : see operating instructions or
Oil grade : see operating instructions or
Ambient temperature : -12 ... +34 °C
Supply voltage : 3 x 380 ... 420V (IEC 38)
Supply frequency : 50Hz
Declaration by the manufacturer : BA 73 00 12 0035 EN Rev. c

Drawing no. Oil supply system : 6 113 279
Drawing no. Lubrication Diagram : 6 113 280
Drawing no. (Terminal Wiring Plan) : 6 113 281
List of equipment : GL 1.319.555 EN Rev.

Edition: August 1993
Section 2 BA 73 00 02 0000 EN
General Notes Page 1 of 2
Contents
1. Introduction 2
2. General scope of application 2
3. Use as specified 2
4. Copyright 2
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Hesselmann DOA

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 30.08.1993 Nr.
Section 2 BA 73 00 02 0000 EN
General Notes Page 2 of 2
1. Introduction
The Operating Instructions must be read, understood in all respects and observed by those persons
who are responsible for use of the FLENDER product.
Only familiarization with the Operating Instructions will prevent malfunction of the product and ensure
trouble-free operation. It is important therefore that the persons actually responsible should be familiar
with theses Operating Instructions.
Careful study of these Operating Instructions before handling our product and before startup is essen-
tial, as we accept no liability for damage and malfunctions resulting from non-compliance of these
Operating Instructions.
Note: We reserve the right to amend these these Operating Instructions where rendered
necessary by improvement of the products.
2. General scope of application
The product is intended for the scope of application as specified in the Technical Data.
3. Use as specified
The product is designed only for the scope of application specified in the Technical Data.
Before the product is used outside the scope of use as specified by the contract, this must be agreed
with FLENDER, as otherwise the warranty will be invalidated.
4. Copyright
Copyright of these Operating Instructions remains the property of FLENDER AG.

These Operating Instructions are intended for the installation, operating and supervisory personnel.
They may not be duplicated in whole or in part or used without authorization for the purpose of
competition or communicated to others.
FLENDER AG
D-46393 Bocholt
Germany
Phone: 02871/92-0
Fax: 02871/92-2596

Edition: September 1992
Section 3 BA 73 00 03 0003 EN
Safety Instructions Page 1 of 3
Contents
1. Explanation of symbols and instructions 2

1.1 Industrial Safety symbol 2
1.2 Cautionary instruction 2
2. Industrial Safety instructions 2

A. Friedr. Flender AG, D 46393 Bocholt, Datum Nam: Hesselmann DOA

Section 3 BA 73 00 03 0003 EN
1. Explanation of symbols and instructions
1.1 Industrial Safety symbol

This symbol will be found against all Industrial Safety instructions in these Operating
Instructions where there is danger to life and limb of persons. Please observe these
instructions and exercise special caution in such instances. Please pass all Industrial
Safety instructions onto other users as well. In addition to the instructions in these
Operating Instructions, generally applicable safety and accident prevention rules
must be observed.
1.2 Cautionary instruction

This ”Caution!” instruction will be found in places where special caution is to be ob-
served, in order that the guidelines, rules, instructions and correct sequence of
Caution! operation are observed, and that damage and destruction of the machine and/or other
system components is prevented.
2. Industrial Safety instructions
The following Industrial Safety instructions should be specially observed:

S The oil supply system is constructed in accordance with the state of the art and safe in operation. This
oil supply system may however give rise to hazards if it is used improperly or subjected to use for
which it was not intended by untrained personnel.
S Every person engaged in installation, dismantling and reassembly, startup, operation and mainte-
nance (inspection, servicing, repair) of the oil supply system MUST have read and understood the
complete Operating Instructions, in particular the ”Safety” Operating Instructions.
S The oil supply system is intended for the scope of application specified in the Technical Data.
Any usage over and above this will be considered as improper use. The manufacturer accepts no
liability for damage resulting therefrom; the risk will be borne solely by the user.
S Proper usage will also be taken to include observance of the installation, dismantling and reassembly,
startup, operating and maintenance instructions specified by the manufacturer.
S The oil supply system may only be operated, serviced and repaired by authorized, trained and
suitable instructed personnel.
S Responsibility during installation, dismantling and reassembly, startup, operation and maintenance
must be clearly defined and observed, so that there is no confusion as to responsibility from the aspect
of safety.
S Screwed pipe connections, flanged joint and monitoring devices may be undone as long as the
system is under pressure. First, pumps have to be switched off, and aggregates under pressure have
to be released.
S Any mode of operation which adversely affects the safety of the oil supply system is to be prohibited.
S The operator is obliged to inform the user of the system immediately of any changes occurring in
the oil supply system which adversely affect its safety.

Section 3 BA 73 00 03 0003 EN
S The user is obliged at all times to operate the oil supply system only when it is in satisfactory condition.
S The user MUST ensure cleanliness and unimpeded view at the place of installation of the oil supply
system by means of suitable instructions and inspections.
S Unauthorized conversion and modifications which adversely affect the safety of the oil supply system
are NOT permitted.
S All work on the oil supply system MUST be carried out only when it is stationary.
S Before commencing work on the oil supply system, its drives and ancillary equipment MUST be
secured to prevent accidental switch-on.
S Before restarting after repairs, it should be checked that all safety devices are fitted.
S Safety devices may only be removed when stationary, with the oil supply system secured.
S The manufacturer’s instructions on the application of solvents should be observed.
S When draining oil, environmental protection requirements should be observed.
S The loadability of the lifting gear to be installed must be at least that of the heaviest component weight
(see Operating Instructions, ”Technical Data”).
S In ALL cases, operation of the oil supply system will be subject to the local safety and accident
prevention rules.

Edition: February 1994
Section 4 BA 97 00 04 0000 EN
Transport and storage Page 1 of 2
Contents
1. Packing 2
2. Extent of disassembly 2
3. Handling 2
4. Storage 2
5. Scope of supply 2
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name Reinders PZ 5

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 01.02.1994 Rev.: a
Section 4 BA 97 00 04 0000 EN
Transport and storage Page 2 of 2
1. Packing
The type of packing will also be determined by the means of shipment. Packing will, unless specially
agreed by contract, comply with the HPE Packing Guide lines as specified by the Federal Association
for Wooden Materials, Pallets and Export Packing e.V. and by the German Machine Building Institutes.
The symbols appearing on the packing in accordance with DIN 55 402 Part 1 should be observed.
This side up Fragile Keep dry Protect Centre of Use no Sling here
goods from heat gravity hooks
2. Extent of disassembly
The oil supply system is shipped in assembled state.
(Weight see section 1 ”Technical Data”)
3. Handling
Special care should be exercised when handling the oil supply system to
prevent damage due to the effect of force or careless loading and unloading.
Ropes or chains are to be used for handling the oil supply system. Attach only to the base frame or the
oil container. Ensure that the ropes do not damage fittings and oil lines. A lifting beam will therefore be
necessary for protection. The lengths of the ropes should be such that the base frame or the oil contai-
ner is suspended horizontally.
4. Storage
When the shipping packing is removed, the oil supply system must be stored on site in a clean, dry area.
The oil supply system is to be properly covered to prevent penetration of dust and moisture.
It must be ensured that temperature fluctuations in the place of storage do not lead to condensation
forming in the oil supply system.
It must be ensured that no external damage can occur!

The openings are sealed with plugs or wooden flanges.
The preservation is adequate for normal shipping conditions and a period of 6 months until startup takes
place (storage in dry rooms).
If storage is to exceed 6 months, it is essential to consult FLENDER AG.
The external paint coating is resistant to weak acids, alkalies, oils and solvents, sea water, tropical
conditions, and temperatures up to 140 °C / 284 °F.
5. Scope of supply
The contents of the packages are listed in the package list. Check for completeness on receipt. Any
shipping damage and/or missing parts are to be reported immediately in writing. After consultation with
FLENDER AG, an expert should be called in.
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name Reinders PZ 5

Edition: December 1992
Section 5 BA 97 00 05 0006 EN
Technical description Page 1 of 2
Contents
1. General configuration 2
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name Reinders SKO

Section 5 BA 97 00 05 0006 EN
Technical description Page 2 of 2
1. General configuration
The oil supply system described below is used for oil cooling and/or lubrication of a gear unit (see
Section 1 ”Technical Data”).
The oil supply system has been subjected to an exhaustive trial run in conjunction with the gear unit
and tested in accordance with the order data.
The oil supply is ensured by means of one pump assembly.
The pump draws the oil via a suction line from the pump sump of the gear unit.
A filter is provided in the oil circuit for filtration of the circulating oil.
The quantity of heat generated by losses, which is not dissipatable by convection, is dissipated by
means of a cooler.
Filtered and recooled oil is then passed back to the gear unit via a pressure line.
The modules described above are mounted on a base frame.

Section 6 BA 97 00 06 0000 EN
Assembly Page 1 of 3
Contents
1. General Notes 2
2. Installation conditions 2
3. Installation 2
4. Final operations 3
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Reinders SKO

Section 6 BA 97 00 06 0000 EN
1. General Notes
We earnestly recommend having installation of the oil supply system carried out by Flender personnel.
No liability is accepted for damage incurred as a result of improper execution by third parties.
2. Installation conditions
When planning space layout (e.g. planning carried out by customer), ensure that there is sufficient
space around the oil supply system to permit unimpeded assembly and repair work. Machines installed
upstream and downstream of the oil supply system should be located accordingly.
The load carrying capacity of hoists to be installed and used must at least be
adequate for the data of the oil supply system; see Section 1 ”Technical Data”.
Installation of the oil supply system must be carried out on a level, firm and rigid foundation. Ensure
that the oil can be drained off and that there is sufficient air supply for the motors. The valves and
wearing parts must be readily accessible and permit easy inspection.
The permissible deviation of the installation surface of the oil supply system from the horizontal is
2 mm/1 m (0.08”/40”); if necessary, shims should be used.
3. Installation
For handling of the oil supply system, see Section 4 ”Handling and Storage”.
Packing and shipping protection devices should be removed before installation. Carry out a visual
check for shipping damage and contamination. In the case of shipping damage, see Section 4 ”Handling
and Storage”.
All preserved flange surfaces should be cleaned with a solvent, e.g. benzine.
Observe environment protection requirements.
Connecting lines are supplied loose.
The interfaces are provided with suitable flanges or screw unions.

Compensators should be used for vibration insulation and to compensate for linear expansion.
Customer supplied pipe fastenings (plastic clips) should be used for pipe connection. The distance
between 2 clips must be less than 2 m / 78.7”.
Ensure that the pipes are not stressed.

After pipe installation, the lines should be flushed through. Welded pipes should be pickled.

Section 6 BA 97 00 06 0000 EN
Electrical connections of motors and monitors should be carried out in accordance with terminal
drawings, equipment lists and specifications. Check voltage and circuits.
The sealing plugs and wooden flanges should be removed and the pipe fit tings supplied loose installed
in the system in accordance with lubrication diagram and drawings (see Section 1 ”Technical Data”).
Parts supplied loose with threaded connection should be sealed with Loctite 572 after thorough
cleaning.
To secure the system, use screws in accordance with the dimensioned drawing (see Section 1
”Technical Data”) and tighten with the torque specified by the screw manufacturer. Holding-down bolts
with metric thread in accordance with DIN 13 Sheet 20 in Strength Class 8.8 in accordance with DIN 267
should be used.
4. Final operations
After installing the oil supply system, all visible screw fastenings should be checked for tightness and
tightened if necessary.
Fit all safety devices necessary !

Section 7 BA 97 00 07 0001 EN
Startup Page 1 of 3
Contents
1. Filling with oil 2
2. Oil pump 2
3. Oil cooler 2
4. Startup 3

Section 7 BA 97 00 07 0001 EN
Startup Page 2 of 3
1. Filling with oil
The following provisions are recommendations based on long years of experience. They are given
however without any responsibility on the part of the gear unit manufacturer. Responsibility for the oil
grade lies with the manufacturer of the oil and the operator of the system has to ensure satis factory
state of the oil grade (see Operating Instructions ”Gear unit”).
In all cases, before startup, the gear unit/oil supply system should be filled with oil (see Operating
Instructions ”Gear unit”). After filling, the filler openings should be properly reclosed and sealed.
Only oils in accordance with the specification should be used (see Operating Instructions ”Gear unit”).
Mixing oils of different manufacturers is NOT permissible.
To remove residues of preservatives which can lead to oil foaming, the oil supply system together with
the gear unit should be flushed before startup (see Operating Instructions ”Gear unit”).
The oil must then be drained carefully from the oil supply system, the monitors and the oil compartment
in the gear unit while it is hot. It may only be reused as flushing oil. If the flushing oil is to be used in
another system, it should first be carefully purified.
Fresh oil in accordance with the specification should be used for startup (see Operating Instructions
”Gear unit”).
Fill the oil supply system with oil in accordance with the Operating Instructions ”Gear unit” via the gear
unit resp. the oil container. Filling can be carried out with an auxiliary oil pump. Ensure that no dirt is
allowed to enter the oil circuit.
Fill until the specified oil level is reached on the oil level gauge with the pump stationary (see Operating
Instructions ”Gear unit”). The pump should then be started.
Before initial startup of the gear unit, the oil supply system must be run for at least 15 minutes to allow
all oil compartments to fill up (see Operating Instructions ”Gear unit”). Stop the oil supply system again
after wards and correct the oil level if necessary.
All pipes, screw unions and flanges should be tightened, this applying particularly to suction lines (to
prevent air being drawn into the system). Leaks should be resealed.
2. Oil pump
Oil pumps may only be run in one direction of rotation. The direction of
Caution!
rotation of motors must agree with the direction of rotation arrow on the pump.
3. Oil cooler
For the oil cooler, the customer / operator has to observe the space required for taking in the cooling
air in accordance with the assembly drawing (see Section 1 ”Technical Data”).

Section 7 BA 97 00 07 0001 EN
Startup Page 3 of 3
4. Startup
Before starting up the oil supply system, check that the requirements in accordance with these
Operating Instructions and the requirements in accordance with the gear unit Operating Instructions
have been fulfilled.
Caution! Before startup, filling with oil must be carried out.
Caution! Before startup, check the cooling air circulation!
Caution! Stop valves are to be secured to prevent accidental closure.
Before startup and after repairs and maintenance work, the oil supply system is to be cleaned
thoroughly to remove any impurities. This applies particularly to water (e.g. rain water and leakage of
the cooler) in order to prevent mixture of water and oil.
All pumps, filters and coolers must be suitably bled.
The works setting of the pressure relief valves/safety valves carried out by us
at our works may NOT be altered, as it is not used to regulate the pressure and
rate of flow. It is intended ONLY as overload protection!

Section 8 BA 97 11 08 1004 EN
Operation Page 1 of 4
Contents
1. Operation 2
1.1 Lubrication diagram 2
1.2 Control information 2
1.3 Interlocking instructions 3
1.3.1 Fan motor 3
1.3.1 Pump enable 3
1.3.1 Gear unit enable 3
1.3.2 Warning 3
1.3.3 Gear unit stop 3
1.4 Response to malfunctions 4
1.5 Shut-down 4
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: SHA/BMA TFAE

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 2006−08−11 Rev.:
Operating Instructions Edition: August 2006
Section 8 BA 97 11 08 1004 EN
1. Operation
Note: The ”Safety instructions” in section 3 must be observed.

Note: Please also observe the operating instructions of the gear unit.
1.1 Lubrication diagram
For the relevant lubrication diagram drawing number, refer to the list of equipment.
1.2 Control information
The part numbers (...) given in the following text have been taken from the enclosed list of equipment,
assembly drawing and the lubrication diagram.
The following control information must be noted for the individual components:
Note: In addition to this control information, the specifications in the enclosed equipment
list must always be observed.
Note: Only the control information of the part numbers shown in the list of equipment applies
to the delivered oil supply system. For the specific switch points and values, refer to
the list of equipment.
Pump (10)
When the pump is operating, the system pressure is limited by a pressure relief valve integrated into
the pump.
Caution! The factory adjustment of this valve must not be changed!
Filter (20)
The filter is monitored visually by means of a differential pressure indicator and electrically by means
of a differential pressure monitor.
Temperature control valve (32)
A temperature control valve is located in the by−pass of the cooler.
Pressure gauge (45)
The oil pressure is indicated visually by means of a pressure gauge.
Pressure measuring transducer (50)

The pressure in the oil supply system is monitored by means of pressure measuring transducer.It sends
an outputsignal in proportion to the pressure.
Thermometer (60)
The oil temperature is indicated visually by means of a thermometer.
Resistance thermometer (65)
The temperature of the system is monitored by means of a resistance thermometer with transmitter.
Der Transmitter gibt ein der Öltemperatur proportionales Ausgangssignal.
Volumetric flow meter (80)
The oil flow to the gear unit is monitored by means of a volumetric flow meter. The volumetric flow meter
sends an output signal in proportion to the spuare of the oil flow volume.

Section 8 BA 97 11 08 1004 EN
General
A delay time of 10 s is to be provided for the pressure transducer and the flow monitor.
After switching off the main drive the oil supply system must continue to run until the drive has come
to a complete standstill.
1.3 Interlocking instructions
1.3.1 Fan motor
FAN MOTOR ON takes place when the following condition is fulfilled:
Oil temperature > Temperature value (65.1)
FAN MOTOR OFF takes place when the following condition is fulfilled:
Oil temperature < Temperature value (65.2)
1.3.2 Pump enable
PUMP ENABLE takes place when the following condition is fulfilled:
1.3.3 Enable gear unit
ENABLE GEAR UNIT takes place when all the following conditions are fulfilled:
Filter differential pressure < Switch point (20)
Oil pressure > Pressure value (50.1)
Öldurchflußmenge > Volumetric flow value (80.1)
Run-up time on the oil supply system at least 1 minutes.
1.3.4 Warning
WARNING is given when at least one of the following conditions is fulfilled:
Filter differential pressure > switch point (20) after a period of 30 s

Oil pressure < Pressure value (50.1)
Öil flow quantity < Volumetric flow value (80.1)
1.3.5 Gear unit stop
GEAR UNIT STOP takes place when at least one of the following conditions is fulfilled:
Oil pressure < Pressure value (50.2)
Öil flow quantity < Volumetric flow value (80.2)
If, when GEAR UNIT STOP occurs, the oil temperature is > switch point (65.4), the pump must be set
to remain on up to an oil temperature < switch point (65.3).

Section 8 BA 97 11 08 1004 EN
1.4 Response to malfunctions

Irrespective of the following information, the local safety requirements will
apply in all cases for operation of the oil supply system.
Monitoring during operation is essential to duly identify any malfunctions occurring (see Section 9,
”Disturbances, reasons and remedy”) and thus to implement preventive measures. The operating
pressures and oil temperatures should be recorded regularly.
If irregularities at variance with the normal condition are noticed during operation, or if the operating data
change, it is essential that the cause be identified immediately. If necessary, shut the system off. If the
causes cannot be identified, even with the aid of the Troubleshooting List, FLENDER should be
informed at once (see Section 11, ”Stocking spare parts, customer service addresses”).
We most urgently recommend that a lockable emergency switch be provided

to ensure that the system is secured to prevent accidental switch-on during
maintenance, repairs, or malfunctions. In addition, we would draw attention
to the relevant accident prevention regulations on site!
For restart after malfunction, the information in Section 7, ”Start-up”, must be observed.
1.5 Shut-down
If the gear unit and oil supply system are shut down for longer periods, the following measures are
necessary:
a) Gear unit and oil supply system must remain filled with oil. Every 4 weeks gear unit and oil supply
system must be run for 1 hour. The necessary prelubrication and lubrication times should be
observed.
b) If the measures listed under a) are not possible, the gear unit and the oil supply system must be
preserved.
Recommended preservative agent:
Preservation time up to 24 months: Castrol Alpha SP 220 S
For storage periods longer than 24 months the oil supply system must be re-preserved.
Preservation time up to 36 months: TRIBOL 1390 special anti-corrosion oil when using PAO-based
synthetic oil.
If the oil supply system is shut down for a longer period or if there is a danger of freezing, the cooling
water must be drained off.
For periods out of service exceeding 36 months, it is essential to consult FLENDER

(see also ”Gear unit” operating instructions).

Edition: May 1994
Section 9 BA 97 00 09 0010 EN
Disturbance, Reasons and Remedy Page 1 of 3
Contents
1. General 2
2. Possible malfunctions 2

Edition: May 1994
Section 9 BA 97 00 09 0010 EN
1. General
The malfunctions listed below are only intended as points of reference for troubleshooting. With such
a complex system, all other modules must always be included in troubleshooting. If the cause of the
malfunction is not clear, we recommend therefore that the specialist personnel of FLENDER be
consulted in tracing possible causes.
2. Possible malfunctions
Disturbance Reasons Remedy

Lubricating oil temperature too Cooler motor does not run Check power supply of cooler
high motor and temperature
monitor, respectively and repair
or replace, if required.
Cooler contains air Bleed cooler
Cooler dirty Clean or replace cooler.

Lubricating oil temperature too Gear unit not yet warmed up to Wait
low operating temperature
Lubricating oil pressure too low Filter clogged Clean or replace filter element
Pressure limiting valve wrongly Correct oil pressure at

set pressure limiting valve
Pressure limiting valve Repair or replace pressure

defective limiting valve
Suction line blocked Clean suction line
Pump aspirating air Check suction line and remedy

any leaks
Lubricating oil temperature too qv.

high
Oil viscosity too low Check viscosity and if

necessary fill with correct oil
Pump defective Repair or replace defective

Pump drive defective pump

Edition: May 1994
Section 9 BA 97 00 09 0010 EN
Disturbance Reasons Remedy
Lubricating oil pressure too Gear unit not yet warmed up to Wait
high operating temperature
Pressure limiting valve wrongly Correct oil pressure at limiting

set valve
Pressure limiting valve Repair or replace pressure

defective limiting valve
Lubricating oil lines to and at Locate blocked line and clean

gear unit blocked
Oil viscosity too high Check viscosity and if

necessary fill with correct oil
Clearly apparent or Pipes dirty Clean pipes
accumulated filter residues (scale, welding residues)
Abraded particels from gear Check gear unit (bearings,

unit tooth systems, alignment) and
rectify defects
Lubricating oil dirty Carry out oil change
Abraded particels from Repair or replace defective

defective pump pump
Oil consumption too high Leak in pipes, connections, Tighten screws
valves or gear unit Reseal
Shaft outlets on gear unit Renew seal rings

leaking
Cooler leaking Seal cooler or renew cooler
Filter leaking Seal filter


Section 10 BA 97 00 10 0002 EN
Maintenance and repair Page 1 of 2
Contents
1. Safety 2
2. Oils 2
3. Oil pump 2
4. Filter 2
5. Oil cooler 2
6. Preservation 2

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 27.11.1992 Rev.: a) 27.02.97 MAC
Section 10 BA 97 00 10 0002 EN
Maintenance and repair Page 2 of 2
1. Safety
During maintenance and inspection, Section 3 ”Safety” and Section 8 ”Operation” should be observed.
2. Oils
Oil grades and necessary oil change intervals will be found in the ”Gear unit” Operating Instructions
Section 10.
3. Oil pump
The special Operating Instructions of our supplier should be observed for the oil pump(s) (see
Section 12 ”Appendix”).
4. Filter
The special Operating Instructions of our supplier should be observed for the filters (see Section 12
”Appendix”).
5. Oil cooler
The special Operating Instructions of our supplier should be observed for the oil coolers (see Section 12
”Appendix).
6. Preservation
See Section 8 ”Operation”.


Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 27.11.1992 Rev.: a) 27.02.97 MAC
Section 11 BA 73 00 11 0000 EN
Spare parts stock, Service addresses Page 1 of 2
Contents
1. Spare parts stock 2
2. Addresses of replacement part suppliers and service organizations 2


Section 11 BA 73 00 11 0000 EN
Spare parts stock, Service addresses Page 2 of 2
1. Spare parts stock
A stock of the most important replacement and wearing parts is essential for satisfactory operation and
serviceability of the gear unit at all times.
Please use the Spare Parts List for ordering spare parts.
For further information, see the Spare Parts Drawing contained in the Spare Parts List.
Only original replacement parts supplied by us are covered by our warranty.

Attention is drawn expressly to the fact that replacement parts and accessories not
supplied by us have not been tested or approved by us. Installation and/or use of such
Caution! products can therefore under certain circumstances alter the structurally specified
properties of the gear unit and can as a result impair active and/or passive safety.
FLENDER accept no liability of any sort for damage caused by the use of replacement
parts and accessories which are not original Flender; their use will invalidate our
warranty in every respect.
Please note that special production and supply specifications frequently exist for individual components
and that we always supply replacement parts in accordance with the state of the art and the latest legal
requirements.
The following data should be stated when ordering replacement parts:
Order No.
Part No.
Quantity
2. Addresses of replacement part suppliers and service organizations
Please use the addresses listed below when ordering replacement parts or requesting a service fitter,
please refer to Section 12 ”Appendix”.

Edition: April 2004
Declaration by the manufacturer BA 73 00 12 0021 EN

Page 1 of 1

as defined by machinery directive 98/37/EC Annex II B
We hereby declare that the products supplied by us are meant for being installed in
a machine and that their putting into operation is prohibited until it has been
ascertained that the machine, in which these components will be installed,
corresponds to the regulations of the EC guideline (original version 98/37/EC incl. the
further amendments).
This declaration by the manufacturer takes into consideration all harmonized

standards - as far as applicable to our products - published by the EC Commission
in the Official Journal of the European Community.
Bocholt, 2004-04-06
Date Signature (Director HDE Engineering)
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Hesselmann QMND

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 1994-12-30 Rev.: c) 2004-04-06 Hes
Edition: January 2006
BA 73 00 12 0010 EN
Service facility addresses Page 1 of 5
Alfred-Flender-Straße 77 Postfach 1364 Tel.: (0 28 71) 92 - 0 contact@flender.com

46395 Bocholt 46393 Bocholt Fax: (0 28 71) 92 - 25 96 www.flender.com
A. FRIEDR. FLENDER AG Alfred-Flender-Straße 77 Postfach 1364 Tel.: (0 28 71) 92 - 0 ksc.nord@flender.com

Kundenservice Center Nord 46395 Bocholt 46393 Bocholt Fax: (0 28 71) 92 - 14 35 www.flender.com
A. FRIEDR. FLENDER AG Bahnhofstraße 40 - 44 Postfach 1709 Tel.: (0 70 71) 7 07 - 0 ksc.sued@flender.com

Kundenservice Center Süd 72072 Tübingen 72007 Tübingen Fax: (0 70 71) 7 07 - 3 40 www.flender.com
Tel.: (0 81 31) 90 03 - 0 ksc.sued@flender.com
Kundenservice Center Süd Liebigstraße 14 85757 Karlsfeld
Fax: (0 81 31) 90 03 - 33 www.flender.com
(Außenstelle München)
Tel.: (0 30) 91 42 50 58 ksc.ost@flender.com
Kundenservice Center Schlossallee 8 13156 Berlin
Fax: (0 30) 47 48 79 30 www.flender.com
Ost / Osteuropa
A. FRIEDR. FLENDER AG Tel.: (0 28 71) 92 - 0 contact@flender.com

Am Industriepark 2 46562 Voerde
Werk Friedrichsfeld Fax: (0 28 71) 92 - 25 96 www.flender.com
A. FRIEDR. FLENDER AG Thierbacher Straße 24 Postfach 44 / 45 Tel.: (03 73 81) 60 ute.tappert@flender.com

Getriebewerk Penig 09322 Penig 09320 Penig Fax: (03 73 81) 8 02 86 www.flender.com
A. FRIEDR. FLENDER AG Industriepark Bocholt Tel.: (0 28 71) 92 - 28 68 couplings@flender.com

46395 Bocholt
Kupplungswerk Mussum Schlavenhorst 100 Fax: (0 28 71) 92 - 25 79 www.flender.com
flender.guss@flender-
A. FRIEDR. FLENDER AG Obere Hauptstraße 09228 Chemnitz / Tel.: (0 37 22) 64 - 0
guss.com
FLENDER GUSS 228 - 230 Wittgensdorf Fax: (0 37 22) 94 - 1 38
www.flender-guss.de
Am Industriepark 2 Postfach 201160 Tel.: (0 28 71) 9 24 info@winergy-ag.com

WINERGY AG
46562 Voerde 46553 Voerde Fax: (0 28 71) 92 - 24 87 www.winergy-ag.com
sales-motox@flender-
Bahnhofstraße 40 - 44 Postfach 1709 Tel.: (0 70 71) 7 07 - 0
FLENDER TÜBINGEN GMBH motox.com
72072 Tübingen 72007 Tübingen Fax: (0 70 71) 7 07 - 4 00
www.flender.com
Hans-Loher-Straße 32 Postfach 1164 Tel.: (0 85 31) 3 90 info@loher.de

LOHER GMBH
94099 Ruhstorf 94095 Ruhstorf Fax: (0 85 31) 3 94 37 www.loher.de
Am Industriepark 2 Postfach 201160 Tel.: (0 28 71) 92 - 22 10 infos@flender-service.com
FLENDER SERVICE
46562 Voerde 46553 Voerde Fax: (0 28 71) 92 - 13 47 www.flender-service.com
INTERNATIONAL
Werk Herne
Postfach 101720 Tel.: (0 23 23) 9 40 - 0
Südstraße 111
44607 Herne Fax: (0 23 23) 9 40 - 3 33 infos@flender-service.com
44625 Herne
www.flender service.com
www.flender-service.com
Vertriebsbüro Penig
Postfach 44 / 45 Tel.: (03 73 81) 61 - 5 20 infos@flender-service.com
Thierbacher Straße 24
09320 Penig Fax: (03 73 81) 61 - 4 88 www.flender-service.com
09322 Penig
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Hesselmann TFED

Operating Instructions Edition: January 2006
BA 73 00 12 0010 EN
EUROPE
Industriezentrum Nö-Süd
Phone: +43 (0) 22 36 - 6 45 70 office@flender.at
AUSTRIA Flender Ges.m.b.H. Strasse 4, Objekt 14 2355 Wiener Neudorf
Fax: +43 (0) 22 36 - 6 45 70 10 www.flender.at
Postfach 132
BELGIUM & Phone: +32 (0) 2 - 2 53 10 30
N.V. Flender Belge S.A. Cyriel Buyssestraat 130 1800 Vilvoorde sales@flender.be
LUXEMBOURG Fax: +32 (0) 2 - 2 53 09 66
Phone: +359 (0) 2 - 9 80 66 06
BULGARIA Auto-Profi N GmbH 52, Alabin Str. 1000 Sofia flender@auto-profi.com
Fax: +359 (0) 2 - 9 80 33 01
CROATIA / SLOVENIA Phone: +385 (0) 1 - 2 30 60 25
BOSNIA- HUM - Naklada d.o.o. Mandroviceva 3 a 10 000 Zagreb flender@hi.htnet.hr
Fax: +385 (0) 1 - 2 30 60 24
HERZEGOVINA
Branch Office Phone: +420 315 - 62 12 20
CZECH REPUBLIC A. Friedr. Flender AG 27 601 Melnik info-cz@flender.com
Fibichova 218 Fax: +420 315 - 62 12 22
kontakt@
Phone: +45 - 70 22 60 03
DENMARK Flender Scandinavia A/S Rugmarken 35 B 3520 Farum flenderscandinavia.com
Fax: +45 - 44 99 16 62
www.flenderscandinavia.com
ESTHONIA / LATVIA Addinol Mineralöl 11 415 Tallinn Phone: +372 (0) 6 - 27 99 99 flender@addinol.ee
Suur-Söjamäe 32
LITHUANIA Marketing OÜ (Esthonia) Fax: +372 (0) 6 - 27 99 90 www.addinol.ee
Phone: +358 (0) 9 - 4 77 84 10 webmaster@flender.fi
FINLAND Flender Oy Ruosilantie 2 B 00 390 Helsinki
Fax: +358 (0) 9 - 4 36 14 10 www.flender.fi
Head Office 78 996 Elancourt Phone: +33 (0) 1 - 30 66 39 00
FRANCE Flender S.a.r.l. sales@flender.fr
3, rue Jean Monnet - B.P. 5 Cedex Fax: +33 (0) 1 - 30 66 35 13
Sales Office
69 230 Saint Genis Phone: +33 (0) 4 - 72 83 95 20
Flender S.a.r.l Agence de Lyon sales@flender.fr
Laval Fax: +33 (0) 4 - 72 83 95 39
Parc Inopolis, Route de Vourles
1, rue du Vieux Moulin 67 400 Illkirch -
Graffenstaden Phone: +33 (0) 3 - 88 67 60 00
FRANCE Flender-Graffenstaden SA flencomm@flender-graff.com
B.P. 84 67 402 Illkirch - Fax: +33 (0) 3 - 88 67 06 17
Graffenstaden
Phone: +30 210 - 2 91 72 80
GREECE Flender Hellas Ltd. 2, Delfon str. 11 146 Athens flender@otenet.gr
Fax: +30 210 - 2 91 71 02
Phone: +36 (0) 1 - 3 45 07 90 flender@monornet.hu
HUNGARY Wentech Kft. Bécsi Út 3 - 5 1023 Budapest
Fax: +36 (0) 1 - 3 45 07 92 jambor.laszlo@axelero.hu
Parco Tecnologico Manzoni
Phone: +39 (0) 02 - 95 96 31
ITALY Flender Cigala S.p.A. Palazzina G 20 040 Caponago (MI) info@flendercigala.it
Fax: +39 (0) 02 - 95 74 39 30
Viale delle industrie, 17
Lage Brink 5 - 7 7317 BD Apeldoorn Phone: +31 (0) 55 - 5 27 50 00 sales@flender.nl
THE NETHERLANDS Flender Nederland B.V.
Postbus 1073 7301 BH Apeldoorn Fax: +31 (0) 55 - 5 21 80 11 www.flender.nl
Boterdiep 37 3077 AW Rotterdam Phone: +31 (0) 10 - 4 97 08 08 info@bruinhof.nl
THE NETHERLANDS Bruinhof B.V.
Postbus 9607 3007 AP Rotterdam Fax: +31 (0) 10 - 4 82 43 50 www.bruinhof.nl
kontakt@
Phone: +45 - 70 22 60 03
NORWAY Flender Scandinavia A/S Rugmarken 35 B 3520 Farum flenderscandinavia.com
Fax: +45 - 44 99 16 62
Branch Office
Phone: +48 (0) 32 - 2 26 45 61 flender@pro.onet.pl
POLAND A. Friedr. Flender AG Przedstawicielstwo w Polsce 43 - 190 Mikolów
Fax: +48 (0) 32 - 2 26 45 62 www.flender.pl
ul. Wyzwolenia 27
Phone: +351 (0) 21 - 7 54 24 10
PORTUGAL Rodamientos FEYC, S.A R. Jaime Lopes Dias, 1668 CV 1750 - 124 Lissabon info@rfportugal.com
Fax: +351 (0) 21 - 7 54 24 19
B-dul Garii Obor nr. 8 D Phone: +40 (0) 21 - 2 52 98 61
ROMANIA CN Industrial Group srl 021 747 Bucuresti office@flender.ro
Sector 2 Fax: +40 (0) 21 - 2 52 98 60
Phone: +7 (0) 8 12 - 3 20 90 34
RUSSIA Flender OOO Tjuschina 4 - 6 191 119 St. Petersburg flendergus@mail.spbnit.ru
Fax: +7 (0) 8 12 - 3 20 90 82
Branch Office Phone: +421 (0) 51 - 7 70 32 67
SLOVAKIA A. Friedr. Flender AG 08 001 Presov micenko.flender@nextra.sk

Vajanského 49, P.O. Box 286 Fax: +421 (0) 51 - 7 70 32 67
Poligono Industrial San
Phone: +34 (0) 91 - 6 83 61 86 f-iberica@flender.es
SPAIN Flender Ibérica S.A. Marcos Calle Morse, 31 28 906 Getafe - Madrid
Fax: +34 (0) 91 - 6 83 46 50 www.flender.es
(Parcela D - 15)
kontakt@
Phone: +46 (0) 302 - 1 25 90
SWEDEN Flender Scandinavia Äsenvägen 2 44 339 Lerum flenderscandinavia.com
Fax: +46 (0) 302 - 1 25 56
Phone: +41 (0) 62 - 8 85 76 00 info@flender.ch
SWITZERLAND Flender AG Zeughausstr. 48 5600 Lenzburg
Fax: +41 (0) 62 - 8 85 76 76 www.flender.ch
Flender Güc Aktarma
IMES Sanayi, Sitesi 34 776 Dudullu - Phone: +90 (0) 2 16 - 4 66 51 41 cuzkan@flendertr.com
TURKEY Sistemleri Sanayi ve
E Blok 502, Sokak No. 22 Istanbul Fax: +90 (0) 2 16 - 3 64 59 13 www.flendertr.com
Ticaret Ltd. Sti.
DIV-Deutsche Phone: +380 (0) 44 - 2 30 29 43
UKRAINE Prospect Pobedy 44 03 057 Kiev flender@div.kiev.ua
Industrievertretung Fax: +380 (0) 44 - 2 30 29 30
Bradford
UNITED KINGDOM & Flender Power Phone: +44 (0) 12 74 - 65 77 00 info@flender-power.co.uk
Thornbury Works, Leeds Road West Yorkshire
EIRE Transmission Ltd. Fax: +44 (0) 12 74 - 66 98 36 www.flender-power.co.uk
BD3 7EB
SERBIA-
MONTENEGRO Phone: +381 (0) 11 - 60 44 73
G.P.Inzenjering d.o.o. III Bulevar 54 / 19 11 070 Novi Beograd flender@eunet.yu
ALBANIA Fax: +381 (0) 11 - 3 11 67 91
MACEDONIA

BA 73 00 12 0010 EN
AFRICA
NORTH AFRICAN 78 996 Elancourt Phone: +33 (0) 1 - 30 66 39 00
Flender S.a.r.l. 3, rue Jean Monnet - B.P. 5 sales@flender.fr
COUNTRIES Cedex Fax: +33 (0) 1 - 30 66 35 13
Phone: +20 (0) 2 - 5 75 15 44
EGYPT Sons of Farid Hassanen 81 Matbaa Ahlia Street Boulac 11 221, Cairo hussein@sonfarid.com
Fax: +20 (0) 2 - 5 75 17 02
Head Office
Flender Power Phone: +27 (0) 11 - 5 71 20 00 sales@flender.co.za
SOUTH AFRICA Cnr. Furnace St & Quality Rd. Isando - Johannesburg
Transmission (Pty.) Ltd. Fax: +27 (0) 11 - 3 92 24 34 www.flender.co.za
P.O. Box 131 Isando 1600
Sales Offices
Flender Power Unit 3 Marconi Park, 9 Marconi Phone: +27 (0) 21 - 5 51 50 03
sales@flender.co.za
Transmission (Pty.) Ltd. Crescent, Montague Gardens, Cape Town Fax: +27 (0) 21 - 5 52 38 24
P.O. Box 37 291 Chempet 7442
Unit 3 Goshawk Park
Flender Power Phone: +27 (0) 31 - 7 05 38 92
Falcon Industrial Estate New Germany - Durban sales@flender.co.za
Transmission (Pty.) Ltd. Fax: +27 (0) 31 - 7 05 38 72
P.O. Box 1608 New Germany 3620
Flender Power 9 Industrial Crescent, Ext. 25 Witbank Phone: +27 (0) 13 - 6 92 34 38
sales@flender.co.za
Transmission (Pty.) Ltd. P.O. Box 17 609 Witbank 1035 Fax: +27 (0) 13 - 6 92 34 52
Unit 14 King Fisher Park, Alton
Flender Power Phone: +27 (0) 35 - 7 51 15 63
Cnr. Ceramic Curve & Alumina Richards Bay sales@flender.co.za
Transmission (Pty.) Ltd. Fax: +27 (0) 35 - 7 51 15 64
Allee, P.O. Box 101 995 Meerensee 3901
AMERICA
C 1067 ABN Phone: +54 (0) 11 - 43 31 66 10
ARGENTINA Chilicote S.A. Avda. Julio A. Roca 546 chilicote@chilicote.com.ar
Buenos Aires Fax: +54 (0) 11 - 43 31 42 78
Head Office
32 210 - 660 Phone: +55 (0) 31 - 33 69 20 00
BRASIL Flender Brasil Ltda. Rua Quatorze, 60 vendas@flenderbrasil.com
Contagem - MG Fax: +55 (0) 31 - 33 31 18 93
Cidade Industrial
Sales Offices
04 576 - 050 Phone: +55 (0) 11 - 55 05 99 33
Flender Brasil Ltda. Rua James Watt, 152 flesao@uol.com.br
São Paulo - SP Fax: +55 (0) 11 - 55 05 30 10
conjunto 142 - Brooklin Novo
Rua Campos Sales, 1095 14 015 - 110 Phone: +55 (0) 16 - 6 35 15 90
Flender Brasil Ltda. flender.ribpreto@uol.com.br
sala 14 - centro Ribeirão Preto - SP Fax: +55 (0) 16 - 6 35 11 05
Rua da Mitra - quadra 30 - lote16
65 075 - 770 Phone: +55 (0) 98 - 32 25 84 92
Flender Brasil Ltda. Edifício Cristal - sala 207 flenderslz@uol.com.br
São Luis - MA Fax: +55 (0) 98 - 32 25 84 93
Bairro Renascença
Rua Padre Anchieta, 1691 80 730 - 000 Phone: +55 (0) 41 - 3 36 28 49
Flender Brasil Ltda. quality.engineer@bol.com.br
conjunto 1110 - Bairro Bigorrilho Curitiba - PR Fax: +55 (0) 41 - 3 36 28 49
Rua José Alexandre Buaiz,
29 050 - 545 Phone: +55 (0) 27 - 32 24 37 35
Flender Brasil Ltda. 160 sala 1017 - Enseada do flender.vitoria@uol.com.br
Vitória - ES Fax: +55 (0) 27 - 32 24 37 36
Suá
Flender Power Markham Phone: +1 (0) 9 05 - 3 05 10 21 info@flenderpti.com
CANADA 215 Shields Court, Units 4 - 6
Transmission Inc. Ontario L3R 8V2 Fax: +1 (0) 9 05 - 3 05 10 23 www.flender.ca
CHILE / ARGENTINA
BOLIVIA / ECUADOR Phone: +56 (0) 2 - 2 35 32 49 flender@flender.cl
Flender Cono Sur Ltda. Avda. Galvarino Gallardo 1534 Providencia, Santiago
PARAGUAY Fax: +56 (0) 2 - 2 64 20 25 www.flender.cl
URUGUAY
Flender Liaison Office Colombia
A.G.P. Representaciones Phone: +57 (0) 1 - 5 70 63 53 aguerrero@agp.com.co
COLOMBIA Av Boyaca No. 23 A Bogotá
Ltda. Fax: +57 (0) 1 - 5 70 73 35 www.agp.com.co
50 Bodega UA 7 - 1
Flender de Mexico Head Office Phone: +52 (0) 2 22 - 2 37 19 00 szugasti@flendermexico.com
MEXICO 72 000 Puebla
S.A. de C.V. 17, Pte, 713 Centro Fax: +52 (0) 2 22 - 2 37 11 33 www.flendermexico.com
Sales Offices
Flender de Mexico Phone: +52 (0) 55 - 52 54 30 37
Lago Nargis No. 38 11 520 Mexico, D.F. info@flendermexico.com
S.A. de C.V. Fax: +52 (0) 55 - 55 31 69 39
Col. Granada
Flender de Mexico Ave. San Pedro No. 231 - 5 Phone: +52 (0) 81 - 83 63 82 82
64 660 Monterrey, N.L. info@flendermexico.com

S.A. de C.V. Col. Miravalle Fax: +52 (0) 81 - 83 63 82 83
Phone: +56 (0) 2 - 2 35 32 49 flender@flender.cl
PERU Flender Cono Sur Ltda. Avda. Galvarino Gallardo 1534 Providencia, Santiago
Fax: +56 (0) 2 - 2 64 20 25 www.flender.cl
950 Tollgate Road Phone: +1 (0) 8 47 - 9 31 19 90 flender@flenderusa.com
USA Flender Corporation Elgin, IL. 60 123
P.O. Box 1449 Fax: +1 (0) 8 47 - 9 31 07 11 www.flenderusa.com
Service Centers West Phone: +1 (0) 6 61 - 3 25 44 78
Flender Corporation Bakersfield, CA. 93 308 flender1@lightspeed.net
4234 Foster Ave. Fax: +1 (0) 6 61 - 3 25 44 70
Calle Johan Schafer o Segunda Phone: +58 (0) 2 12 - 21 52 61 fhtransm@telcel.net.ve
VENEZUELA F. H. Transmisiones S.A. Petare, Caracas
Calle, Municipio Sucre Fax: +58 (0) 2 12 - 21 18 38 www.fhtransmisiones.com

BA 73 00 12 0010 EN
ASIA
BANGLADESH No. 2 St. George’s Gate Road Phone: +91 (0) 33 - 2 23 05 45
Flender Limited Kolkata - 700 022 flender@flenderindia.com
SRI LANKA 5th Floor, Hastings Fax: +91 (0) 33 - 2 23 18 57
Head Office
PEOPLE’S REPUBLIC Flender Power Trans- Shuanghu-Shuangchen Rd. Phone: +86 (0) 22 - 26 97 20 63 flender@flendertj.com
Tianjin 300 400
OF CHINA mission (Tianjin) Co., Ltd. West, Beichen Economic Fax: +86 (0) 22 - 26 97 20 61 www.flendertj.com
Development Area (BEDA)
Sales Offices
Flender Power Trans- C - 414, Lufthansa Center Phone: +86 (0) 10 - 64 62 21 51
Beijing 100 016 beijing@flenderprc.com.cn
mission (Tianjin) Co., Ltd. 50 Liangmaqiao Rd. Fax: +86 (0) 10 - 64 62 21 43
Chaoyang District
Flender Power Trans- 1101 - 1102 Harbour Ring Plaza Phone: +86 (0) 21 - 53 85 31 48 shanghai@
Shanghai 200 001
mission (Tianjin) Co., Ltd. 18 Xizang Zhong Rd. Fax: +86 (0) 21 - 53 85 31 46 flenderprc.com.cn
Flender Power Trans- Rm. 1503, Jianyin Building Phone: +86 (0) 27 - 85 48 67 15
Wuhan 430 015 wuhan@flenderprc.com.cn
mission (Tianjin) Co., Ltd. 709 Jianshedadao, Hankou Fax: +86 (0) 27 - 85 48 68 36
Rm. 2802, Guangzhou
Flender Power Trans- Phone: +86 (0) 20 - 87 32 60 42 guangzhou@
International Electronics Tower Guangzhou 510 095
mission (Tianjin) Co., Ltd. Fax: +86 (0) 20 - 87 32 60 45 flenderprc.com.cn
403 Huanshi Rd. East
Flender Power Trans- G - 6 / F Guoxin Mansion Phone: +86 (0) 28 - 86 19 83 72
Chengdu 610 015 chengdu@flenderprc.com.cn
mission (Tianjin) Co., Ltd. 77 Xiyu Street Fax: +86 (0) 28 - 86 19 88 10
Rm. 3 - 705, Tower D
Flender Power Trans- City Plaza Shenyang Phone: +86 (0) 24 - 23 34 20 48
Shenyang 110 001 shenyang@flenderprc.com.cn
mission (Tianjin) Co., Ltd. 206 Nanjing Street (N) Fax: +86 (0) 24 - 23 34 20 46
Heping District
Rm. 302, Shanzi Zhong Da
Flender Power Trans- Phone: +86 (0) 29 - 87 20 32 68
International Mansion Xi’an 710 002 xian@flenderprc.com.cn
mission (Tianjin) Co., Ltd. Fax: +86 (0) 29 - 87 20 32 04
30 Southern Rd.
Flender Power Trans- Rm. 23E, Xinhua Plaza, No. 6 Phone: +86 (0) 871 - 3 12 43 68
Kunming 650 051 kunming@flenderprc.com.cn
mission (Tianjin) Co., Ltd. Renmin East Rd. Fax: +86 (0) 871 - 3 12 45 66
Rm. 1007, Building A, Golden
Flender Power Trans- Phone: +86 (0) 371 - 5 38 80 85 zhengzhou@
Center, Jincheng International Zhengzhou 450 008
mission (Tianjin) Co., Ltd. Fax: +86 (0) 371 - 5 38 80 89 flenderprc.com.cn
Plaza, No. 68 Jingsan Rd.
Flender Power Trans- Rm. 908 (east), No. 188 Phone: +86 (0) 25 - 83 24 25 50
Nanjing 210 024 nanjing@flenderprc.com.cn
mission (Tianjin) Co., Ltd. Guangzhou Rd. Fax: +86 (0) 25 - 83 24 48 20
Rm. 1408, Pearl River
Flender Power Trans- Phone: +86 (0) 411 - 83 77 93 55
International Building No. 99 Dalian 116 011 dalian@flenderprc.com.cn
mission (Tianjin) Co., Ltd. Fax: +86 (0) 411 - 83 77 92 19
Xinkai Rd. Xigang District
Rm. 1401, Tianlin Building
Flender Power Trans- Hunan Gold Source Hotel Phone: +86 (0) 731 - 5 16 73 09 changsha@
Changsha 410 007
mission (Tianjin) Co., Ltd. No. 279, Second Block Fax: +86 (0) 731 - 5 16 47 46 flenderprc.com.cn
Furong Rd.
Head Office
Hastings Phone: +91 (0) 33 - 22 23 05 45
INDIA Flender Limited No. 2 St. George’s Gate Road flender@flenderindia.com
Kolkata - 700 022 Fax: +91 (0) 33 - 22 23 18 57
5th Floor
Industrial Growth Centre Nimpura Phone: +91 (0) 3222 - 23 33 07
Flender Limited works@flenderindia.com
Rakhajungle Kharagpur - 721 302 Fax: +91 (0) 3222 - 23 33 64
Eastern Regional Sales Office
Hastings Phone: +91 (0) 33 - 22 23 05 45
Flender Limited No. 2 St. George’s Gate Road ero@flenderindia.com
Kolkata - 700 022 Fax: +91 (0) 33 - 22 23 08 30
5th Floor
Western Regional Sales Office Vashi Phone: +91 (0) 22 - 27 65 72 27
Flender Limited wro@flenderindia.com
Plot No. 23, Sector 19 - C Navi Mumbai - 400 705 Fax: +91 (0) 22 - 27 65 72 28
Southern Regional Sales Office Aminjikarai Phone: +91 (0) 44 - 23 74 39 21
Flender Limited sro@flenderindia.com
41 Nelson Manickam Road Chennai - 600 029 Fax: +91 (0) 44 - 23 74 39 19
Northern Regional Sales Office
Phone: +91 (0) 11 - 51 85 96 56
Flender Limited 302 Bhikaji Cama Bhawan New Delhi - 110 066 nro@flenderindia.com
Fax: +91 (0) 11 - 51 85 96 59

11 Bhikaji Cama Palace
Phone: +62 (0) 21 - 58 90 20 15
INDONESIA Flender Singapore Pte. Ltd. 6 - 01 Wisma Presisi Jakarta Barat 11 620 bobwall@cbn.net.id
Fax: +62 (0) 21 - 58 90 20 19
Jl. Taman Aries Blok A1 No. 1
P.O. Box 15 745 - 493
Phone: +98 (0) 21 - 8 73 02 14
IRAN Cimaghand Co. Ltd. No. 13, 16th East Street Tehran 15 156 info@cimaghand.com
Fax: +98 (0) 21 - 8 73 39 70
Beyhaghi Ave., Argentina Sq.
Phone: +972 (0) 52 - 4 76 14 26 ram@greenshpon.de
ISRAEL Greenshpon Boaz 3 34487 Haifa
Fax: +972 (0) 4 - 8 14 60 37 www.greenshpon.co.il
WBG Marive East 21 F
Phone: +81 (0) 43 - 2 13 39 30
JAPAN Flender Japan Co., Ltd. Nakase 2 - 6 Chiba 261 - 7121 contact@flender-japan.com
Fax: +81 (0) 43 - 2 13 39 55
Mihama-ku, Chiba-shi
Phone: +7 (0) - 32 72 - 43 39 54
KAZAKHSTAN KazGate GmbH Abay ave 143 480 009 Almaty flender@kazgate.de
Fax: +7 (0) - 32 72 - 77 90 82
7thFl. Dorim Bldg.
Phone: +82 (0) 2 - 34 78 63 37 sales@flender-korea.com
KOREA Flender Ltd. 1823 Bangbae- Dong Seoul 137 - 060
Fax: +82 (0) 2 - 34 78 63 45 www.flender-korea.com
Seocho - Ku
Al-Showaikh Ind. Area Phone: +965 (0) - 4 82 97 15
KUWAIT South Gulf Company Safat 13 123 adelameen@awalnet.net.sa
P.O. Box 26229 Fax: +965 (0) - 4 82 97 20
Dahr-el-Jamal
Phone: +961 (0) 1 - 49 82 72
LEBANON Gabriel Acar & Fils s.a.r.l. Zone Industrielle, Sin-el-Fil Beyrouth gacar@beirut.com
Fax: +961 (0) 1 - 49 49 71
B.P. 80 484

BA 73 00 12 0010 EN
47301 Petaling Jaya Phone: +60 (0) 3 - 78 80 42 63
MALAYSIA Flender Singapore Pte. Ltd. 37 A - 2, Jalan PJU 1/39 flender@tm.net.my
Selangor Darul Ehsan Fax: +60 (0) 3 - 78 80 42 73
Dataran Prima
Phone: +49 (0) 28 71 - 92 22 59
PAKISTAN A. Friedr. Flender AG Postfach 1364 46 393 Bocholt ludger.wittag@flender.com
Fax: +49 (0) 28 71 - 92 15 16
28 / F, Unit 2814, The Enter- Phone: +63 (0) 2 - 8 49 39 93
PHILIPPINES Flender Singapore Pte. Ltd. Makati City junt@flender.com.ph
prise Centre, 6766 Ayala Ave- Fax: +63 (0) 2 - 8 49 39 17
nue corner, Paeso de Roxas
BAHRAIN / IRAQ Flender Güc Aktarma Middle East Sales Office
LYBIA / JORDAN 34776 Dudullu - Phone: +90 (0) 2 16 - 4 99 66 23
Sistemleri Sanayi ve IMES Sanayi Sitesi meso@flendertr.com
OMAN / QATAR Istanbul Fax: +90 (0) 2 16 - 3 64 59 13
U.A.E. / YEMEN
Ticaret Ltd. Sti. E Blok 502, Sokak No. 22
Bandaria Area, Dohan Bldg. Phone: +966 (0) 3 - 8 87 53 32

SAUDI ARABIA South Gulf Sands Est. Al-Khobar 31952 adelameen@awalnet.net.sa
Flat 3 / 1, P.O. Box 32150 Fax: +966 (0) 3 - 8 87 53 31
Phone: +65 (0) - 68 97 94 66 flender@singnet.com.sg
SINGAPORE Flender Singapore Pte. Ltd. 13 A, Tech Park Crescent Singapore 63 7843
Fax: +65 (0) - 68 97 94 11 www.flender.com.sg
Mezzeh Autostrade
Transportation Phone: +963 (0) 11 - 6 11 67 94
SYRIA Misrabi Co & Trading Damascus ismael.misrabi@gmx.net
Building 4 / A, 5th Floor Fax: +963 (0) 11 - 6 11 09 08
P.O. Box 12450
1 F, No. 5, Lane 240 Phone: +886 (0) 2 - 26 93 24 41
TAIWAN Flender Taiwan Limited Taipei Hsien 221 flender_tw@flender.com.tw
Nan Yang Street, Hsichih Fax: +886 (0) 2 - 26 94 36 11
Talay-Thong Tower, 53 Moo 9 A. Sriracha Phone: +66 (0) 38 - 49 51 66 - 8
THAILAND Flender Singapore Pte. Ltd. contact@flender.th.com
10th Floor Room 1001 Chonburi 20 230 Fax: +66 (0) 38 - 49 51 69
Sukhumvit Rd., T. Tungsukla
Phone: +84 (0) 8 - 8 23 62 97
VIETNAM Flender Singapore Pte. Ltd. Suite 22, 16 F Saigon Tower Ho Chi Minh City flender_vn@flender.com.vn
Fax: +84 (0) 8 - 8 23 62 88
29 Le Duan Street, District 1
AUSTRALIA
Head Office
Phone: +61 (0) 2 - 97 56 23 22 sales@flender.com.au
Flender (Australia) Pty. Ltd. 9 Nello Place, P.O. Box 6047 N.S.W. 2164, Sydney
Fax: +61 (0) 2 - 97 56 48 92 www.flender.com.au
Wetherill Park
Sales Offices
Phone: +61 (0) 3 - 95 57 08 11
Flender (Australia) Pty. Ltd. Suite 3, 261 Centre Rd. VIC 3204, Melbourne sales@flender.com.au
Fax: +61 (0) 3 - 95 57 08 22
Bentleigh
Suite 5, 1407 Logan Rd. Phone: +61 (0) 7 - 34 22 23 89
Flender (Australia) Pty. Ltd. QLD 4122, Brisbane sales@flender.com.au
Mt. Gravatt Fax: +61 (0) 7 - 34 22 24 03
Suite 2 W.A. 6104 Phone: +61 (0) 8 - 94 77 41 66
Flender (Australia) Pty. Ltd. sales@flender.com.au
403 Great Eastern Highway Redcliffe - Perth Fax: +61 (0) 8 - 94 77 65 11
9 Nello Place, P.O. Box 6047 Phone: +61 (0) 2 - 97 56 23 22
NEW ZEALAND Flender (Australia) Pty. Ltd. N.S.W. 2164, Sydney sales@flender.com.au
Wetherill Park Fax: +61 (0) 2 - 97 56 48 92

BA STE.PUM.000 EN
OPERATING MANUAL
Steimel Gear Pumps

and
Pump Units
Series B, R, SF, T
Type designation : ..........................................................................................
Serial No. : ...................................................................................................
Gebr. Steimel GmbH & Co

Maschinenfabrik
Postfach 1565
D-53762 Hennef
Telephone (02242) 88 09 - 0 Fax (02242) 88 09 160
Edition: 2.95 DBA-ZP02-E Sheet 1 of 14

TABLE OF CONTENTS
1 General 6 Starting up / shutting down

1.1 Intended application 6.1 Preparations for starting up
1.2 Product information 6.2 Initial commissioning
1.2.1 Type designation and works serial No. 6.3 Placing back into operation
1.2.2 Technical data sheet 6.4 Shutting down
1.2.3 Permitted use
7 Maintenance / repair
2 Safety 7.1 General information
2.1 Identification of safety instructions in the 7.2 Shaft seal
Operating Manual 7.2.1 Stuffing box packing
2.2 Qualification and training of operating 7.2.2 Axial face seal / rotary shaft seal
personnel 7.2.3 Twin seals
2.3 Hazards in the event of non-compliance 7.2.4 Pressure relief valve
with the safety instructions 7.3 Dismantling and re-assembly
2.4 Compliance with regulations pertaining 7.3.1 Basic instructions
to safety at work 7.3.2 Dismantling the unit
2.5 Safety instructions relevant for operation 7.3.3 Dismantling the pump
2.6 Safety instructions relevant for maintenance, 7.3.4 Assembling the pump / unit
inspection and assembly work 7.4 Spare parts
2.7 Unauthorised alterations and production
of spare parts 8 Related drawings
2.8 Unauthorised modes of operation
9 Faults; causes and remedies
3 Transport and intermediate storage
3.1 Transport
3.2 Intermediate storage
4 Technical description
4.2 Construction and mode of operation
4.3 Mechanical construction
4.3.1 Pump casing
4.3.2 Gear wheels
4.3.3 Shafts, bearings and lubrication
4.3.4 Shaft seal
4.3.5 Drive
4.4 Accessories
4.4.1 Pressure relief valve
4.4.2 Heating and cooling units
5 Mounting / installation
5.1 Installation position
5.2 Mounting for the first time
5.3 Drive elements
5.3.1 Aligning flexible couplings
5.3.2 Coupling guard
5.4 Electrical connection
5.5 Pipes
5.5.1 Purging
5.5.2 Connecting pipes
5.5.3 Additional connections
5.5.4 Suction line
5.5.5 Delivery line
5.5.6 Pressure test and leakage test
5.6 Protection against foreign bodies
and contamination

GENERAL INFORMATION / SAFETY
1 General - operating or working range / scheduled or

permitted use
1.1 Intended application - sound pressure level
- power requirement
Steimel gear pumps are suitable for pumping lube - internal preservation
oils, fuel oils and other lubricating fluids. - surface protection / paint finish
The fluids pumped may not contain any abrasive - weight
components and may not chemically attack the - references to tests, certificates and
materials of which the pump is made. acceptance tests
The field of application of these pumps extends - date of issue
from oil hydraulics through lubrication systems to
pure pumping applications. in the case of pump units, also:
Above all, the pumped medium must always be
clean and have good lubricating properties in order - drive type / motor / transmission
to ensure that the pump operates correctly, in order - motor and transmission data
to ensure a high level of operating reliability and - coupling / belt drive
safety and in order to ensure a long service life. - sub-plate, intermediate bracket /
pump mount
1.2 Product information - accessories / safety facilities
- references to required certificates
1.2.1 Type designation and works serial No. - miscellaneous.
The full type designation is specified in the 1.2.3 Permitted use

technical data sheet or the order confirmation.
The works serial No. comprises the contract No. The pump / pump unit is designed only for the field
and a consecutive serial No. (e.g. 94 1234-2). It is of application listed in the technical data sheet of
imprinted directly on the rating plate or on the our order confirmation.
pump. Differing operating conditions will necessitate new
contractual agreements.
1.2.2 Technical data sheet
2 Safety
The technical data sheet is a part of our sales order
confirmation and should contain all important This Operating Manual gives basic instructions
technical details agreed between the purchaser and which are to be observed during installation,
manufacturer, such as operation and maintenance of the pump. It is
therefore imperative that this Manual be read by the
- designation, type, size responsible personnel / operator prior to assembly
- item No. and commissioning. It is always to be kept available
- project drawing / dimension sheet at the installation site.
- spare parts list for parts subject to wear
- related Operating Manuals It is not only the general safety instructions
- suction and delivery connection contained under this main heading "Safety" that are
- materials to be observed but also the specific information
- shaft seal provided under the other main headings.
- pumped medium / field of application
- direction of rotation 2.1 Identification of safety instructions in the
- accessories Operating Manual
- hydraulic parameters such as delivery rate,
operating pressure, speed, viscosity range Safety instructions given in this Manual, non-
and temperature range compliance with which would affect safety are
identified by the following symbol:
If required, also:
- pressure relief valve / safety facilities

- special installation position
- suction characteristics See DIN 4844-W 9

SAFETY
or where electrical safety is involved, with 2.4 Compliance with regulations pertaining
to safety at work
When operating the pump, the safety instructions

see DIN 4844-W 8. contained in this Manual, the relevant national
accident prevention regulations and any other
The word CAUTION service and safety instructions issued by the plant
operator are to be observed.
indicates safety information which may result in
risks to the machine and its function if the 2.5 Safety instructions relevant for the plant
information is not observed. operator
It is imperative that signs affixed to the machine, - If hot or cold machine components involve
e.g. hazards, they must be guarded against
accidental contact on site.
- arrow indicating the direction of rotation
- Guards for moving parts (e.g. coupling) must
- symbols indicating fluid connections not be removed from the machine while in
operation.
be observed and kept legible.
- Any leakage of hazardous (e.g. explosive,
2.2 Qualification and training of operating toxic, hot) fluids (e.g. from the shaft seal) must
personnel be drained away so as to prevent any risk to
persons or the environment. Statutory regulations
The personnel responsible for operation, are to be complied with.
maintenance, inspection and assembly must be
adequately qualified. Scope of responsibility and - Hazards resulting from electricity are to be
supervision of the personnel must be exactly prevented (see for example, the VDE Specifica-
defined by the plant operator. If the staff do not tions and the bye-laws of the local power supply
have the necessary knowledge, they must be utilities).
trained and instructed, which may be performed by
the machine manufacturer or supplier on behalf of 2.6 Safety instructions relevant for mainte-
the plant operator. Moreover, the plant operator is nance, inspection and assembly work
to make sure that the contents of the Operating
Manual are fully understood by the personnel. It shall be the plant operator's responsibility to
ensure that all maintenance, inspection and
2.3 Hazards in the event of non-compliance assembly work is performed by authorised and
with the safety instructions qualified personnel who have adequately
familiarised themselves with the subject matter by
Non-compliance with the safety instructions may studying this Manual in detail.
produce a risk to the personnel as well as to the
environment and the machine and results in a loss Any work on the machine shall only be performed
of any right to claim damages. when it is at a standstill, it being imperative that the
procedure for shutting down of the machine
For example, non-compliance may involve the described in this Manual be followed.
following hazards: Pumps and pump units which convey hazardous
media must be decontaminated.
- Failure of important functions of the
machine/plant On completion of work all safety and protective
facilities must be re-installed and made operative
- Failure of specified procedures of maintenance again.
and repair
Prior to restarting the machine, the instructions
- Exposure of people to electrical, mechanical and listed under "Initial commissioning" are to be
chemical hazards observed.
- Endangering the environment owing to hazardous

substances being released.

TECHNICAL DESCRIPTION
2.7 Unauthorised alterations and production 3.2 Intermediate storage

of spare parts
The pump / the pump unit must be stored on a
Any modification may be made to the machine only timber support at a protective location in the
after consultation with the manufacturer. Using position of normal use and must be covered.
spare parts and accessories authorised by the
manufacturer is in the interest of safety. Use of It is not permitted to stack heavy pumps /
other parts may exempt the manufacturer from any pump units one above the other.
liability.
The pump is not provided with internal preservation.
2.8 Unauthorised modes of operation In some cases, a film of test medium originating
from the test bench run may still adhere to the
The reliability of the machine delivered will be only inside faces. A mineral oil is used as the test
guaranteed if it is used in the manner intended, in medium unless otherwise agreed.
accordance with Clause 1 of this Manual. The limit Should you intend to store the unit for long periods,
values specified in the data sheet must under no we advise you to contractually agree on a special
circumstances be exceeded. internal preservation.
The condition of the pump and its preservation
3 Transport and intermediate storage must be checked at least once per year!
If stored in the open air, please carefully cover the
3.1 Transport pump / pump unit and ensure that it is not exposed
either to moisture or foreign bodies.
The pump / the pump unit is delivered in assembled
condition. Lube oils for transmissions, confining and 4 Technical description
sealing fluid and valves / fittings are delivered in
separate packagings if necessary. 4.1 General description
The pump / the pump unit is packaged differently, The gear pump, being the most popular type of
depending on the transport route and size. The rotary, positive-displacement pump, owes its great
packaging complies with our general packaging popularity primarily to the sophisticated involute
guidelines unless otherwise contractually agreed. gearing which permits low-cost series production
When transporting the complete unit, the cables with high precision, besides its simple construction.
must be attached, as shown, to pump and motor Most gear pumps have straight-toothed spur gears.
(not to the eyebolt of the motor and pump). Certain types are fitted with helical-tooth spur gears
or with double-helical (herring-bone) gears in an
effort to achieve greater running smoothness.
4.2 Construction and mode of operation
In line with the diverse fields of application of the

gear pumps, we have developed a variety of
different models.
Very low-pressure gear pumps for pumping
moderately fluid to viscous media generally have a
The motor suspension eyebolts are suitable only f large displacement volume and low speed of
or the weight of the motor. Likewise, the rotation. It is more economical to pump low-
pump eyebolt is suitable only for the weight viscosity media with small, high-speed gear pumps.
of the pump. Consequently, additional The mode of operation of the external gear pump
loads attached to the motor and pump may not be results from the engaged teeth. This is where the
raised with these eyebolts. actual separation process between suction and
pressure chamber occurs.
The drive gear wheel / drive pinion drives the
mating gear wheel / mating pinion, thus causing the
Please avoid jerky movements, shock and intermeshing teeth to release the tooth spaces
heavy vibration when raising and lowering abruptly.
during transportation !

MOUNTING / INSTALLATION
When the gear wheels, which are surrounded by a gear wheels are designed as pinions. Materials,
casing or adapter on all sides, rotate, the tooth surface hardnesses, wear-resistant coatings and
spaces fill with the medium to be pumped as the gearing quality will depend on the customer's sales
result of the partial vacuum produced and convey it order.
outwards and around to the delivery end. Combing
of the gear wheels which are turning in opposite 4.3.3 Shafts, bearings and lubrication
directions forces the medium into the delivery line.
The delivery pressure produced by a pump builds The pump shafts are mounted in plain bearing
up in the delivery line depending on the resistances bushes. The bearing points must be adequately
opposing the delivery flow. These resistances result lubricated by the medium!
from pipe friction and the various installed fittings,
fixtures and devices. CAUTION The pump must always receive fluid
The power demand increases with increasing and may never be allowed to run dry!
delivery pressure!
The running play on the sliding surfaces is rated so
The pump may never be operated as to constantly guarantee an adequate lubrication
CAUTION with the suction or delivery line film.
closed! The lower the viscosity of a medium to be pumped,
the closer the running play must be kept in order to
achieve a favourable volumetric efficiency of the
pump. However, this also necessitates a purer
medium to be pumped in order to achieve high
Suction Delivery operating reliability and as long a pump service life
as possible.
4.3.4 Shaft seal
On versions with stuffing box packing (P), this

packing must drip slightly during operation in order
4.3 Mechanical construction to dissipate the frictional heat.
Ensure that the leakage is safely collected or
4.3.1 Pump casing discharged in controlled fashion.
The pump casing encloses the gear wheels and is On versions with axial face seal (G), this seal has
generally equipped with a suction and delivery only slight or invisible (vapour) leakage losses
connection for the pipes. during operation. It requires no maintenance.
Depending on the particular type, it also contains a
pressure relief valve and one side of the drive and No maintenance is required either on versions with
counter-shaft bearing assembly. rotary shaft seal (R).
In the case of the disk or plate design, the gear
wheels are enclosed by a so-called adapter which In the case of twin seals, such as GG or GR
has the shape of a plate, the thickness of which versions, a quench fluid recipient serves to
corresponds to approximately the length of the gear lubricate and cool the downstream seal. These seal
wheel. combinations serve to exclude air in the case of
The drive and counter-cover serves to media which react in an undesirable manner when
accommodate the shaft bearing. coming into contact with atmospheric oxygen.
The shaft seal is accommodated in the drive cover
or in a casing. 4.3.5 Drive
4.3.2 Gear wheels The pump must be driven free of

CAUTION vibration via a flexible coupling and
Gear wheels have an involute gearing. Straight- the drive shaft may be subjected
tooth spur gears are generally used in feed pumps. neither to radial forces nor axial forces!
Owing to the greater running smoothness, helical- Any radial loading of the shaft journal resulting from
tooth spur gears are given preference in high- V belts, chains, drive gear wheels or so forth is
speed lube oil pumps in the low pressure range. cushioned by an additional radial bearing which is
The gear wheel bodies are generally connected to accommodated inside or outside the pump.
the shaft by interference fits and, in some cases, Please state the relevant parameters for design of
also by feather keys. In many cases, shafts and this bearing in your purchase order.

4.4 Accessories carefully aligned. Wherever possible, please use

torsion-resistant sub-plates or frames.
On pump units with a sub-plate made
CAUTION
The pump can be delivered with a built-in or of grey cast iron, please ensure that
mounted pressure relief valve or circulation valve the deposit surface is absolutely flat
which returns the pumped medium from the and level!
delivery end to the suction end in order to protect On uneven deposit surfaces, the sub-plates may
against overloading of the pump. This valve is also be aligned with the aid of shims, but these
suitable for occasional, brief response, not owing to shims must be well-set (snugly fitting).
regular operation. Rapid heating of the medium
occurs should the valve respond for a longer 5.3 Drive elements
period, and this may result in undesirable changes
and may also disturb proper operation of the pump. Please also refer to 4.3.5 Drive.
We recommend inserting bypass-relief valves in a - On a pump with free shaft extension, remove the
bypass with a return line to the supply tank for high shaft protection (if applicable, corrosion protec-
pressures and long response times. tion, e.g. with solvent, but not with emery paper).
The setting of the pressure relief valve may - Fit and lock the drive element onto the shaft.
be changed only after procuring the prior
consent of the pump manufacturer! Fit the coupling using a fitting tool. On
CAUTION
The final pressure of the valve lies 20-30 % no account may you force the
above the opening pressure. coupling on by knocking or tapping
since this could damage the shaft, gear wheels,
4.4.2 Heating and cooling units bearing assembly, thrust rings and retaining rings
for instance.
Types TM have double-walled casings or corres-
ponding ducts and can be heated or cooled with a 5.3.1 Aligning flexible couplings
liquid or gaseous medium. Temperature sensors in
the pump serve to monitor and safeguard the pump The unit is correctly aligned if a straight-edge
against inadmissible switch-on of the drive motor. placed axially over both coupling halves is the
same distance from the relevant shaft at all points
Types TE are heated with electrical heating on the circumference, whereby it must be noted
cartridges. The temperature is controlled steplessly that the measurement point must be turned as well
by means of a system regulator. by hand.
Moreover, both coupling halves must be the same
5 Mounting / installation distance from each other at all points on the
circumference. This can be verified with a probe or
5.1 Installation position gauge.
Example: Aligning a flexible coupling without
Unless otherwise agreed, the pump should be intermediate sleeve or gear rim.
mounted / installed so that the drive shaft and
counter-shaft are vertically adjacent. The fact that Straight-edge
the line connections are then horizontal is the best
method of guaranteeing that as large a fluid
quantity as possible remains in the pump when the
pump is switched off. It then normally inducts this
fluid "reservoir" easily again under normal
conditions when restarted.
5.2 Mounting for the first time Gauge
Base-mounted pumps may be mounted only on

precisely level supports, in order to avoid twisting.
The deviation between the two coupling halves
should not exceed 0.3 mm either radially or axially.
Flange pumps must be mounted in a precisely
This must also be ensured at operating
machined flange centring ring. If machines are to
temperature and with supply pressure applied.
be coupled, please ensure that the machines are

5.3.2 Coupling guard Elongation of the pipes resulting from temperature

variations must be compensated for by suitable
In accordance with the accident prevention regu- measures.
lations, the pump may be operated only with a
coupling guard. If this coupling guard is not 5.5.3 Additional connections
supplied by us, at the express request of the
orderer, the operator must provide such a guard. The dimensions and position of the additional
connections required for the pump, e.g. for sealing,
5.4 Electrical connection purging or leakage fluid, are specified in the
installation and piping plan.
The electrical connection must be made by a
qualified electrician in accordance with the 5.5.4 Suction line
applicable safety regulations. Please refer to the
Installation Instructions and Operating Manual In the case of short suction lines, the nominal dia-
provided by the motor manufacturer. Please refer to meter should be at least that of the pump connec-
the Installation Instructions and Operating Manual tion. On longer pipes, determine the most economi-
of the equipment manufacturer for safety facilities cal nominal diameter in each individual case.
and control equipment. Adapters for increasing to larger nominal diameters
should be designed with as gentle an expansion
5.5 Pipes angle as possible in order to reduce pressure
losses.
5.5.1 Purging The suction line should always be as short and
straight as possible. The total suction-end resis-
The suction and delivery connection of the pump tance may not exceed 0.4 bar in operating condi-
are sealed with plastic caps. The pump interiors still tion. In start-up condition, it may be max. 0.65 bar
contain residual quantities of the testing oil or, for a period of up to approx. 30 min (until operating
possibly, a preservation agent. If contractually temperature is reached).
agreed, pumps are also cleaned by us after the trial The total resistance comprises the geodetic suction
run. These pumps are then entirely free of such head and the pipe resistance, including the resis-
residue. tance of any built-in fixtures and fittings. It is
Should the pump be purged before initial commis- measured as a partial vacuum using a vacuum
sioning, we recommend using either the medium to meter directly at the pump suction connection.
be pumped or a neutral agent for this purpose. The flow velocity is a further characteristic para-
Please do not use water or fluids containing water meter for the suction line. Always endeavour to
since this could entail the risk of corrosion, apart achieve a value of 1...1.5 m/s for the flow velocity in
from on pumps made of high-grade steel or the case of oil.
stainless steel. A partial vacuum greater than 0.4 bar impairs the
Before the pump is installed in a new pump's volumetric efficiency, thus reducing the
CAUTION delivery capacity and resulting in cavitation.
installation, the tanks, pipes and
connections must be cleaned Cavitation causes increasing noise and greater
thoroughly, flushed through and blown through with wear in the long term.
compressed air. Welding beads, scale and other Installing a vacuum meter at the pump suction
contamination frequently only become detached connection is particularly advisable for checking
after a certain period. In order to prevent this, the partial vacuum in the suction line and
please take appropriate measures, such as assessing the degree of contamination of any
sandblasting, before installation. suction filter installed.
Foreign bodies will endanger the The suction line must be absolutely
CAUTION tight !
CAUTION operational reliability and safety of the
pump and may lead to blockage
or total failure. 5.5.5 Delivery line
5.5.2 Connecting pipes The operating or delivery pressure must be

checked with a pressure gauge fitted directly at the
On no account may the pump be used as a fixed pump delivery connection. The delivery pressure or
support on long pipes. Long pipes must be sup- total resistance comprises the individual resis-
ported directly ahead of the pump and must be tances of the actuators, the geodetic pressure head
connected free of strain. On no account may their and pipe resistances.
weight be borne by the pump.

CAUTION Line and actuator resistances depend 2. Secondary contamination

on viscosity. It is advisable to fit a
pressure relief valve in order to avoid overloading Circulation pumps, e.g. for oil supply systems, are
the pump as the result of inadmissibly high subjected to contamination which, after commis-
pressure. sioning, forms continually in the sliding surfaces of
The flow velocity in the delivery line should not the gear components as abrasion or abraded wear
exceed 3 m/s in the case of oil. in the form of metallic particles and which can be
Should there be air in the suction line, this may entrained by the lube oil.
cause induction problems when starting the pump, Gear pumps can be protected against primary
e.g.: contamination by coarse filters or plate-type filters
- if the pump is to pump against a closed system fitted in the suction line.
(loaded non-return valve), Depending on the filter rating, these suction filters
- if two pumps operating in parallel are mutually retain foreign bodies of a specific size.
safeguarded by means of non-return valves. The filter clogs up gradually as the
The situation can be remedied by bleeding the CAUTION result of contamination and silting-up,
delivery line or by a small bypass line (DN 4-6) thus impeding induction of the feed
upstream of the non-return valve. The bypass is stream by the pump. This will be noticeable since
then connected back to the tank. the pump will become noisier.
On forced-circulation lubrication systems such as (see also 8.4 Faults)
those conventional in gear construction, cleaning A filter rating of 0.05 to 0.13 mm is appropriate,
filters must be fitted in the delivery line. depending on pump design. The larger the filter
The overall circulating volume of the lube oil must area, the longer will be the maintenance intervals.
not be selected too low so that it does not overheat Gear pumps are best protected against secondary
as the result of frequent pumping through the circuit contamination by means of changeover filters or
and inadequate cooling. A cooler or heat exchanger double self-bypassing filters fitted in the delivery
must be provided if necessary. line and designed for continuous filtration. Whilst
one filter chamber is in operation, the other is at
5.5.6 Pressure test and leakage test standby. The filters can be equipped with visual
differential pressure indicators or electrical contacts
These tests must be conducted statically before for remote monitoring in order to permit the
the pump is installed. Special-purpose boiler and increasing contamination of the filter to be
pipe test pumps must be used for this purpose. On recognised.
no account may the feed pump be used ! One of the other aspects which must be borne in
Test pressures generally lie mind when selecting the filter rating and size is the
substantially above the pump design viscosity range of the lube oil. Consequently, the
CAUTION
pressure so that the pump could be filter manufacturer should be consulted. Filter
damaged. (see also 5.5.1 Purging) ratings of 25-60 µm are conventional for lube oils.
5.6 Protection against foreign bodies and CAUTION Foreign bodies endanger the opera-
contamination tional safety and reliability of the
pump and may lead to blockage or total failure.
A distinction is made between two types of Larger quantities of ultra-fine contamination will
contamination: cause abrasion wear on the sliding surfaces and
will reduce the service life of the pump.
1. Primary contamination
6 Starting up / shutting down
- Filling and feed pumps are exposed to foreign
bodies, dirt particles or mineral pigments which 6.1 Preparations for starting up
are located in the medium to be pumped.
Before starting up, inspect the pump installation in
- Pipe elements, in particular upstream of the order to establish that it is in proper working order
pump, may be contaminated with fine dirt as specified in the technical documentation.
particles such as metal swarf, welding or
soldering beads or abrasives etc. originating In the case of electric motor-driven pumps, the
from production or installation. electrical connections may be made only by a
(see also 5.5.1 Purging) qualified electrician.
Facilities for personal safety (e.g.
CAUTION contact guard on clutches and belts)
must be fitted.

STARTING UP / SHUTTING DOWN
6.2 Initial commissioning 6.3 Placing back into operation
Ensure that there is adequate medium in the pump In principle, the same procedure as that described
before initial commissioning. in Point 6.2 Initial commissioning must be noted in
Gear pumps are always self-priming pumps. Under this case.
normal circumstances, they may induct the air If the pump has been placed out of operation for a
present in the suction line and convey it into the long period, please check that there is still
delivery line. It is advisable to also fill the suction adequate fluid in the pump in order to ensure
line with the medium to be pumped before starting, reliable re-induction.
particularly in the case of extremely unfavourable
suction conditions, in order to prevent the pump CAUTION Check the mobility of the internal
running dry. components of the pump in the case
Fill the pump and, wherever possible, of media which could set (e.g. by turning the drive
CAUTION also the suction line with the fluid to shaft).
be pumped and then bleed.
Always avoid the pump running dry! CAUTION On no account may a cold pump be
Should there be shut-off elements in the suction or started up suddenly with a hot
delivery line, these elements must be opened fully. medium. The temperature of the pump must be
Fully open all additional connections provided, e.g. increased slowly in order to avoid seizing of the
for sealing or purging fluid etc., and check flow. pump as the result of thermal shock.
Heavy pumps generally have an eyebolt for 6.4 Shutting down

attaching load suspension devices at the topmost
point on the casing. There may be a screw plug at Depending on the particular system, the pump
this point on small pumps. Depending on the should be allowed to idle for an adequate period -
particular design, the eyebolt is located either in a with the heating source switched off - until the
tapped blind hole or in a through-hole with thread. pumped fluid’s temperature has dropped to such an
The latter offers the option of filling or bleeding the extent as to avoid heat build-up in the pump.
pump. Close the shut-off element in the supply line if the
pump has been out of operation for a long period.
Check the direction of rotation. Close off additional connections.
CAUTION Each pump features a direction-of-
rotation arrow. If the pump is operated The shaft seal must be supplied with sealing fluid
in the wrong direction, this could entail the risk of even when at standstill on pumps in which the
overloading the shaft seal and causing it to leak. pumped fluid is supplied under vacuum.
Pumps suitable for clockwise and counter-
clockwise rotation are exceptions to this rule. Media which set should be drained off. The pump
The direction of rotation can even be checked with can be used at most only briefly and at low purging
the pump full and with the shut-off elements open pressure in order to clean the pipe system.
by briefly switching the drive on and off. The intention to use the pump as a
CAUTION purging pump must be known when
CAUTION Gear pumps are positive-displace- designing the pump in order to ensure
ment pumps. material compatibility.
If the pump pumps into a closed delivery line, it will High purging pressures and long operating times
be overloaded and fail. should be avoided in the case of purging or
cleaning fluids with poor lubrication properties
Pressure relief valves protect pumps against owing to the risk of jamming or seizing on the
damage and overload (see also 4.4.1 Pressure sliding surfaces of the pump.
relief valve).
7 Maintenance / repair
Proper functioning of the pump can be checked by
listening to the noise and by checking the pressure 7.1 General information
gauge. The time taken from switching on to
pumping should not exceed 30 seconds. Steimel gear pumps largely require no maintenance
under normal operating conditions if they are
operated with media having good lubrication
properties.

MAINTENANCE / REPAIR
It is advisable to regularly check the performance The rotary shaft seal requires no maintenance
data. Integration of corresponding monitoring either. Should it leak, it must be renewed.
devices, such as operating hours counters,
pressure gauges, pressure and temperature 7.2.3 Twin seals
monitors etc., will depend on the requirements and
the relevant regulations. On twin seals and combined seals, the quench fluid
level in the recipient must be checked constantly
Please note the following points when carrying out and topped up if necessary.
maintenance work on the overall system:
- Check that all securing screws, bolts and
connections are tight and retighten if necessary. Please follow the steps below should it be
necessary to regulate / adjust the opening pressure
- Check alignment of the coupling. Examine of the pressure relieve valve:
elastomers for wear.
- Unscrew the pressure cap and undo the lock nut.
- Check the pump for leaks, in particular the
shaft seals. - The required opening pressure can be set by
turning the threaded bushing / regulating screw
7.2 Shaft seal which is then accessible.
Turning clockwise: increases the opening
7.2.1 Stuffing box packing pressure.
Turning counter-clockwise: reduces the opening
The stuffing box gland nut may be tightened only pressure.
lightly so that the packing allows slight leakage Recommended values for pressure setting:
during operation, thus dissipating the frictional heat. approx. 10 % above the operating pressure /
working pressure of the system.
If the leakage rate is too high after a long operating
period, tighten the nuts on the stuffing box gland - Screw the pressure cap back on
uniformly by 1/6 of a turn. Then observe the leak- (do not forget the sealant).
age. If it is no longer possible to tighten the stuffing
box gland nut, you must fit an extra packing ring. It 7.3 Dismantling and re-assembly
is generally not necessary to replace the entire
7.3.1 Basic instructions
packing assembly.
Should it be necessary to renew the packing The unit must be safeguarded so that it cannot be
assembly nevertheless, also assess the condition switched on before starting dismantling work.
of the shaft bearing assembly and the seal seat. The shut-off elements in the supply and delivery
If there are signs of major scoring on the shaft, the line must be closed. The pump must have reached
shaft must be exchanged since, otherwise, this will ambient temperature.
impair sealing with new packing rings.
7.3.2 Dismantling the unit
The joints of the packing rings or cut ring sections
must be mutually offset by approx. 90°. 1. Disconnect the electrical power supply
The joint should be at the top on the last ring at the 2. Remove any fitted additional connections
gland end. 3.: Unit on sub-plate:
The packing rings must be carefully bent open both 3.1. Remove the coupling guard
axially and radially only sufficiently to permit them to 3.2. Disconnect the motor terminals
just be slid over the shaft. Detach the motor from the sub-plate
3.3. Disengage the pump and motor
7.2.2 Axial face seal / rotary shaft seal 3.4. by moving the motor's position
3.5. Detach the suction and delivery connection
Maintenance of the axial face seal is restricted to 3.6. Detach the pump from the sub-plate
occasionally checking for leaks. 4.: Unit with pump support / intermediate
Very slight leakage of the axial face seal is bracket:
permitted. 4.1. Disconnect the motor terminals
Should the leakage be higher than this, the axial 4.2. Detach the motor
face seal must be renewed. When doing this, also 4.3. Detach the suction and delivery connection
inspect the pump bearing assembly. 4.4. Detach the pump from the pump support /
intermediate bracket

MAINTENANCE / REPAIR
7.3.3 Dismantling the pump at the position of the sealing edge on the old
ring.
Please refer to the various exploded views (if This can be achieved by:
available). - exchanging the shaft or shaft bushing
Identify the position of the pump components and - fitting with a spacer ring
number them consecutively! - pressing in to different depths in the location
1. Undo the casing bolts hole.
2. Release the counter-cover from the casing - Use a press-in tool and a suitable press-in die
using 2 forcing threads and hexagon when pressing in.
bolts - Make sure that you do not damage the sealing
3. Pull the counter-shaft with gear wheel out lip at sharp edges when sliding into the shaft!
of the pump casing - On smooth shafts, round off the keyways and
4. Release the safety catch on the coupling turned grooves. Fitted shafts should have a
half and detach it with an extractor tool conical bevel. If this is not possible, an
and then detach the feather key installation sleeve must be used to assist in
5. Version with packing: assembly.
5.1. Undo the gland stuffing box • Axial face seal
6. Direction of rotation-dependent axial face please refer to the special Installation Instructions
seal: and Operating Manual
6 1. Pull out the axial face seal • Pressure relief valve
7. Direction of rotation-independent axial please refer to Point 7.2.4
face seal:
(Please refer to the special Installation 7.4 Spare parts
Instructions and Operating Manual)
8. Version with single thrust bearing: Keeping a stock of the most important spare parts
8.1. Detach the bearing catch and parts subject to wear at the installation site is
9. Version with rotary shaft seal: an important precondition for ensuring that the
9.1. Detach the seal locating cover pump is always ready for operation.
10. Pull the drive shaft with gear wheel On the other hand, we recommend that you keep in
out of the pump casing stock a reserve pump and return the removed
11. On pumps with bearing components pump to our works for repair if necessary.
made of carbon / ceramic material,
always ensure that you take great care Please refer to our spare parts list with cutaway
when dismantling! view when ordering spare parts.
Use absolutely no force since these
components are fragile and could fracture. We are able to assume warranty only for original
spare parts supplied by us.
7.3.4 Assembling the pump / unit
It must be expressly pointed out that spare parts
Follow the generally valid rules applicable in the and accessories not supplied by us are not tested
field of mechanical engineering and machine cons- by us and are not approved by us. Installation
truction when re-assembling. and/or use of such products may thus impair design
O-rings must be inspected for damage and must be characteristics of the pump and thus endanger
replaced by new O-rings if necessary. active and/or passive safety. We are unable to ac-
cept liability and accept claims under warranty for
Flat gaskets must always be renewed. Ensure that damage and loss occurring as the result of using
the new gasket has precisely the same thickness non-original spare parts and accessories.
as the old gasket.
Hylomar SQ 32/M or Epple 33 for instance may be Please state the following information when sub-
used as permanently elastic universal seals. mitting orders for spare parts:
All seal and gasket residue must be removed
completely. When re-assembling, follow the re- - Contract No. / Serial No.
verse procedure to that followed when dismantling. - Part No.
• Stuffing box packing, see Point 7.2.1 - Quantity
• Rotary shaft seal
- Always use new rotary shaft seals. 8 Related documents
- Always ensure that they are fitted in the correct
position. Please refer to the technical data sheet or the sales
- The sealing edge of the new ring should not be order confirmation for the related documents.

FAULTS; CAUSES AND REMEDIES

FAULTS; CAUSES AND REMEDIES

ENGLISH
Information on safety and commissioning Types: 5AP, 6AP,C,F,16BA,7BA,7AA

for low voltage asynchronous motors
(in accordance with L. V. directive 73/23/EEC)
Shaft height: 56 to 315 mm

1 General information Do not obstruct ventilation! Discharged air, also from neighbouring
Electric motors have dangerous voltage-carrying and rotating equipment, must not be sucked in again immediately.
components as well as surfaces that may become hot. All work Checking of bearing grease must be carry out when motors are longer
than 12 months storaged. When storage conditions are the cause of
involved in the transport, connection, commissioning and regular
grease depreciation (presence of condensate, consistency change)
maintenance must be carried out by qualified, responsible
the grease must be exchanged. Grease exchangr must be carry out
specialists (note VDE 0105; IEC 364). Improper behaviour may result
no later than in three year interval.
in serious injury and damage to property. The applicable national,
local and works regulations and requirements must be complied
5 Electrical connection
with.
Work is only permitted to be carried out by qualified specialists on
2 Intended use the stationary motor, while disconnected and prevented from
being switched on again. This also applies for the auxiliary power
These motors are intended for commercial installations. They comply circuits (e.g. Anti-condensation heaters).
with the harmonized standards of the EN60034 (VDE 0530) series.
Utilization in areas subject to explosion hazard is not permitted, Check that the equipment is potential-free!
unless expressly intended for this purpose (see additional notes). If the tolerance limits are exceeded that are specified in EN 60034,
In certain special cases, for example, on use in non-commercial part 1 / IEC 34-1 (voltage ± 5%, frequency ± 2%, shape of curve,
installations, if requirements are more strict (e.g. protection against symmetry) the heating effect is increased and the electromagnetic
contact with children’s fingers), it is the responsibility of the customer compatibility is affected. Please note the specifications on the rating
to ensure compliance on installing the equipment. If the tolerance limits are exceeded that are specified in EN 60034,
plate and the connection diagram in the terminal box.
The motors are rated for ambient temperatures of -20°C to +40°C and part 1 / IEC 34-1 (voltage ± 5%, frequency ± 2%, shape of curve,
Connections must be made in such a way as to ensure that a
site altitudes ≤ 1000 m above sea level. Any contradictory information symmetry) the heating effect is increased and the electromagnetic
permanently safe electrical connection is maintained (no protruding
on the rating plate must be observed. The conditions on site must compatibility is affected. Please note the specifications on the rating
wire ends); use the corresponding cable end pieces. Create a safe
correspond to all rating plate specifications. plate and the connection diagram in the terminal box.
earth continuity connection.
Connections must be made in such a way as to ensure that a
Low voltage motors are components for installation in machinery Tightening torques
permanently for terminal
safe electrical board connections
connection is maintained (no protruding
in terms of the Machine directive 89/392/EEC. Commissioning wire ends); use the corresponding cable end pieces. Create a safe
Thread ∅
earth continuity M 4 M 5 M 6 M 8 M10 M12 M16
connection.
must not take place until it has been proved that the end product
conforms with this guideline (please note EN 60204-1). Tightening torques for terminal1,8..
Tightening 0,8.. board2,7.. 5,5.. 9..
connections 16.. 36..
torque [Nm] ..1,2 ..2,5 ..4 ..8 ..13 ..20 ..40
3 Transport and storage Thread ∅ M 4 M 5 M 6 M 8 M10 M12 M16
Clearences in air between bare live parts themselves and between
Any damage detected after dispatch should be reported immediately bare live parts and earth must 1,8..
Tightening 0,8.. be ≥ 2,7..
5,5 mm 5,5.. ≤ 69016..
(Urated9.. V) . 36..
to the transport company and commissioning must be postponed. torque [Nm] ..1,2 ..2,5 ..4 ..8 ..13 ..20 ..40
It must be ensured that the terminal box does not contain foreign
Tighten the eyebolts. They are designed for the weight of the motor
only therefore do not attach any additional loads. If necessary, use bodies, dirt orinhumidity.
Clearences Seal any
air between bareunused cable
live parts entry openings
themselves against
and between
suitable, adequately dimensioned transporting equipment (e.g. rope dust live
bare andparts
water.
and earth must be ≥ 5,5 mm (Urated ≤ 690 V) .
guides). Secure the featherkey on test operation without drive components.
It must be ensured that the terminal box does not contain foreign
Remove existing shipping braces before commissioning; and reuse For motors with brakes, check that the brakes are operating perfectly
bodies, dirt or humidity. Seal any unused cable entry openings against
for subsequent transport. If motors are stored, a dry, dust-free and before commissioning.
dust and water.
low vibration (vr m s ≤ 0.2 mm/s) environment is important (to avoid
Secure the featherkey on test operation without drive components.
bearing standstill damage). On long-term storage, the regrease 6 Operation
For motors with brakes, check that the brakes are operating perfectly
interval of the bearings is reduced. Vibration levels of vr m s ≤ 3.5 mm/s (PN ≤ 15 kW) or vr m s ≤ 4.5 mm/
Before commissioning, measure the impedance of the insulation. If before commissioning.
s (PN > 15 kW) are quite acceptable in the coupled state.
values ≤1kΩ per volt of rated voltage are measured, the windings If deviations
6 Operation from normal operation occur - e.g. increased
must be dried out.
temperatures, noises, vibration - the motor should be switched
When motors with roller bearings for increased cantilever force are Vibration levels of vr m s ≤ 3.5 mm/s (PN ≤ 15 kW) or vr m s ≤ 4.5 mm/
off in the event of doubt. Determine the causes and contact the
operated the value of cantilever force must be minimal 30% of s (PN > 15 kW) are quite acceptable in the coupled state.
manufacturer if necessary. Do not disconnect protective equipment,
permissible cantilever force (see catalogue). Operating with smaller If deviations from normal operation occur - e.g. increased
even under test operation.
cantilever force is the cause of bearing faults. temperatures, noises, vibration - the motor should be switched
Under dirty operating conditions, clean the air channels regularly.
off in the event of doubt. Determine the causes and contact the
Open any closed condensate water holes from time to time!
4 Installation manufacturer if necessary. Do not disconnect protective equipment,
Ensure an even underlying surface, good foot or flange fixing and even under test operation.
For motors without regreasing facilities, bearing or grease
precise alignment for direct coupling. It is important to ensure that the Under dirty operating conditions, clean the air channels regularly.
replacement must be carried out in accordance with the manufacturer’s
mounting conditions do not cause resonance with the rotational Open any closed condensate water holes from time to time!
instructions, or after 3 years, whichever is sooner.
frequency and the doubled supply frequency. Turn the rotor by hand
Bearings with regreasing facilities must be regreased when the
and listen for any unusual grinding noises. Check the direction of For motors without regreasing facilities, bearing or grease
motor is running.
rotation in the decoupled state (note section 5). replacement must be carried out in accordance with the manufacturer’s
Only mount or remove drive components (belt pulley, coupling, etc.) In the case of motors with separate ventilation, the separately-
instructions, or after 3 years, whichever is sooner.
using suitable tools (heat up), and cover to shield against contact. driven fan must be switched on throughout motor operation.
Bearings with regreasing facilities must be regreased when the
Avoid unpermissible belt tensions (see catalogue and technical data). motor is running.
The balancing type is specified on the shaft end face or rating plate 7 Further information
In the case of motors with separate ventilation, the separately-
(H = half- and F = full-key balancing). On mounting the drive, note the Information provided about any
driven fan must be switched onadditional
throughoutequipment must be noted!
motor operation.
balancing type! In the case of half key balancing, the protruding,
visible part of the half-featherkey must be removed.
A canopy is recommended for designs with the shaft end pointing
7 Further information
downwards, and with the shaft end pointing upwards a cover must be Information provided about any additional equipment must be noted!
provided by the customer to prevent foreign bodies from falling into
the fan. These notes on safety and commissioning must be retained
for future reference!
2
09.02 DBA-DM01-E 1/1
Edition: May 1995
B 5921 EN
Double change-over filter Page 1 of 3
These operating instructions are binding for double change-over filters according to FLENDER works
standard W 5921.
Function
Double change-over filters are designed for continuous filtration. Normally, only one filter chamber is in
operation, the second filter chamber being held in reserve. As soon as the filter is clogged by increasing
contamination (see indicator contamination), changeover takes place to the second filter chamber.
Change-over of the liquid flow from one chamber to the other takes place without interrupting the actual liquid
flow.
Startup
Before startup, the entire system should be flushed through. This ensures that possible contamination occuring
during installation will not cause any malfunctions. Normally, the filter will be operated in single chamber mode.
In case of extremely high viscosity (cold start at low oil temperatures and/or high initial impurity content), parallel
operation of both filter chambers is advisable (switch-over lever in centre position). After completion of the
startup phase, change over to single chamber mode. The shut-off filter element intended as backup in
subsequent single chamber mode must be cleaned immediately after change-over to permit utilizing the full
impurity collection capacity.
Cleaning
Increasing contamination of the filter is apparent from the contamination indicator. The filter element held in
reserve should be filled (by slowly turning the switch-over lever, while at the same time opening the venting
screw until oil emerges). The pressure of the shut-off filter element should be released by opening the venting
screw and drained by unscrewing the drain plug. Afterwards, the filter chamber should be unscrewed and the
filter element withdrawn. The filter element should be washed with fresh cleaning liquid, such as benzine or
warmed diesel oil, and then blown through from the inside to the outside.

Edition: May 1995
B 5921 EN
Cable connection b
PG 11 e
q f2
Outlet
Contamination P R Venting screw
X
indicator
f1
Type 2.F2
g2
c
X Name plate
Inlet
SW 27 P
g2 120 °
150
X Filter bowl
(flange connection) Switch-over lever
Drain plug
assembly S
R k
t
for a
Nom.
diam. d f1 f2 d1 d2 t
32 G 1 1/4 41 32 42.2 47.0 2.0
50 G2 45 36 61.0 74.0 3.0
80 - 50 41 81.0 89.0 -
Table 1: Flange connection dimensions
Nom. Flow Mesh Filter Weight Mesh

diam. rate area length width
V per filter
element a b c e h k D R S P q g1 g2 1)
l/min cm2 kg mm
32 150 1500 187 216 215 72 115 324 105 86 G 3/8 40 M 10 10 150 110 13 60 or 25
50 350 3500 267 260 247 88 134 435 130 110 G 1/2 40 M 12 9 160 130 20 60 or 25
80 900 9000 358 352 316 103 183 568 180 158 G 3/4 70 M 16 12 185 160 31 60 or 25
Table 2: Filter dimensions
1) The ”nominal” mesh width is determined by the smallest particle size of which 90 % is retained in the filter
mesh.

Edition: May 1995
B 5921 EN
Technical Data
Operating pressure : max. 16 bar
Operating temperature : max. 120 °C
Oil flow velocity : max. 3 m/s
Contamination indicator : Type 2.F2 (differential pressure Dp 2 bar)

1 two-way contact
Electrical limit data (max. contact loading)

Switching voltage u v 250 V DC + AC
Switching current I v 1 A
Switching capacity P v 30 W or v 60 VA
Type of protection IP 65
Materials
Housing and switch-over element : GG-25
Filter bowl : GK-AL
Filter (cage mesh) : CrNi/Al
Diaphragm : Perbunan
O-rings : Perbunan
O-ring dimensions : on filter chamber for DN 32: 85.09 x 5.33
50: 104.14 x 5.33
80: 148.59 x 5.33
on inlet flange for DN 32: 37.47 x 5.33
50: 59.69 x 5.33
80: 85.09 x 5.33

on outlet flange for DN 32: 40.87 x 3.53
50: 63.09 x 3.53
80: 91.67 x 3.53
Circuit diagram for contamination indicator
2 P

BA MVA.REG.000 EN
1/9
MVA Am KirchenHölzl 7 eMail
Mess- und D-82166 Gräfelfing/München info@mva-messvt.de
VerfahrensTechnik Fon +49-89-8583 69-0 interNet
GmbH Fax +49-89-8583 69-70 www.mva-messvt.de
THERMOSTATIC VALVES
(SELF ACTUATED TYPES)
MVA SERIES ``M...... ´´ GENERAL INFORMATION
MVA Thermostatic Valves are used to provide reliable, automatic control of fluid temperatures
in turbines, compressors and engine water jacket and lubricating oil cooling systems. They are
also suitable for process control and industrial applications where fluids must be mixed or
diverted depending on their temperatures. They may also be applied to co-generation systems
to control temperatures in the heat recovery loop assuring proper engine cooling and
maximising heat recovery.
All MVA Thermostatic Valves are equipped with positive 3-way valve action in which the water
or lubricating oil is positively made to flow in the direction required. On jacket water applications
when the engine is started up and is cold, the MVA Thermostatic Valve causes all of the water
to be positively by-passed back into the engine, thus providing the quickest warm-up period
possible. After warm up, the correct amount of water is by-passed and automatically mixed with
the cold water returning from the heat exchanger or other cooling device to produce the desired
jacket water outlet temperature. If ever required, the MVA Thermostatic Valve will shut off
positively on the by-pass line for maximum cooling. The 3-way action of the MVA Thermostatic
Valve allows a constant volume of water through the pump and engine at all times with no
pump restriction when the engine is cold.
ADJUSTMENTS & MAINTENANCE
No adjustments are ever required on MVA Thermostatic Valves. Once installed a MVA
Thermostatic Valve will provide years of trouble-free service.
TEMPERATURE SETTINGS
Because MVA Thermostatic Valves are set to a predetermined temperature at the factory,
costly errors due to mistakes of operating personnel are eliminated. After a MVA Thermostatic
Valve has been installed, it is impossible for the operator to arbitrarily change the operating
temperature and run the engine too cold or too hot unless the temperature element assemblies
themselves are changed.
MVA Thermostatic Valves are temperature rated for the expected nominal operating
temperature in jacket water service. On lubricating oil applications the system operating
temperature may be slightly above the nominal rating, depending on the type of oil flow rate, oil
cooler capacity and other conditions of the system.
For long life, MVA Thermostatic Valves should not be operated continuously at temperatures
more than about 75°F (24°C) above their nominal ratings. If higher continuous over-
temperatures are expected, contact the factory for recommendations.
OPERATION
The power creating medium utilises the expansion of a special thermostatic wax material which
remains in a semi-solid form and which is highly sensitive to temperature changes.
Rev. 01 07.11.05 page 1 of 9 MrDBlE1105.doc

BA MVA.REG.000 EN
2/9
INSTRUCTIONS FOR MVA TEMPERATURE VALVE MODEL "M" WITH AND WITHOUT
MANUAL OVERRIDE
1) Maintenance
Properly applied and installed, MVA Thermostatic Valves require minimal maintenance. An
inspection at 2 or 3 year intervals is adequate to detect and make provision for manual wear.
Excessive temperatures, chemical, electrolytic attack or cavitation will shorten the life of the
element assemblies, seals and seats. These items are replaceable. Water additives may cause
swelling of the O-ring seals around the stem and the sliding valve to a point where they may
affect valve action and require replacement. Synthetic base lubricants will definitely attack the
O-ring seals which may be replaced by O-rings of alternate materials. Contact the MVA factory
for recommendations.
Carbonates, scale and other solids must not be permitted to build up on sliding valve or sensing
cup surfaces. The valve and element assemblies may be cleaned with mild acid or Oakite
solutions. Hard scale may require wire brush buffing.
2) Manual override
If for any reason "M"-Thermostatic valves with manual override should not work properly, each
element assembly is fitted with an infinitaly variable override which allows on accurate manual
temperature regulation.
Before the manual override is used we recommend, however, to check whether the cause of
trouble is not somewhere in the system, according to paragraph 3) "Trouble shooting". Manual
override should only be used in emergency case.
If a thermostatic valve with several element assemblies is installed (DN 65 - DN 125) it is
recommended to open one element assembly after the other against cooler by turning screw
until desired temperature is nearly reached. Final regulation is done with next element
assembly.
3) Trouble-Shooting
In the event that your cooling system does not operate close to the desired temperature, the
following check list may point to one or more causes for the problem.

BA MVA.REG.000 EN
3/9
3.1 System Temperature too cold

a) Insufficient heat rejected to coolant to maintain the temperature
b) Wrong nominal temperature selected
c) Thermostatic valve is greatly oversized for the system flow rate or cooling
capacity of the system is much greater than is required
d) Thermostatic valve ist installed backwards, forces water to cooler and causes engine to
run cold under all conditions
e) Worn O-ring seal around the element assembly
f) Too great a pressure difference (in excess 1,7 bar) between ports 2 and 3
g) Foreign material is stuck between sliding valve and seat
h) Element assembly may have been over-temperated sufficiently to affect calibration or
rupture wax seal and does therefore not close "2"-port completely anymore. Requires
complete new element assembly.
3.2 System Temperature too hot

a) Cooling capacity of system not adequate
b) Thermostatic valve too small for flow rate (also causes high pressure drop and possibly
cavitation)
c) Valve installed backwards; as temperature increases, Port 2 closes, reducing flow to
cooler
d) Bypass will not close due to worn or pitted seats, sliding valve, O-ring seal, etc.
e) Worn O-ring seal around the element assembly
f) Element assembly may have been over temperated sufficiently to affect calibration or
rupture wax seal and does therefore not fully open "3"-port anymore. Requires complete
new element assembly.
g) Solids build up on sliding valve prevents proper action of element assembly
h) Foreign material stuck between sliding valve and seat
i) Excessive pressure differential between port (very low pressure through bypass leg, very
high pressure in cooler)
3.3 Additional Considerations

a) Thermometers: A thermometer that reads the same whether system is cold or hot needs
replacing
b) Location of thermometers: on horizontal pipe runs, these should be in the side of the pipe
when possible, particularly on oil systems. Also, pipes do not always run full so the
thermometer may not be immersed in the fluid
c) Thermometers should be as far as possible downstream from the confluence of two
streams of different temperature to allow complete mixing
d) Look for bypasses or "sneak circuits" which prevent thermostatic valve control of the
complete system

BA MVA.REG.000 EN
4/9
The next pages show you some different PIPING DIAGRAMS

Fig. 7 COOLING WATER-HEAT
EXCHANGER
Compen-
x This scheme shows the cooling water circuit
3
sation
1
of a fix installed or a ship engine with cooling
tank MVA by a heat exchanger. The MVA Thermostatic
Valve is in such a way installed, that the
engine temperature of the cooling water at the
outlet of the engine will be maintained
Cooling water constant. Should exist any problem cause by
enclosed air, a narrow ventilation pipe (x)
Fig. 7 Heat exchanger
leading from the highest point of the system
to the compensation tank will help.
Fig. 8 COOLING WATER –AIR COOLING

DEVICE
3
1
MVA This arrangement is used practically always
in vehicles and fixed installed engines with
air cooling device. Here, the temperature of
engine
the cooling water also will be maintained
constant at the outlet of the engine.
Cooling water
Fig. 8 cooling device
Fig. 9 COOLING WATER –DIRECT

out board
COOLING
2
1
MVA
Today, small and medium size engines are
partially still cooled directly by sea water,
W
although the disadvantages of such systems
engine T are well known. In Fig. 9 the temperature of
Sea water
the cooling water is maintained constant at
Cooling water the engine’s outlet. If the point T is above
Cooling device the water line, a non-return-valve (W) must
Fig. 9
be installed, in order to avoid that the cooling
system looses all its fluid if the engine is
stopped.
Fig 10 COOLING WATER CONTROL BY
MIXING
x
Compen-
sation-tank
Contrary to the system shown in Fig. 7 cold
and warm water are mixed and the
temperature will be maintained constant at
the inlet of the engine.
engine
1 X serves, if necessary, for ventilation of the
MVA
system.
3 Another possibility for this kind of control is
Cooling water shown in Fig. 12
Heat exchanger
Fig. 10

BA MVA.REG.000 EN
5/9
The next page show you some different PIPING DIAGRAMS
Fig. 11 LUBRICATION OIL CONTROL

BY SHORT- CIRCUIT (DIVERTING)
In this scheme the MVA Thermostatic

1
MVA Valve is located in the lubrication oil
engine
circuit as a short- circuit controller.
2 Similar as in Fig. 7 the temperature of
the cooling water, in this scheme the
lubricant temperature of the oil, that means the
temperature of the oil at the outlet of
Lubricant cooling the engine is maintained constant.
Fig. 11 device
Fig. 12 LUBRICATION OIL CONTROL

BY MIXING
In this system the MVA Thermostatic

2 Valve mixes the warm oil coming from
engine 1 the engine with the cold one coming
MVA from the cooling device.
This assures, that the temperature of
lubricant the oil flow to the bearings, that means
the temperature of the oil at the inlet of
Lubricant cooling
Fig. 12 device the engine will be maintained constant.

BA MVA.REG.000 EN
6/9
M 20 ...M 40
K
E/ d/ n t 3 L
J K
DN
2 DN
2 3 DN D 2 3 M
M M
1 1 1 1 1
J K
BSP BSP
NPT NPT
J
A B C
PN10/16 PN25/40** 125/150 lbs 300 lbs**

BSP A B J K L M t D/E/d/n D/E/d/n D/E/d/n D/E/d/n
NPT C mm mm mm mm mm mm mm mm mm
20 3/4" C 87 61 50/56** 160/167**
20T 3/4" B 105/98,5* 178 101 18 105/75/18/4 105/75/18/4 98,5/70/16/4 117,5/82,5/19/4
25 1" C 87 61 50/56** 160/167**
25T 1" B 115/108* 178 101 18 115/85/18/4 115/85/18/4 108/79,5/16/4 124/89/19/4
32 11/4" C 87 73 39 160/167**
40J 11/2” C 87 73 39 160/167**
40T 11/2” A 96 156 96
40T B 150/127* 178 101 18 150/110/18/4 150/110/18/4 127/99/16/4 155,6/114,3/22/4
*125/ 150 lbs **SS / CS
delta p max. = 1,37 bar (20 p.s.i.)
CI CS Bz Al bar
0,7
BSP A B DI SS
0,6
NPT C kg kg kg kg
0,5
20 3/4" C 2,15 2,2 2,2 2,1
0,4
4 °E
20T B 7,7 7,7 9,1 4,8
0,3
25 1" C 2,15 2,2 2,2 2,1
0,2
25T B 7,7 7,7 9,1 4,8
0,1
32 11/4" C 3,0 3,2 3,4 2,1
40J 11/2" C 3,0 3,2 3,4 2,1
40T 11/2"
DN
A 4,1 4,1 4,9 4,2
20 2,0 2,3 3,8 5,2 5,6 7,0
40T B 7,7 7,7 9,1 4,8
25 2,2 2,5 4,2 5,7 6,2 7.8 m³/h
32 2,5 2,8 4,8 6,5 7,1 8,8
40 5,2 8,5 11,0 14,0 16,8 18,5

BA MVA.REG.000 EN
7/9
M 50 ...M 150
K
t
E/ d/ n
3 L
DN 2
D 2 3 M
M
t
1 N
1
J K J
D
A B C
PN10/16 PN25/40 125/150lbs 300lbs

DN A B J K L M N t D/E/d/n D/E/d/n D/E/d/n D/E/d/n
C mm mm mm mm mm mm mm mm mm
50 C 139 113 121 270 1 20 165/125/18/4 165/125/18/4 152,4/120,6/19/4 165/127/19/8
50 A B 140 225 150 1 20 165/125/18/4 165/125/18/4 152,4/120,6/19/4 165/127/19/8
65 A B 210 254/267* 165/171* 2 20 185/145/18/4 185/145/18/8 178/140/19/4 190,5/149/22,2/8
80 A B 210 267 171 2 22 200/160/18/8 200/160/18/8 190,5/152/19/4 203,6/168,3/22,2/8
100 A B 284 403/409* 217/220* 4 24 220/180/18/8 235/190/22/8 229/190,5/19/8 254/200/22,2/8
125 A B 349 489 241 6 26 250/210/18/8 270/220/26/8 254/216/22,2/8 279,4/235/22,2/8
150 A B 488 489 254 8 26 285/240/23/8 300/250/26/8 279,4/241,3/22,2/8 317,5/270/22,2/12
*SS *SS
delta p max. = 1,37 bar (20 p.s.i.)
CI CS Al
bar
0,7
DN A B DI SS
0,6
C kg kg kg
0,5
50 C 18 20 7 4 °E
50 AB 18 20 7
0,4
65 AB 24 31 10 0,3
80 AB 25 32 14 0,2
100 A B 60 60 24 0,1
125 A B 125 125 35
150 A B 136 136 48 DN
50 10 15 20 25 30 35
65 19 28 38 47 55 65
80 20 30 40 50 60 70 m³/h
100 40 60 80 100 120 140
125 60 90 120 150 180 210
150 90 135 180 225 270 315

BA MVA.REG.000 EN
8/9
CODE FOR THERMOSTATIC VALVES MODEL M20 … M40
M 25 C 1 A 120 C A
type of thermostatic valve leak hole

M20, M20T, M25, M25T, M32J, A = no leak hole
M32T, M40J, M40T B = 1 mm leak hole
C = 2 mm leak hole
size of valve D = 3 mm leak hole
M20, M20T : 3/4“ /DN 20 E = 4 mm leak hole
M25, M25T : 1“ /DN 25 X = without O-ring element
M32J, M32T : 1 ¼“ /DN 32
M40J, M40T : 1 ½“ /DN 40 special requirements
C = seat cast in body (standard)
D = bronze seat (special)
E = cast seat & leak hole
valve housing material in body
A = aluminium H = seat cast in body with
B = bronze kanigen plated element
C = cast iron 23 = PTFE seals + kanigen plated
D = spheroidal graphite cast iron element
E = stainless steel ASTM A351 CF- 8M 30 = flow-reduction
S = cast steel ASTM A216 WCB 38 = manual override
nominal temperature of the

elements no.
port connections °F / °C “cold” “warm”
1 = BSP parallel 065/18 15 - 25°C
2 = BSP taper 075/24 20 - 30
3 = NPT 085/30 26 - 34
4 = flanges DIN 2501-1 PN 10 095/34 30 - 40
5 = flanges ANSI B16.5 (Class 150) RF 100/38 33 - 42
6 = flanges DIN 2501-1 PN 40 110/43 38 - 47
7 = flanges ANSI B16.5 (Class 300) RF 120/49 44 - 55
8 = flanges DIN 2501-1 PN 16 130/55 49 - 60
140/60 55 - 66
150/66 60 - 71
type of element 160/71 66 - 77
A = 2040A standard, seal mat. Nitrile Rubber (BUNA N) 170/77 73 - 82
B = 2040 A standard, seal material Viton 175/79 77 - 85
180/82 79 - 88
190/88 85 - 93
valve size DN 40 there is a reduction possible 205/96 93 - 103
for example: M40S5B175-30 237/114 107 - 123

BA MVA.REG.000 EN
9/9
CODE FOR THERMOSTATIC VALVES MODEL M 50 … M 150
M 80T C 2 G 120 D A
type of thermostatic valve

M = standard with and without Leak hole
Manual override A = no leak hole
B = 2 mm leak hole
C = 4 mm leak hole
size of valve D = 6 mm leak hole
DN 50H with 2” BSP E = 8 mm leak hole
DN 50 / 50T with flanges X = without O-ring element
DN 65T with flanges
DN 80T with flanges
DN 100 / 100T with flanges
DN 125 with flanges special requirements
DN 150 with flanges D = standard - bronze seat
02 = special flanges
03 = special welding-connection
valve housing material 06 = alu-bronce housing
A = aluminium 25 = PTFE seals
B = bronze Others on request
C = cast iron
D = spheroidal graphite cast iron nominal temperature of the elements
E = stainless ASTM A351 CF-8M no. “cold” “warm”
S = cast steel ASTM A216 WCB
075 °F = 24°C 21 °C - 29 °C
port connections flanges 090 = 32 27 - 35
1 = DIN 2501-1 PN 6 095 = 35 30 - 41
2 = DIN 2501-1 PN 10 100 = 38 35 - 43
3 = DIN 2501-1 PN 16 105 = 41 35 - 45
4 = ANSI B16.1 (Class 125) RF 110 = 43 38 - 47
5 = ANSI B16.5 (Class 150) RF 115 = 46 40 - 50
6 = DIN 2501-1 PN 25 120 = 49 44 - 54
7 = ANSI B16.5 (Class 300) RF 130 = 55 52 - 60
8 = DIN 2501-1 PN 40 135 = 57 54 - 63
B = BSP parallel 140 = 60 57 - 66
145 = 63 60 - 69
type of element 150 = 66 63 - 71
G = 2001A standard for water and oil 155 = 68 66 - 74
H = 2012A standard with manual over ride 160 = 71 68 - 77
J = 2030A standard for salt water 165 = 74 71 - 79
L = 2030P kanigen plated 170 = 77 74 - 82
M = 2035P kanigen plated 175 = 79 77 - 85
with manual override 180 = 82 79 - 88
185 = 85 82 - 91
195 = 91 87 - 98
205 = 96 93 - 102
215 = 102 99 - 107
Valve size DN 50 can bee in housing model T (Fig. A,B) and F 225 = 108 102 - 113
(Fig. C). Model T has in the coding the „T“ added. 230 = 110 104 - 115
240 = 116 108 - 122
for example: M50TC2G110DA

Edition: March 2002
B 5914 EN
Page 1 of 1

!
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)

(
* "% 0 ... 10 bar 0 ... 40 bar 0 ... 40 bar 0 ... 250 bar 0 ... 400 bar

( "% 0 ... 140 psi 0 ... 580 psi 0 ... 580 psi 0 ... 3625 psi 0 ... 5800 psi
+

) GL98
-34 ... +100 °C
+100 °C
3 bar 0.1 linear
3 bar 0.5 40 bar 2.0 linear 40 bar 2.0 linear 250 bar 10 linear 400 bar 20 linear
)
Class 1.6 ... 3 bar
Class 4 Class 1.6...40 bar Class 1.6...40 bar Class 1.6...40 bar Class 1.6...40 bar

3 ... 10 bar
)
- ./ 0 $
,

- 1/. 0 $
!
$ - $
(

"+%
&!

R 1/4 G 1/4
&

IP 65
2
! 0.21 kg

BA DAN.DUM.000 EN
2/4
Data sheet Pressure transmitter type MBS 3050
Technical data Main specifications

Pressure connections see page 1
0-1 0-1.6 0-2.5 0-4 0-6 0-10 0-16
Measuring ranges [bar]
0-25 0-40 0-60 0-100 0-160 0-250 0-400 0-600
Output signals 4-20 mA 0-5 V 1-5 V 1-6 V 0-10 V
Electrical connections see page 3
Performance (IEC 770)

Accuracy ±0.5% FS (typ.)
±1% FS (max.)
Non-linearity (best fit straight line) ≤ ±0.5% FS
Hysteresis and repeatability ≤ ±0.1% FS
Thermal zero point shift ≤ ±0.1% FS/10K (typ.)
≤ ±0.2% FS/10K (max.)
Thermal sensitivity (span) shift ≤ ±0.1% FS/10K (typ.)
≤ ±0.2% FS/10K (max.)
Response time (liquids) < 4 ms
Overload pressure (static) 6 × FS (max. 1500 bar)
Burst pressure 6 × FS (max. 2000 bar)
Durability, P: 10-90% FS >10×106 cycles
Electrical specifications
Nom. output signal (short-circuit protected)
4 − 20 mA d.c. 0-5, 1-5, 1-6 V d.c. 0-10 V d.c.
Supply voltage [UB], polarity protected 9 → 32 V d.c. 9 → 30 V d.c. 15 → 30 V d.c.
Supply - current consumption - ≤ 5 mA ≤ 8 mA
Supply voltage dependency ≤ ±0.05% FS/10 V
Current limitation
(linear output up to 1.5x nom. range) 34 mA (typ.) -
Output impedance - ≤ 25Ω
Load [RL] (load connected to 0V) RL ≤ (UB-9V)/0.02 RL ≥ 10 kΩ RL ≥ 15 kΩ
Environmental conditions
Medium temperature range −40 → +85°C
Ambient temperature range (depending on electrical connection) see page 3
Compensated temperature range 0 → +80°C
Transport temperature range −50 → +85°C
EMC - Emission EN 61000-6-3
Air mode 8 kV EN 61000-6-2
Electrostatic discharge
Contact mode 4 kV EN 61000-6-2
field 10 V/m, 26 MHz - 1 GHz EN 61000-6-2
EMC - Immunity RF
conducted 10 Vrms, 150 kHz - 30 MHz EN 61000-6-2
burst 4 kV (CM), Clamp EN 61000-6-2
Transient
surge 1 kV (CM,DM), Rg = 42Ω EN 61000-6-2
Insulation resistance > 100 MΩ at 100 V d.c.
Mains frequency test 500 V, 50 Hz SEN 361503
15.9 mm-pp, 5 Hz - 25 Hz
Vibration stability Sinusoidal IEC 60068-2-6
20 g, 25 Hz - 2 kHz
Random 7.5 g rms, 5 Hz - 1 kHz IEC 60068-2-34, IEC 60068-2-36
Shock 500 g / 1 ms IEC 60068-2-27
Shock resistance
Free fall IEC 60068-2-32
Enclosure (depending on electrical connection) see page 3
Mechanical characteristics
Wetted parts DIN 17440-1.4404 (AISI 316 L)
Materials
Enclosure DIN 17440-1.4404 (AISI 316 L)
Electrical connections See page 3
Weight (depending on pressure connection and electrical connection) 0.2-0.3 kg
2 DKACT.PD.P20.O2.02  Danfoss A/S 11-2002

BA DAN.DUM.000 EN
3/4
Application and media MBS 3050 with integrated pulse-snubber is

conditions specially suited for hydraulic applications
where cavitation, liquid hammer or pressure
peaks may occur – influences that often
cause a short but extreme excess of the
measuring range of the transmitter.
The integrated pulse-snubber is in principle

designed as a nozzle mounted in the
passage between the measured medium
and the pressure sensitive element of the
transmitter.
Media condition
Application Clogging of the nozzle may occur in liquids
Cavitation, liquid hammer and pressure containing particles. Mounting the transmitter
peaks may occur in hydraulic systems with in an upright position minimizes the risk of
changes in flow velocity, e.g. fast closing of a clogging, because the flow in the nozzle is
valve or pump starts and stops. restricted to the start-up period when the
dead volume behind the nozzle fills, and
The problem may occur on the inlet and furthermore because the nozzle orifice is
outlet side, even at rather low operating relatively big (0.3 mm). The media viscosity
pressures. has only little effect on the response time.
Even at a viscosities up to 100 cSt, the
response time will not exceed 4 ms.
Electrical connections
Type code, page 4
1 2 5 7 8 3
DIN 43650, Pg 9 AMP Econoseal IEC 947-5-2 ISO 15170-A1-3.2-Sn AMP Superseal 2 m screened cable
J series (male) M12×1 (Bayonet plug) 1.5 series (male)
Ambient temperature
-40 → + 85 °C -40 → + 85 °C -25 → +85 °C -40 → +85 °C -40 → +85 °C -30 → +85 °C
Enclosure
IP 65 IP 67 IP 67 IP 67 / IP 69K IP 67 IP67
Materials
Glass filled Glass filled Nickel plated Glass filled Glass filled Polyolifin cable
polyamid, PA 6.6 polyamid, PA 6.61) brass, CuZn/Ni polyester, PBT polyamid, PA 6.62) with PE shrinkage tubing
Electrical connection, 4-20 mA output (2 wire)

Pin 1: +supply Pin 1: +supply Pin 1: +supply Pin 1: +supply Pin 1: +supply Brown wire: +supply
Pin 2: ÷supply Pin 2: ÷supply Pin 2: Not used Pin 2: ÷supply Pin 2: ÷supply Black wire: ÷supply
Pin 3: Not used Pin 3: Not used Pin 3: Not used Pin 3: Ventilation Pin 3: Not used Red wire: Not used
Earth: Connected to Pin 4: ÷supply Pin 4: Not used Orange: Not used
MBS housing Screen: Not connected
to MBS housing
Electrical connection, 0-5V, 1-5V, 1-6V, 0-10V output
Pin 1: +supply Pin 1: +supply Pin 1: +supply Pin 1: +supply Pin 1: +supply Brown wire: Output
Pin 2: ÷supply Pin 2: ÷supply Pin 2: not used Pin 2: Output Pin 2: ÷supply Black wire: ÷supply
Pin 3: Output Pin 3: Output Pin 3: Output Pin 3: Ventilation Pin 3: Output Red wire: + supply
Earth: Connected to Pin 4: ÷supply Pin 4: ÷supply Orange: Not used
MBS housing Screen: Not connected
to MBS housing
1)
Female plug: Glass filled polyester, PBT
2)
Wire: PETFE (teflon)
Protection sleeve: PBT mesh (polyester)
 Danfoss A/S 11-2002 DKACT.PD.P20.O2.02 3
BA DAN.DUM.000 EN
4/4
Ordering,
Special versions MBS 3050- −
Pressure connection (see page 1)

Measuring G B 0 4 .. DIN 3852-E-G1⁄4,Gasket:DIN 3869-14-NBR
range E B 0 8 .. G1⁄2 A (EN 837)
0 - 1 bar ........... 1 0 E C 0 4 .. 1⁄4 -18 NPT
0 - 1.6 bar ........ 1 2 F A 0 9 .. DIN 3852-E-M14×1.5
0 - 2.5 bar ........ 1 4 .. Gasket: DIN 3869-14-NBR
0 - 4 bar ........... 1 6
0 - 6 bar ........... 1 8
0 - 10 bar ......... 2 0 Electrical connection(see pages 1 and 3)
0 - 16 bar ......... 2 2 1 ................................. Plug (DIN 43650), Pg 9
0 - 25 bar ......... 2 4 2 ................................. *)Plug, AMP Econoseal, J-series, male
0 - 40 bar ......... 2 6 excl. female plug
0 - 60 bar ......... 2 8 3 ................................. With 2 m cable
0 - 100 bar ....... 3 0 5 ................................. *)Plug, IEC 947-5-2, M12×1, male
0 - 160 bar ....... 3 2 excl. female plug
0 - 250 bar ....... 3 4 7 ................................. Plug ISO 15170-AI-3.2-Sn, male
0 - 400 bar ....... 3 6 excl. female plug
0 - 600 bar ....... 3 8 8 ................................. *)Plug Amp Superseal I.5 series, male
excl. female plug
Pressure
reference *)Gauge versions only available as sealed gauge versions
Gauge (relative) ............... 1
Absolute ............................ 2
Output signal
1 .......................................... 4-20 mA
2 .......................................... 0-5 V
3 .......................................... 1-5 V
4 .......................................... 1-6 V
5 .......................................... 0-10 V
Ordering standard With DIN 43650, Pg 9 plug

versions Pressure connection Output signal Measuring range Type Code no.
0-250 bar MBS 3050-3411-1GB04 060G3582
4-20 mA
0-400 bar MBS 3050 3611-1GB04 060G3583
DIN 3852-E-G1/4 0-250 bar MBS 3050-3413-1GB04 060G3584
1-5 V
0-400 bar MBS 3050-3613-1GB04 060G3585
0-250 bar MBS 3050-3415-1GB04 060G3557
0-10 V
0-400 bar MBS 3050-3615-1GB04 060G3586
4 DKACT.PD.P20.O2.02  Danfoss A/S 11-2002

Edition: April 1999
B 5924 EN
Dial thermometer Page 1 of 1
Bimetallic dial thermometers according to FLENDER works standard W 5924 are precision instruments for
visual temperature monitoring of liquid and gaseous media.
Dimension drawing
Scale graduation - 20 ... + 120 °C ––> - 4 ... + 249 °F
Design
Material: Compl. stainless steel (CrNiSt)
Indicating range: - 20 ... + 120 °C

Dial face: Double scale, outer -20 ... +120 °C black
inner -4 ... +249 °F red
Damping liquid: bis(2-ethylhexyl)-adipate for synthesis (GC>98%)
Max. admissible ambient temperature: - 35 °C

Inspection glass: acrylic glass (PMMA)
Precision of indication: Class 1.5 acc. to DIN 16 203

Scale graduation: °C = 2°
°F = 5°
Installation
When installing the thermometer take care that the immersion tube is dipped into the medium to be monitored.

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 24.05.1995 Rev.: a) 1999-04-26 HES
Edition: March 2002
B 6100 EN
General
The electric resistance in the resistance thermometer sensor changes as the temperature fluctuates. This
change of resistance on the PT 100 or the converted output signal of the measuring transducer (4 to 20 mA)
can be used to measure temperature with an evaluating instrument or to define a switch point by means of limit
switches.
Operation
Pt 100 measuring thermometer sensor
The electrical conductivity of metal (here platinum) is based on the mobility of conduction electrons. As the
temperature rises, the movement of the atoms in the metal lattice about their rest position intensifies and so
obstructs the electrons flowing to the plus pole of a power source. This obstruction sets up a resistance in linear
proportion to the temperature.
To generate the output signal a constant test current (approx. 1 mA) is applied to the Pt 100. The resistance
in the Pt 100 causes a drop in voltage (U = R · l), which can be evaluated.
Measuring transducer
The two-wire measuring transducer is mounted in the J-head only if requested by the customer. It should be
noted that here only a single connection is possible.
The measuring transducer converts the temperature-dependent resistance to a standard uniform signal
of 4 to 20 mA. This signal can be transmitted over long distances without interference.
Technical Date - Pt 100

– Type of protection Terminal head: IP 65
– Tolerance class: DIN IEC 60751 Class B
(at 0 °C ±0.3 K, at 100 °C ±0.8 K)
– Ambient temperature range for J head: –20 °C to +100 °C
– Ambient temperature range for protective tube: –50 °C to +200 °C
– Test temperature range: –50 °C to +150 °C
Material
– Terminal head: GD-AlSi9Cu3
– Protective sleeve for measuring thermometer sensor: 1.4571
– Spring: wire DIN 2076-A-0.8 (stainless steel)
– Guide tube: 1.4571
– Terminal base: ceramic

– Adapter: 1.4301
– Gasket NBR (Perbunan)

Edition: March 2002
B 6100 EN
Technical data - Measuring transducer

– Measuring input: Pt 100 (DIN EN 60751)
– Measuring range: –50 °C to +150 °C
– Ambient temperature: –20 °C to +85 °C
– Terminal type: two-wire
– Minimum measuring range: 25 K
– Maximum measuring range: 1050 K
– Sensor line resistance with three-wire connection: ≤ 11 W per line
– Sensor line resistance with two-wire connection: 0 W per line resistance
– Sensor current: ≤ 0,5 mA
– Measuring rate: continuous measurement, as signal path analog
Measuring circuit monitoring system
– Drop below range: falling to ≤ 3.6 mA
– Rise over range: rising to ≥ 22 mA ... < 28 mA (typical 24 mA)
– Probe short circuit: ≤ 3,6 mA
– Probe and line break: positive: ≥ 22 mA ... < 28 mA (typical 24 mA)
negative: ≤ 3,6 mA
Output
– Output signal: impressed DC 4 ... 20 mA
– Transient response: temperature-linear
– Transmission accuracy: ≤ ± 0.1 %
– Attenuation of residual ripple of feed voltage: 40 dB
– Working resistance (Rb): RB =

– Influence of working resistance: ≤ ± 0,02 % / 100 W

– Adjustment time with temperature change: ≤ 10 ms
– Balancing conditions: DC 24 V / approx. 22 °C
– Balancing accuracy: ≤ ± 0.2 %
Voltage supply
– Voltage supply (Ub): DC 7.5 ... 30 V
– Pole confusion protection: yes
– Voltage supply influence: ≤ 0.01 % / V deviation of 24 V
Environmental influences
– Operating temperature range: –40 to +85 °C
– Temperature influence: ≤ 0.01 % / K deviation of 22 °C
– Climate resistance: rel. humidity ≤ 95 % on annual average without dew contact
– Vibration strength: acc. to GL characteristic 2
– EMV: EN 61326
Housing
– Material: Polycarbonate (encapsulated)
– Screw connection: ≤ 1.5 mm2
– Assembly: in terminal head Form J
– Mounting position: any
– Weight: approx. 12 g

Edition: March 2002
B 6100 EN
Connection
The customer can minimise measuring inaccuracies by using multiple wires. At Flender, as a rule, a 3- or 4-wire
arrangement from an additional terminal box is provided for (Fig. 1, 2). At the customer’s specific request, the
3/4-wire arrangement can be used from the J-head (Figure 4, 5). Through lack of space, however, the 4-wire
arrangement is possible only with a single connection (Fig. 5).
Customer Customer
Terminal box Terminal box
Resistance thermometer Resistance thermometer

Fig. 1: 3-wire arrangement Fig. 2: 4-wire arrangement
from terminal box from terminal box
Customer Customer Customer
Terminal Terminal Terminal

box box box
Resistance thermometer Resistance thermometer Resistance thermometer

Fig. 3: 2-wire circuit from Fig. 4: 3-wire circuit from Fig. 5: 4-wire circuit from
terminal head of Pt 100 terminal head of Pt 100 terminal head of Pt 100
Connection for measuring transducer
Connection for Connection values

Voltage supply

Current output Working resistance

Voltage supply
Analog inputs

Resistance thermometer
series W
in two-wire circuit
í

Edition: March 2002
B 6100 EN
Types
EL = Installation length ≈ 61
40 14 3
∅ 49
G 1/2A
∅8
25 SW 27
∅ 5.8
crimped in
O-rings
≈ 33
Guide tube
∅ 26.9-0.2
0
!et t" D#$ 3%&' M16 x 1.5
Terminal head IP 65
e(t)*e t+e,m"mete, - &1001
+5
EL-10 = Installation length ≈ 61
+5
25-10 50 14 3
10+5 Spring travel ∅ 49

SW 27
G 1/2A
∅8
Guide tube
∅ 5.8
Spring
crimped in
≈ 33
∅ 26.9-0.2
0

Pt 100 doubled
SW 17
!et t" D#$ 3%&'
M16 x 1.5
Terminal head IP 65
e(t)*e t+e,m"mete, - &1002
122
100 ≈ 61
14 3
G 1/2A
SW 27 SW 27 ∅ 49
∅ 9.5
Guide tube
Protective tube
≈ 33
26.9-0.2
0

Pt 100 doubled
∅
SW 17
!et t" D#$ 3%&'
Terminal head IP 65 M16 x 1.5
e(t)*e t+e,m"mete, - &1003

Edition: March 2002
B 6100 EN
NL = Nominal length
EL = Installation length 73 ≈ 74
40 14 62 8 Spring travel for clamp on
25 3
crimped in
SW 27 SW 18 SW 27
∅ 49
∅ 5.8
∅8
O-rings
≈ 33
∅ 26.9-0.2
Guide tube Adapter
G 1/2A
0 28
sprung
Measuring resistance screw connection
!et t" D#$ 3%&' Terminal head IP 65 M16 x 1.5
e(t)*e t+e,m"mete, - &1004
Adjustment by means of sprung screw connection
Housing
Terminal head
≈5
Measuring tip
Anti-friction bearing
A B C D
a) Insert guide tube ”A” into hole in housing until the measuring tip of the resistance thermometer makes
contact.
b) Screw screw connection ”B” into the housing as far as it will go.
c) Pull out screw connection ”C” approx. 5 mm towards the terminal head. Then lock nut ”D” with screw
connection ”C”. This ensures that the pretensioned spring keeps the measuring tip permanently in contact
with the part to be measured.

B 5927 EN
Volume flow meter Page 1 of 5
These Operating Instructions are binding for volume flow meters to Flender Works Standard W 5927.
General
The volume flow meter described here works in accordance with the orifice plate measuring system, using the
Witte orifice plate, by which measurements from Reynold’s number Remin = 50 to Remax. 2320 can be carried
out virtually independently of viscosity. Measurement requires an even flow of 8 x pipe inner diameter upstream
and 5 x pipe inner diameter downstream of the orifice plate (undisturbed straight length of pipe). The meter can
be mounted in any position. Calibration for vertical mounting is done at the works.
The volume flow meter is available in two versions:
Variant A: With indicator scale and two contacts (changeover contacts).

Variant B: Without indicator scale and with analog output signal.
This analog signal is in linear proportion to the differential pressure and in
quadratic proportion to the volume flow.
Operation and construction

In the position of equilibrium the spring forces on both sides of the diaphragm are in balance. The differential
pressure to be measured causes a force to be exerted on one side of the diaphragm. This force shifts the
diaphragm system against the measuring range spring until it is in balance with the spring forces. If overload
occurs, the diaphragm is supported against metal contact surfaces.
In the case of variant A a centrally located tappet transmits the movement of the diaphragm system to the dial
train and the actuating elements of the micro-switches.
In the case of variant B a pressure transducer converts the differential pressure into a 4 - 20 mA signal. This
analog signal is in linear proportion to the differential pressure and in quadratic proportion to the volume flow.
Section 2. 3.
1. Pressure chamber
2. Dial train (variant A only) 4.
3. Tappet (variant A only)

5.
4. Micro-switch actuating elements (variant A only)
1.
5. Measuring springs
6. Measuring diaphragm
6.
A. Friedr. Flender AG, D 46393 Bocholt, Datum Name: Köster DOA

Tel. 02871/92-0, Telefax 02871/922596, http://www.flender.com 13.04.1999 Rev.: b) 2003-09-10 HES
B 5927 EN
Variant A: With indicator scale and two contacts (changeover contacts)

Technical data
Operating pressure: max. 16 bar
Operating temperature: - 10 ... + 90 °C (operating temperature)
permiss. ambient temperature: - 40 °C (storage temperature)

Measurement accuracy: ∼ ± 2.5 % of the full-scale reading
Scaling: 0 ... 100 %

Switching hysteresis: ∼ 2,5 %
max. switching capacity: 5 A / 250 V AC / 500 VA (a.c. voltage)

0.4 A / 30 V DC / 25 W (d.c. voltage)
Type of protection: IP 65
Output: 2 changeover contacts (separately adjustable)
Connection diagram
Material
Membranes: Viton
Measuring-device base: GGG-40

Shield: St
Pressure chamber: Aluminium anodized (black)

Cover: plastic, very strong
Example: With a max. pump output of 112 l/min a volume flow meter with a volume flow range of up to
155 l/min can be used.
155 l/min % ⇒ 100 %
112 l/min % ⇒ 72 %
Design: A volume flow meter must be selected to the maximum value of the volume flow range of which
the max. pump output comes as near as possible.

B 5927 EN
Determining the volume flow (throughput)

e.g. volume flow range of up to 280 l/min (see sign on unit)
280 l/min x Pointer deflection % 280 l/min x 80

Pointer deflection 80 % => = = 224 l/min
100 % 100
Volume flow meter top section
Cable terminal
M 20 x 1,5
Zero adjustment
Switching adjustment
(internal)
In the case of use in an explosion hazard area the flow monitor can be made intrinsically safe by means of a
break relay (see example).
Explosion-hazard-free area
Intrinsically safe circuit Explosion-hazard area
(EEx ia) IIC
EN 50 014 ... 50 020
2 S1.1
1
28 l/min 3
6 S1.2
5
25 l/min 4
1 2 3 7 8 9
U1 12 15
10 13
11 14
16 17 18
PE L1 N

B 5927 EN
Variant B: Without indicator scale and with analog output signal

(not suitable for explosion-hazard-area)
Technical data
Operating pressure: max. 25 bar

Operating temperature: - 10 ... + 70 °C (operating temperature)
permiss. ambient temperature: - 30 °C (storage temperature)

Linearity: < 2 % of full-scale reading
Signal scaling: 0 ... 100 %
Switching hysteresis: < 1 % of full-scale reading

Signal type: analog 4 - 20 mA (not linear); 24 V DC
Connection diagram (two-wire connection)
Material
Membranes: Viton
Measuring-device base: GGG-40
Shield: St
Pressure chamber: Aluminium anodized (black)
Cover: plastic, very strong


B 5927 EN
Example: The 4 - 20 mA signal scaling ranges from 0 to 100 %. With a max. pump output of 112 l/min a
volume flow meter with a volume flow range of up to 155 l/min can be used.
155 l/min => 100 % => 20 mA

112 l/min => 72,3% => 12,35 mA
100,8 l/min => 65 % => 10,76 mA
77,5 l/min => 50 % => 8 mA
0 l/min => 0% => 4 mA
Design: This means that, when the pump is at full output, the output signal is 12.35 mA. If this pump
is running at only 90 % of its max. output (=100.8 l/min), the output signal is 10.76 mA.
Output signal: Output signal = 4 mA + 16 mA x (Qist / Q100%)2
Relation between output flow and output signal
20
18
16
14
Output signal in mA
12
10
0
0 20 40 60 80 100
Volume flow in %
Volume flow meter top section

Cable terminal
M 20 x 1,5

1 2 3 4 5 6 7 8
A A
B B
PROYECTO REPOTENCIONAMIENTO
C
LOS PELAMBRES C
D D
E E
F Date 22.06.06 120-CV-005-01 Order No. = F

Drawn TBK
Anlagendeckblatt 6 113 281 4214492 +SLGS
Checked TBK 120-CV-006-01 Schaltplan Ölversorgungsanlage 1
Cover sheet Wiring diagram oil supply system ADB 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
Netz Schaltschrank Externe Steuerung

Mains Switch cabinet 1 External control
0 3
= = =
+MCC +SLGS +EXT
B B
Ölversorgungsanlage Getriebe
Oil supply system Gearbox
Klemmenplan 6 123 673
C Terminal diagram 6 123 673 C
= =
+OLGS +B3FH
FLENDER FLENDER
D Klemmenleistenbezeichnung für -X . . D
Terminal strip marking for
Verdrahtungsfarben:
Hauptstromkreis schwarz Querschnitt nach Belastung
Neutralleiter blau Querschnitt nach Belastung
Schutzleiter grün/gelb Querschnitt nach Belastung
Leistung AC Power AC 1
Steuerstromkreis AC rot 1mm² oder größer nach Belastung
Leistung DC >24V Power DC >24V 2
Steuerstromkreis 24V DC (Pluspol) blau 1mm² oder größer nach Belastung
Steuerstromkreis 24V DC (Minuspol) weiß 1mm² oder größer nach Belastung Leistung DC =<24V Power DC =<24V 3
Sonstiges braun 1mm² oder größer nach Belastung Steuerspannung AC Controlvoltage AC 4
E Fremdspannung orange 1mm² oder größer nach Belastung Steuerspannung DC Controlvoltage DC 5 E
Datensignale Data signals 6
Wiring colours
Sonder Signale Special signals 7
Main circuit bk cross-section according to load
Neutral bu cross-section according to load
E Exi E Exi 8
Potective conductor gn/ye cross-section according to load Sonstige Others 9
Control circuit AC rd 1mm² or larger according to load
Control circuit 24V DC (plus) bu 1mm² or larger according to load
Control circuit 24V DC (minus) wh 1mm² or larger according to load
Specials bn 1mm² or larger according to load
External voltage or 1mm² or larger according to load
F Date
22.06.06 120-CV-005-01 Order No. = F
TBK
Drawn
Anlagenübersicht 6 113 281 4214492 +SLGS
General information Wiring diagram oil supply system ADB 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 1 2 3 4 5 6 7
A Zeile Änd. Benennung Blatt Planart Anlage Gruppe Ort Zeile Änd. Benennung Blatt Planart Anlage Gruppe Ort A
Line Rev. Description Sheet Plantyp Unit Group Place Line Rev. Description Sheet Plantyp Unit Group Place
1 Anlagendeckblatt ADB
1 ADB = +SLGS 21 Klemmenplan 1283
1 VKL = +SLGS-X72 +SLGS
Cover sheet Connection plan
2 Anlagenübersicht AUE
2 ADB = +SLGS 22 Geräteliste 3432
1 ZGL
General information List of equipment
3 Inhaltsverzeichnis INH
1 INH = 23 Geräteliste 3432
2 ZGL
Table of contents List of equipment
4 Aufbauplan SSL
1 SSL = +SLGS 24 *
Cabinet layout *
B 5 Aufbauplan SSL
2 SSL = +SLGS 25 * B
Cabinet layout *
6 Einspeisung ESP
1 STR = +SLGS 26 *
Power supply *
7 SPS - Aufbau SPSA
2 STR = +SLGS 27 *
PLC - Layout *
8 Leistungsteil LT
3 STR = +SLGS 28 *
Power unit *
9 Analogeingabe DSAE
4 STR = +SLGS 29 *
Analog input unit *
C 10 Digital Eingänge DE2
5 STR = +SLGS 30 * C
Digital inputs *
11 Digital Eingänge DE2
6 STR = +SLGS 31 *
Digital inputs *
12 Digital Ausgänge DA2
7 STR = +SLGS 32 *
Digital outputs *
13 Digital Ausgänge DA2
8 STR = +SLGS 33 *
Digital outputs *
14 Potentialfreie Kontakte PFK
9 STR = +SLGS 34 *
Potential free contacts *
D 15 Klemmenplan 1283
1 VKL = +SLGS-X10 +SLGS 35 * D
Connection plan *
16 Klemmenplan 1283
1 VKL = +SLGS-X12 +SLGS 36 *
Connection plan *
17 Klemmenplan 1283
Connection plan *
18 Klemmenplan 1283
Connection plan *
19 Klemmenplan 1283
Connection plan *
E 20 Klemmenplan 1283
1 VKL = +SLGS-X62 +SLGS 40 * E
Connection plan *
Order No. = 5
7
. 6
+
2
1 3
4
Rev. Description Sh.

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Inhaltsverzeichnis 6 113 281 4214492
Table of contents Wiring diagram oil supply system INH 1 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
Typ: AE1073.500 (760x760x300)
+SGLS
B B
H1 H2 H6 H9 H11 H13 H8
H3 H7 H10 H12 H14 H16
S2 S3 S4 S5 S6
C 66 C
- AU
I OT
760
S
N
0
-S20
660
Q1
594
528
D D
E E
760
1:5

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Aufbauplan 6 113 281 4214492 +SLGS
Cabinet layout Wiring diagram oil supply system SSL 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
75x50
B B
F1
F2
F3
T1 Q10 Q30 Q2 G1 D2 D4 W1
75x50
75x50
C C
U65
K10
K30
Q1 K10MK30M K20
75x50
730
610
75x50
470
385
X10,X12,X4,X51,X52,X62,X72
K1
K2
K3
K4
D D
250
185
75X100
30
704
E E
1:5
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Aufbauplan 6 113 281 4214492 +SLGS
Cabinet layout Wiring diagram oil supply system SSL 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A L1 /3.1 A
L2 /3.1
L3 /3.1
-Q2 1 3 5
0,5A
2 4 6
B L1
B
0V 400V
-G1
-T1
PE N M L+
PE
OV 230V fvp
L24 /2.1
-X4 1
PE -X4 2
-S20 11
PE
fvp fvp
12
-Q1 1 3 5
C -X51 1 C
-X51 1
45A +EXT
2 4 6
-F1 1 -F2 1 -F3 1
-S* 11
2 2 2
+EXT 12
-X51 2
-K20 1 -S1 3
+EXT
7 2 5 -X51 2
D D
-K20 A1
A2
SL1 /8.1 fvp
L0 /2.1
-X10 1 2 3 4 SL2 /8.1
-X10 L1 L2 L3 PE -X4 3 4 5
+MCC NOT-AUS
E PE E
Emergency off
3x400V/50Hz L1 N PE
Netz -E1 3 1 2
Mains
/6.5 3 4
Rechtsdrehfeld 5 6
CW field of rotation
21 22
Schaltschrank Heizung
Switch cabinet heater

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Einspeisung 6 113 281 4214492 +SLGS
Power supply Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
PLC S7-300 CP 342-5
CPU 313 C
-D2 -D4 -W1
/5.1 2 E124.0 /6.1 12 E125.0 22 E126.0 /7.1 22 A124.0 /7.5 32 A125.0 16 PAWV752 2 PEWV752 /8.1 2 A0.0 /8.5 12 A1.0
/5.2 3 E124.1 /6.2 13 E125.1 23 E126.1 /7.2 23 A124.1 /7.5 33 A125.1 17 PAWI752 /4.3 3 PEWI752 /8.2 3 A0.1 /8.5 13 A1.1
/5.3 4 E124.2 /6.3 14 E125.2 24 E126.2 /7.2 24 A124.2 /7.6 34 A125.2 18 PAWV754 5 PEWV754 /8.2 4 A0.2 /8.6 14 A1.2
/5.4 5 E124.3 /6.4 15 E125.3 25 E126.3 /7.3 25 A124.3 /7.6 35 A125.3 19 PAWI754 /4.4 6 PEWI754 /8.3 5 A0.3 /8.6 15 A1.3
/5.5 6 E124.4 /6.5 16 E125.4 26 E126.4 /7.3 26 A124.4 /7.6 36 A125.4 14 PEWP760 8 PEWV756 /8.3 6 A0.4 /8.6 16 A1.4
/5.6 7 E124.5 /6.6 17 E125.5 27 E126.5 /7.3 27 A124.5 /7.7 37 A125.5 /4.2 9 PEWI756 /8.3 7 A0.5 /8.7 17 A1.5
B B
/5.7 8 E124.6 /6.7 18 E125.6 28 E126.6 /7.4 28 A124.6 /7.7 38 A125.6 11 PEWV758 /8.4 8 A0.6 /8.7 18 A1.6
/5.8 9 E124.7 /6.8 19 E125.7 29 E126.7 /7.4 29 A124.7 /7.8 39 A125.7 12 PEWI758 /8.4 9 A0.7 /8.8 19 A1.7
1L+ M 1L+ M
1L+ 1M 4M 2L+ 2M 3L+ 3M MPI PtP/DP DP
1 10 11 20 21 30 21 30 31 40 L+ M X1 X2 1 10 11 20 X1 + -
/1.8 L24 fvp fvp fvp fvp fvp fvp fvp

L24 /4.1
/1.8 L0 fvp fvp fvp fvp fvp fvp fvp fvp
L0 /4.1
C C
D D
E E

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SPS - Aufbau 6 113 281 4214492 +SLGS
PLC - Layout Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A /1.8 L1 A
/1.8 L2
/1.8 L3
/6.2
/6.4
-Q10 1 3 5 13 21 -Q30 1 3 5 13 21
14 22 14 22
36A 5,6A
2 4 6 2 4 6
B B
-K10M 1 3 5 -K30M 1 3 5
/8.1 2 4 6 /8.2 2 4 6
C C
D D
-X12 1 2 3 4 -X12 5 6 7 8
PE PE
W V U W V U
-M10 -M30
+OLGS +OLGS
M M
E 3 PE 3 PE E
18,5kW 2,2kW
120-CV-05-01A 120-CV-05-01B
120-CV-06-01A 120-CV-06-01B
Pumpe 10 Kühler
Pump 10 Cooler
F Date22.06.06 120-CV-005-01 Order No. = F

TBK
Drawn
Leistungsteil 6 113 281 4214492 +SLGS
Power unit Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
/2.8 L24 fvp fvp

L24 /5.1
A /2.8 L0 L0 /7.1 A
fvp fvp
-D2 PEWI756 -D2 PEWI752 -D2 PEWI754
/2.5 10 9 /2.5 4 3 /2.5 7 6
B B
10 11 8 7
-U65
1 2
C C
-X72 1 2 -X72 3 4 -X62 1 2 3 -X62 4 5 6

D D
-SHIELD -SHIELD
3 3
1 4
RD RD WH WH
-B65.1 -B65.2 -B50
I BN BK
+ - -B80
I 1(+) 2(-)
+OLGS +OLGS +OLGS
P
E E
Öltemperatur Druck Messumformer Volumenstrom-Meßumformer

Oiltemperature Presser transducer Volume flow transducer

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Analogeingabe 6 113 281 4214492 +SLGS
TBK Checked TBK 120-CV-006-01 Schaltplan Ölversorgungsanlage 4
Analog input unit Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
-D2 E124.0 E124.1 E124.2 E124.3 E124.4 E124.5 E124.6 E124.7
/2.2
2 3 4 5 6 7 8 9
B B
3
-S2 13 23 -S2 23 -S3 13 -S4 13 -S5 13 -S6 13
14 24 2 24 14 14 14 14
C C
/4.8 L24 fvp fvp fvp fvp fvp fvp

L24 /6.1
D D
-X52 1 2 3 4
PE
3 2 1 PE
-S20
+OLGS
P
E E
Differenzdruckwächter Bedienung fern Bedienung vor Ort Start M10 Start M30 Lampentest Reset
Differ. pressure monitor Operating remote Operating local Start M10 Start M30 Lamptest Reset

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Digital Eingänge 6 113 281 4214492 +SLGS
Digital inputs Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
-D2 E125.0 E125.1 E125.2 E125.3 E125.4 E125.5 E125.6 E125.7
/2.3
12 13 14 15 16 17 18 19
-X51 3
B B
-X51 3
+EXT
-Q10 13 -Q30 13 -K20 3 -K* :

+EXT
/3.2 14 /3.3 14 /1.7 4 :
-X51 4
+EXT
C C
-X51 4
/5.8 L24 fvp fvp
D D
E E
Pumpe 10 Kühler NOT-AUS extern Anlage EIN

Pump 10 Cooler Emergency off external System ON

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Digital Eingänge 6 113 281 4214492 +SLGS
TBK Checked TBK 120-CV-006-01 Schaltplan Ölversorgungsanlage 6
Digital inputs Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
-D2 A124.0 A124.1 A124.2 A124.3 A124.4 A124.5 A124.6 A124.7 -D2 A125.0 A125.1 A125.2 A125.3 A125.4 A125.5 A125.6 A125.7
/2.4 /2.4
22 23 24 25 26 27 28 29 32 33 34 35 36 37 38 39
B B
31 31 31 31 31 31 31 31 31 31 31 31 31
-H1 -H2 -H3 -H6 -H7 -H8 -H9 -H10 -H11 -H12 -H13 -H14 -H16
32 32 32 32 32 32 32 32 32 32 32 32 32
C C
/4.8 L0 fvp fvp fvp fvp

/4.8 L0
OLV:BB OLV:P1IB OLV:P1SG OLV:KIB OLV:KSG OLV:FSG OLV:D0,8 OLV:D0,5 OLV:T75 OLV:T80 OLV:V80 OLV:V70 NOT:AUS
D D
Betriebsbereit Pumpe 10 Störung Kühler Störung Öldruck <0,8bar Öltemperatur >75°C Volumenstrom <80% NOT-AUS
Ready for operation Pump 10 fault Cooler fault Oil pressure <0,8bar Oiltemperature >75°C Volume flow <80% Emergency off
Pumpe 10 in Betrieb Kühler in Betrieb Filter verschmutzt Öldruck <0,5bar Öltemperatur >80°C Volumenstrom <70%
Pump 10 in operation Cooler in operation Filter contaminated Oil pressure <0,5bar Oiltemperature >80°C Volume flow <70%
E E

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Digital Ausgänge 6 113 281 4214492 +SLGS
Digital outputs Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
-D4 A0.0 A0.1 A0.2 A0.3 A0.4 A0.5 A0.6 A0.7 -D4 A1.0 A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7
/2.5 /2.6
2 3 4 5 6 7 8 9 12 13 14 15 16 17 18 19
-K10 A1 -K30 A1 -K1 A1 -K2 A1 -K3 A1 -K4 A1
B B
A2 A2 A2 A2 A2 A2
/4.8 L0
1 14 11 2 14 11 /9.1 14 11 /9.2 14 11 /9.3 14 11 /9.4 14 11
12 11 12 11 /9.1 12 11 /9.2 12 11 /9.3 12 11 /9.4 12 11
OLV.P1NE OLV.KNE . . . . . OLV.BB OLV.IB OLV.WG OLV.SG
/1.4 SL1
C C
-K10 11 -K30 11
1 14 2 14
D D
-K10M A1 -K30M A1
A2 A2
/1.8 SL2
1 2 /3.3 1 2
/3.1
3 4 /3.3 3 4
/3.1
5 6 /3.3 5 6
/3.1
13 14
E E

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Digital Ausgänge 6 113 281 4214492 +SLGS
Digital outputs Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
A A
B B
C C
-K1 11 -K2 11 -K3 11 -K4 11
/8.5 12 /8.5 12 /8.6 12 /8.6 12

D D
-K1 11 -K2 11 -K3 11 -K4 11
/8.5 14 /8.5 14 /8.6 14 /8.6 14
-X91 11 14 12 -X91 11 14 12 -X91 11 14 12 -X91 11 14 12

+EXT +EXT +EXT +EXT
Betriebsbereit Warnung
(Relais angezogen) (Relais abgefallen)
E E
Ready for operation Warning
(Relay picked up) (Relay dropped out)
In Betrieb Alarm
(Relais angezogen) (Relais abgefallen)
In operation Alarm
(Relay picked up) (Relay dropped out)

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Potentialfreie Kontakte 6 113 281 4214492 +SLGS
Potential free contacts Wiring diagram oil supply system STR 9 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
+SLGS -X10 Target description cabinet direction A

= + - : max. STR = + - :
= +MCC -X10 L1 UK10N 1 10.0 STR=/1.1 = +SLGS -Q1 2
= +MCC -X10 PE USLKG 10N 4 10.0 STR=/1.1
B B
C C
D D
E E
F Date 07.07.06 120-CV-005-01 Order No. =.+SLGS-X10 F

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Klemmenplan 6 113 281 4214492 +SLGS
Connection plan Wiring diagram oil supply system VKL 1 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
= +OLGS -M10 W UK10N 1 10.0 STR=/3.1 = +SLGS -K10M 2
= +OLGS -M10 V UK10N 2 10.0 STR=/3.1 = +SLGS -K10M 4
= +OLGS -M10 U UK10N 3 10.0 STR=/3.1 = +SLGS -K10M 6
= +OLGS -M10 PE USLKG 10N 4 10.0 STR=/3.2
B B
= +OLGS -M30 W UK5N 5 4.0 STR=/3.3 = +SLGS -K30M 2
= +OLGS -M30 V UK5N 6 4.0 STR=/3.3 = +SLGS -K30M 4
= +OLGS -M30 U UK5N 7 4.0 STR=/3.3 = +SLGS -K30M 6
= +OLGS -M30 PE USLKG 5 8 4.0 STR=/3.3
C C
D D
E E

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1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
USLKG 5 1 4.0 STR=/1.3 = +SLGS -T1 PE
USLKG 5 2 4.0 STR=/1.6 = +SLGS -G1 PE
= +SLGS -S1 5 UK5N 3 4.0 STR=/1.5 = +SLGS -E1 N
UK5N 4 4.0 STR=/1.5 = +SLGS -E1 N
B B
USLKG 5 5 4.0 STR=/1.5 = +SLGS -E1 PE
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
= +EXT -X51 1 UK5N 1 4.0 STR=/1.7 = +SLGS -S20 12
= +EXT -X51 2 UK5N 2 4.0 STR=/1.7 = +SLGS -K20 A1
= +EXT -X51 3 UK5N 3 4.0 STR=/6.8 = +SLGS -D2 19
= +EXT -X51 4 UK5N 4 4.0 STR=/6.8 = +SLGS -S6 14
B B
USLKG 5 5 4.0 R
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
= +OLGS -S20 3 UK5N 1 4.0 STR=/5.1 = +SLGS -D2 2
= +OLGS -S20 2 UK5N 2 4.0 STR=/5.1
= +OLGS -S20 1 UK5N 3 4.0 STR=/5.1
= +OLGS -S20 PE USLKG 5 4 4.0 STR=/5.2
B B
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
= +OLGS -B50 1 UK5N 1 4.0 STR=/4.3
= +OLGS -B50 4 UK5N 2 4.0 STR=/4.3 = +SLGS -D2 3
UK5N 3 4.0 STR=/4.3 = +SLGS -SHIELD 3
= +OLGS -B80 1(+) UK5N 4 4.0 STR=/4.4
B B
= +OLGS -B80 2(-) UK5N 5 4.0 STR=/4.4 = +SLGS -D2 6
UK5N 6 4.0 STR=/4.4 = +SLGS -SHIELD 3
USLKG 5 7 4.0 R
C C
D D
E E

Drawn TBK
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8

= + - : max. STR = + - :
= +OLGS -B65.1 RD UK5N 1 4.0 STR=/4.1 = +SLGS -U65 1
= +OLGS -B65.1 RD UK5N 2 4.0 STR=/4.1 = +SLGS -U65 2
= +OLGS -B65.2 WH UK5N 3 4.0 STR=/4.2
= +OLGS -B65.2 WH UK5N 4 4.0 STR=/4.2
B B
USLKG 5 5 4.0 R
C C
D D
E E

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1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
Zeile Gerät Position Material Nr. Benennung Typ Hersteller
A Line Device Position Idt. No. Description Type Manufacturer A
1 -D2 STR=/2.2 000001251846 Automatisierungsgerät DS95
6ES7 313-5BE00-0AB0 Siemens
PLC - unit
2 -D4 STR=/2.5 000001251849 Digitalausgabe DSDA
6ES7 322-1BH01-0AA0 Siemens
Digital output unit
3 -E1 STR=/1.4 000001256145 Schaltschrank Heizung EH
SK 3107 Rittal
Switch cabinet heater
4 -F1 STR=/1.3 000000361623 Sicherungsautomat FA
FAZ-B10 Moeller
Circuit breaker
5 -F2 STR=/1.4 000000361623 Sicherungsautomat FAZ-B10 Moeller
B FA
B
Circuit breaker
6 -F3 STR=/1.5 000000361623 Sicherungsautomat FA
FAZ-B10 Moeller
Circuit breaker
7 -G1 STR=/1.6 000001212447 Netzteil GN
6ES7 307-1EA00-0AA0 Siemens
Power pack
8 -H1 STR=/7.1 000100363102 Leuchtmelder HL
M22-L-G 24V Moeller
Signal lamp
M22-L-R 24V Moeller
Signal lamp
C 10 -H11 STR=/7.6 000100363127 Leuchtmelder HL
M22-L-Y 24V Moeller C
Signal lamp
M22-L-R 24V Moeller
Signal lamp
M22-L-Y 24V Moeller
Signal lamp
M22-L-R 24V Moeller
Signal lamp
M22-L-R 24V Moeller
Signal lamp
D D
M22-L-W 24V Moeller
Signal lamp
M22-L-R 24V Moeller
Signal lamp
M22-L-W 24V Moeller
Signal lamp
M22-L-R 24V Moeller
Signal lamp
M22-L-Y 24V Moeller
E Signal lamp E
M22-L-Y 24V Moeller
Signal lamp
21 -K1 STR=/8.5 000001255143 Koppelrelais KK
3TX7 Siemens
Couplerelay
3TX7 Siemens
Couplerelay
23 -K10M STR=/8.1 000001335202 Leistungsschütz KL
3RT10 Siemens
Power contactor

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Geräteliste 6 113 281 4214492
List of equipment Wiring diagram oil supply system ZGL 2 Sh.
1 2 3 4 5 6 7 8
3
1 2 3 4 5 6 7 8
Zeile Gerät Position Material Nr. Benennung Typ Hersteller
A Line Device Position Idt. No. Description Type Manufacturer A
3TX7 Siemens
Couplerelay
2 -K20 STR=/1.7 000001255141 Leistungsschütz KL
3RT10 Siemens
Power contactor
3TX7 Siemens
Couplerelay
3TX7 Siemens
Couplerelay
5 -K30M STR=/8.2 000001255142 Leistungsschütz 3RT10 Siemens
B KL
B
Power contactor
3TX7 Siemens
Couplerelay
7 -Q1 STR=/1.1 000100363016 Leistungsschalter QL
3RV10 40-50A+3RV19 330 Siemens
Power switch
8 -Q10 STR=/3.1 000100363017 Motorschutzschalter QM
3RV10 +3RV19/28-40A Siemens
Motor protec. switch
9 -Q2 STR=/1.3 000001255172 Motorschutzschalter QM
3RV10 0,45-0,63A Siemens
C 10 -Q30 STR=/3.3 000100363018 Motorschutzschalter QM
3RV10 +3RV19/4,5-6,3A Siemens C
11 -S1 STR=/1.4 000000361122 Thermostat STW
SK 3110 Rittal
Thermostat
12 -S2 STR=/5.2 000100363141 Schlüsselschalter SS
M22-WRS3 20 R-0-R Moeller
Key operated switch
13 -S3 STR=/5.4 000100363113 Knebelschalter SK
M22-WRLK-W 10 0-R Moeller
Lever switch
14 -S4 STR=/5.6 000100363113 Knebelschalter SK
M22-WRLK-W 10 0-R Moeller
Lever switch
D D
15 -S5 STR=/5.7 000100363108 Drucktaster ST
M22-DL-W 10 Moeller
Push button
16 -S6 STR=/5.8 000100363111 Drucktaster ST
M22-DL-B 10 Moeller
Push button
17 -T1 STR=/1.3 000001304947 Steuertrafo TT
4AM48 4 - 500VA (400/230) Siemens
Control Transformer
18 -U65 STR=/4.1 000001217389 Meßumformer UM
MCR-PT 100-I Phoenix
Transducer
19 -W1 STR=/2.6 000001335148 PROFIBUS DP Schnittstelle WPBS
CP342-5 Siemens
E PROFIBUS DP interface E
20 *
*
21 *
*
22 *
*
23 *
*

Drawn TBK
Geräteliste 6 113 281 4214492
List of equipment Wiring diagram oil supply system ZGL 2 Sh.
1 2 3 4 5 6 7 8
3
List of equipment Type OLGS Page
1 of 3
Size 11
Please quote in correspondence GL 1.319.555 EN
Manufacturer
Part No. Qty. Description
Operating instruction
Switching and monitoring functions in accordance with:

Lubrication schedule drawing no. 6 113 280
Oil−supply system type OLGS, size 11
Assembly drawing no. 6 113 279
Terminal diagram drawing no. 6 113 281
refer also to Operating Instructions BA 1.319.555 EN
10 1 Gear pump STEIMEL

Type to FLENDER works standard: BA STE.PUM.000 ..
F 5958 Size 11 (SF 8/350 RD−VLFM)
Nominal pressure : PN 25
Housing material: EN-GJL-250
Rotation speed:970 1/min
Oil flow rate approx. 335 l/min
Startviscosity < 5000 mm2/s
Operating pressure: < 8 bar
Direction of rotation: cw
with pressure relief valve
set to p > 8 bar
directly coupled with:
Three−phase motor
Type B5
Size 200 L-06
Rotation speed 970 1/min
Output 18,5 kW
Voltage 3x 380 ... 420 V (IEC38)
Frequency 50 Hz
Insulation class F
alitude of installation above sea level: 3000m
20 1 Double change−over filter FLENDER

Type to FLENDER works standard: F 5921 B 5921
Type/No.: 80.60 .2.F2
Connection DN 80
Nominal pressure PN 16
Housing material EN-GJL-250
Material filter dome GK-Al
Filter fineness 60 mm
Filter element of VA metal fabric
with optical differential pressure display
with electrical differential pressure monitor
Type/No.: 2.F2
Number of switching contacts: 1
Contact rating:
1 A / 250 V AC / 60 VA
1 A / 250 V DC / 30 W
Switch point: 20 = 2 bar

2 of 3
Size 11
Manufacturer
30 1 Air oil−cooler FUNKE

Type to FLENDER works standard: BA FUN.OLK−001 ..
W 5937 / 14-1N-750
Funke-Type/No.:2.7814.2.11.11
Quantity of heat to be dissipated: 94 kW
Oil temperature cooler input/output: 81 / 71 °C
Permiss. ambient temperature 34 °C
Starting temperature > 10 °C
Three−phase motor IEC-NORMMOTOR
Type: B14
Size:132S
Speed 750 1/min
Output 2,2 kW
Voltage 3x 380 ... 420 V (IEC 38)
Frequency 50 Hz
Insulation material class F
alitude of installation above sea level: 3000m
32 1 Temperature control valve MVA

Type/No.: M65 C 3 G 130 D A BA MVA.REG.000 ..
Connection DN 65
Nominal pressure: PN 16
Oil flow rate approx.: 335 l/min
Housing material: EN-GJS
with control element type/no.: 2001A
opening towards cooler at 52 °C
valve open at 60 °C
Place of installation: Air oil-cooler bypass
45 1 Manometer FLENDER
Type to Flender works standard: W 5914 B 5914
Connection G 1/4
Nominal size NG 63
Housing material: VA
Measurement range 0-10 bar / 0-140 PSI
50 1 Pressure transducer DANFOSS

Type/No.: MB S 3050-2011-5GB 04 BA DAN.DUM.000 ..
Connection G 1/4
Measurement range: 0 - 10 bar
Output signal: 4 - 20 mA
Feed voltage: 9 - 34 VDC
Pressure value: 50.1 = 0.8 bar
Pressure value: 50.2 = 0.5 bar

3 of 3
Size 11
Manufacturer
60 1 Thermometer FLENDER
Type to Flender works standard W 5924 B 5924
Connection: G 1/2
Nominal size NG 63
Housing material: VA
Measurement range −20 ... +120 °C / -4 ... +249 °F
with proctective tube
Connection protective tube G 1/2
length of protective tube 50 mm

Type to Flender works standard F6100-3 B 6100
Resistance thermometer sensor 2 x PT 100 DIN IEC Kl. B
two−wire circuit
with transmitter
Output signal: 4 - 20 mA
Measurement range: −50...+150 °C
Connection protective tube G 1/2
length of protective tube 68 mm
Temperature value: 65.1 = 55 °C
80 1 Flow monitor FLENDER

Type to Flender works standard W 5927 B 5927
Transmitter type DE16
Output signal: 4 - 20 mA, not linear
Measurement range: 0 - 385 l/min ( 0 l/min ¢ 4 mA ; 385 l/min ¢ 20 mA)
Supply voltage: 24 VDC
Oil flow rate approx. 335 l/min (¢ 16,1 mA)
Volume flow value: 80.1 = 80 % oil flow rate (=268 l/min ¢ 11.7 mA)
Volume flow value: 80.2 = 70 % oil flow rate (=234 l/min ¢ 9.9 mA)

1
Zertifiziert nach EN ISO 9001:2000
Sondermaschinenbau
Fördertechnik
Näscher-SNV GmbH Nordstr.7-9 58300 Wetter
CNC-Zerspanung
ThyssenKrupp Robins, Inc. Lohnfertigung
7730 E. Belleview Avenue, #404
Greenwood Village, Colorado 80111 Telefon: 02335-9799-233
Telefax: 02335-9799-29
E-mail: witt@naescher-snv.de
Internet: www.naescher-snv.de
13.04.2006
LOS PELAMBRES – UPGRADE

Low Speed Flange Couplings with Locking Devices TAS3013-540/675
TKRI Purchase Order 0601 003 6026
Näscher-SNV Order No. 49227 / TF
General Mounting Instructions
The low speed flange coupling with the internal locking devices will be mounted as follows:
1. After opening the cases make sure that the couplings and locking devices are in
good condition and remove any pieces of wood or other pieces from the bore
2. Place and fix a pin of approx. 38 mm in one of the bores that will be used for bolting
the brake disk later
3. Pin should be approx. 250 mm long and the longer end should be faced to the
bottom while coupling is still in horizontal position as delivered
4. DO NOT remove the bolts from the internal locking device that are painted with red
colour ! ! ! !
5. Now the coupling together could be lifted up by crane and by using an appropriate
rope (no steel rope)
6. Make sure that coupling bore is in horizontal position when coupling is lifted up
completely
7. Now the inner surface of the bore should be cleaned carefully with a SLIGHTLY
oiled cloth
8. Unscrew all bolts several turns (2 – 3)
9. Drive coupling together with locking device slowly and carefully on the completely
cleaned surface of the pulley shaft
10. Make sure that there are no particles of any obstacles on the surface of the shaft
11. While coupling is still in horizontal position drive the coupling by crane in the final
position
12. Measure continuously!
13. Now the crane can drop the coupling until the inner bore of the locking device
reaches the shaft
Näscher-SNV GmbH Nordstr. 7-9 58300 Wetter USt-IdNr. DE 811531571 HRB Hagen 5040
Geschäftsführer: Dipl.-Kfm. Ralph Näscher Dipl.-Kffr. Birgit Schwickerath-Näscher Bernd Vorpahl
2
Zertifiziert nach EN ISO 9001:2000
14. The red marked bolts can be removed; they are longer used
15. Tighten bolts by hand
16. Control the vertical position of the surface where the brake disc is connected to
later
17. Drop coupling completely and rope of crane can be removed
18. The bolts are tightened in several steps until the final torque of 1800 Nm is
reached:
First take the smaller torque wrench and use the special adapter that
fits to the torque wrench output (□ 3/4”) and to the nut with □ 1” and
SW 19 (fits into the bolts of locking device).
Adjust the smaller torque wrench (applicable for 140 Nm to 760 Nm) at
360 Nm and tighten the bolts in the sequence as described in the
attached drawing.
Only when ALL BOLTS have reached the 360 Nm, several controls are
necessary, adjust the next torque at the wrench.
Next step is 540 Nm; proceed the same sequence as above and
continue to the next torque after checking several times that ALL
BOLTS have the same torque of 540 Nm.
Next step is 720 Nm; proceed the same sequence as above and
continue to the next torque after checking several times that ALL
BOLTS have the same torque of 720 Nm.
For the following torques of 1080 Nm, 1440 Nm and finally 1800 Nm the
big torque wrench (applicable for 750 Nm to 2000 Nm) should be used.
The special adapter □ 3/4” □ 1” is no longer used, since the nuts fit
directly into the output of the big torque wrench.
Sequences and controlling the torque as described above.
19. During mounting ALWAYS the perpendicular position of flange to pulley shaft
should be controlled
20. Torque and/or sequence should be varied to keep the perpendicular position
21. Only controlled torque wrenches should be used all time
22. After ALL bolts have reached the 1800 Nm the torque should be controlled at least
two times in order to make sure that REALLY ALL bolts have the 1800 Nm
23. Further details can be gathered from the attached information
24. In case of any questions or doubt DO NOT CONTINUE!!! Ask the supplier before
anything uncontrolled is done ! ! !
Näscher-SNV GmbH
Axel Witt
Phone ++49 2335 97 99 233
Fax ++49 2335 97 99 29
Mail witt@naescher-snv.de
Näscher-SNV GmbH Nordstr. 7-9 58300 Wetter USt-IdNr. DE 811531571 HRB Hagen 5040
Geschäftsführer: Dipl.-Kfm. Ralph Näscher Dipl.-Kffr. Birgit Schwickerath-Näscher Bernd Vorpahl
=!~_88- industries I el
.,
~c,
-it/) Western Office [J Eastern Office [J European Office

\ 6500 Dennett Place 108 Skyway Avenue Bath Road
'-..J Delta BC Toronto ON Bridgwater Somerset
Canada V4G 1N4 Canada M9W 4Y9 England TA6 4YQ
Tel: 6049404555 Tel: 4162139991 Tel: 01278456411
Fax: 604 9404565 Fax: 4162139992 Fax: 01278429949
www.jbrakes.com www.brakes.ca www.elevanja.com
USER'S MANUAL
JOHNSON CALIPER BRAKE
DATE: FEBRUARY, 2006
- CUSTOMER NAME: ThyssenKruppRobbins

H
PURCHASE ORDER NO.: 06010026018
JOHNSON IND. JOB NO: 4978
LOCATION: Minera Los Pelambres

Chile
EQillPMENT: (2) 2DH2040BCaliper Brakes

(1) 2DS2040BCaliper Brake
(2) 96 in dia BrakeDiscs
(2) QAM80 Quick Apply Modules
(3) HARS2562Spring Accumulators
JOHNSON INDUSTRIES LTD.

DELTA, B.C. . CANADA
r~ (
~
...~
v ... ~Western Office
8500 River Road
RichmondBC
Canada V6X1Y4
Tel: 6042733737
industries
/ e/evanja
0 EasternOffice
108 SkywayAvenue
TorontoON
Canada M9W4Y9
Tel: 4162139991
DEuropeanOffice
Bath Road
BridgwaterSomerset
England TA64NU
Tel: 01278456411
Fax: 6042739654 Fax: 4162139992 Fax: 01278429949
INDEX
1.0 INSTALLATION
1.1 GENERAL 1
1.2 MOUNTING 1
1.3 PLUMBING 2
1.4 FLUSHING 2
2.0 INSPECTION AND MAINTENANCE

2.1 LININGS 3
2.2 BURNISHING 4
2.3 DISC ... 5
2.4 AIR GAP 6
2.5 LUBRICATION 6
2.6 LIMIT SWITCHES 7
~ 3.0 ACTUATORS
3.1 INSPECTIONAND MAINTENANCE 7
3.2 PRESSURESUPPLY 8
4.0 TROUBLE SHOOTING

4.1 BRAKES WILL NOT RELEASE 8
4.2 BRAKESWILL NOT SET 8
4.3 SLOW BRAKERESPONSE :: : 9
4.4 BRAKES SLIP 9
4.5 RAPID OR ERRATIC UNING WEAR 10
5.0 WARRANTY AND SERVICE

5.1 RECOMMENDED SPAREPARTS 10
5.2 SERVICE 10
5.3 W ARRANTY 11
F:\dbr\generic_DH_man
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v' 1.0 INST ALLA TION
1.1 GENERAL
The Johnson Industries 'DH' series caliper brake is a direct acting type of brake
utilizing hydraulically applied actuators acting directly onto the brake shoe. The calipers
are mounted in a frame via two bearing pins. Teflon slide bearings in the caliper allow
the brake to float laterally on the bearing pins to compensatefor axial movement of the
disc or lining wear. The 'DS' caliper brakes are available in a large range of clamping
forces and can be selectedwith various types of friction grades. The brakes are
available with actuators on either left or right hand side or both sides and three different
styles of basesfor horizontal, vertical or inclined mounting. Contact Johnson Industries
for assistancein selecting a brake most suitable for the user's application.
1.2 MOUNTING
Discs are normally installed prior to placement of the caliper. Discs are shipped with a
rust inhibitor coating applied to the exposed surfaces. This coating will permanently
damage the friction linings if allowed to come in contact with the disc. It is imperative to
thoroughly remove the rust inhibitor with a cleaning solvent prior to installation of the
\-;
calipers. Most calipers are shipped in the releasedmode for ease . of installation.
Before tightening caliper bolts, clamp the caliper onto the disc. This is done by applying
1000 psi of hydraulic pressureto the actuators. The hydraulic power pack used to
manually release the brakes must be limited to a maximum pressure of 2000 psi and the
oil must be filtered to a 10 micron absolute (ISO 18/15) cleanliness level. With the
caliper clamped on the disc verify that the shoes are parallel with the disc and that the
base sits flat. Correct with shims if necessary. Verify that t~.epads are fully seatedon
the disc and that the assembly is centered with the disc. Reposition the brakes or shim
the base if required.
Once the caliper is properly positioned release the brakes and verify that the caliper has
adequatefloat on both sides of the brake frame. After bolting the brake frame in place,
release the caliper and ensure that the caliper floats freely. It is critical that the brakes
have adequateradial clearancebetween the disc outer diameter and the caliper center
plate. This clearance must be checked and verified to be a minimum of 3/16 of an inch.
Once the positioning of the brakes is verified to be correct the brake mounting bolts
must be tightened. Preload the mounting bolts to the value specified on the certified
drawing or to a maximum of seventy-five percent of the bolt proof load. Use either
lock washers or jam nuts to ensure that the mounting bolts do not work loose. The
V Page 1
~
.
_8~8888
V
. brake pedestal mustbedesigned
to allowenoughwrenchclearance
to properlytighten
the mounting bolts.
When operating temperatures exceed 300°F (150°C), oversized bolt holes should be
used in both disc and hub. It is preferable to drill the disc/hub mounting holes together
using the same set up.
1.3 PLUMBING
The brake system must be plumbed with adequately sized piping or tubing, preferably
stainless, suitably rated for the operating pressures. Generally, 1/2 inch diameter JIC
tubing and 1/2 inch diameter pipe is sufficient for most applications. The piping must be
adequately supported with pipe clamps every 4 feet. The connection to the brake must
be done with 3/8 inch diameter flexible hose suitably rated for the operating pressure.
Before connecting to the brakes, the plumbing must be purged to remove all the coarse
contaminants. After connecting to the brakes and hydraulic unit, thoroughly flush all
hydraulic systemsto a 10 micron absolute (ISO 17/14) cleanliness level before
applying full operating pressure.
When all connections have been made, air must be bled from all hydraulic actuators
during initial pressurization. The brakes must be cycled several.times to get all the air
~ out.
1.4 FLUSHING
w
t
~ For hydraulically released brakes the system must be flushed prior to commissioning the
~ equipment to ensure proper and reliable operation of the equipment. This procedure
,
~ must be done periodically or whenever the circuit has been broken to replace a
,.-
t component. For newly commissioned systemsthe piping and/or hoses must also be
r pre-flushed prior to connecting to the equipment to remove any coarse contaminants.
After plumbing the complete system can be flushed by following the guidelines below.
The oil should ideally be flushed to an I.S.O. cleanliness level of 17/14. This cleanliness
level can be achieved by using a ten micron (or finer) filter element with a beta rating of
75 (or higher). The duration of flushing should be sufficient to allow all the oil in the
reservoir and system to be circulated a minimum of four times through the filter.
The set up for flushing should include a suitable filter, as specified above, in the return
line portion of the circuit to filter out contaminants before the oil reachesthe reservoir.
It is undesirable to flush the contaminants into the reservoir as they will be picked up by
\.) the pump and possibly cause damage. Many hydraulic control units have a return line
Page 2
.
_8~8888
V
. filter in which case it is only required that the element be suitably rated. For those cases
that do not have a return line filter a spin-on filter can be temporarily added to the
circuit for flushing.
Many hydraulic brake systems have reciprocating flow type circuits whereas flushing
requires circulatory flow. For these cases a suitably rated hose must be plumbed
betweenthe flushing filter andthe secondactuatorport. For flow throughtype circuits
a return line will alreadybe present.
Flushingis bestaccomplishedwith turbulentflow to "blast" the contaminantsout of the

system. For thosehydrauliccontrol units which havea Brake ReleaseSolenoidValve
turbulentflow is createdby cycling the valve. The valve shouldbe left de-energized
long enoughto chargeup the systemaccumulatorbetweencycles. If the H.P.U. does
not havea BrakeReleaseSolenoidValve then a ball valve canbe temporarilyadded
up streamof the flushing filter.
WARNING!
Do not add a shutoff valve betweenthe filter and
reservoirashigh pressurewill burstthe filter.
v 2.0 INSPECTION AND MAINTENANCE
2.1 LININGS
Friction linings carry only the manufacturer'swarrantyandmust be adequatelytested

by the User in his particularapplicationto verify performancecharacteristics.New
linings must be thoroughlyburnishedand seatedon the disc~N Ratedtorqueis obtained
when the linings arefully bedded. Contaminatedor burnt linings must be discarded.
Allowing oil, grease,slurry etc. to contaminatethe linings will havea severedetrimental

effect on the stoppingcapacityof the brakes. Ensurethat thereareno sourcesof
contaminationnearthe disc or brakes. Lightly contaminatedlinings canbe cleanedwith
a non oil basedsolventandburnished.
When the lining thicknesswearsdown to 0.28 inchesthe shoesmust be removedand

new linings installed. Allowing the linings to wearfurther will eventuallyresult in the
rivets contactingand scoringthe disc. In dynamicapplications,wearingof the linings
beyondthe bottom of the lining groovesor ~llowing the groovesto becomepacked
with loosedebriswill havea detrimentaleffect on the stoppingcapacityof the brakes.
\-.) When installing new linings ensurethat the linings arebondedaswell asriveted andthat
Page3
...
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_8~888-
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" all the rivets are snug. In critical applications it is advantageousto carry a spare set of
lined brakes shoes to avoid down time of operating machinery. Replacement linings
must be as originally specified.
2.2 BURNISHING
Burnishing of friction linings is done to provide good, clean contact between the linings
and disc. The procedure removes minor contamination on the disc or linings as well as
any minor high spots or misalignment of the linings. New linings require burnishing to
fully embed the linings on the disc and periodically over the life of the linings to remove
any light contamination or oxide film from the swept face of the disc.
Before burnishing, ensure that the disc and linings are free from contamination. If
cleaning is required, use a non oil based solvent. If the swept face of the disc has a
heavy oxide layer then initial burnishing is required to remove it. This stage should be
done at a lower temperature and clamping force. After the rust is removed inspect the
linings and verify that the lining grooves have not become packed with loose debris.
Clean out the grooves if necessary. Heavily contaminated or burnt linings must be
discarded.
In addition to preparing the linings and disc for burnishing, any safety interlocks of the
"-" drive mechanism from the brake system should be bridged to aliow the disc to be
driven through the brakes.
To burnish, apply 500 to 750 psi pressure to the actuators and drive through the brakes
at a disc speed of 100 to 150 fpm. The clamping force of the brake shoescan be
adjusted by controlling the pressurein the actuators. It is preferable to burnish at the
high end of the range to reduce the burnishing time but ulti~ately the brake torque while
burnishing will be limited by the torque capacity of the drive. Insufficient lining pressure
during burnishing can polish the lining material, resulting in a reduction of the friction
coefficient. If this has happenedthe linings must be removed and sandedmanually to
scuff the surface.
The temperature must be monitored through out the burnishing process. The
temperature of the disc should be maintained between 250°F (120°) and 450°F
(230°C) for the best results. When the upper temperature limit is reached pause
burnishing until the disc has cooled to the lower limit. It may be necessaryto turn off
the coolant flow for water cooled discs.
V ;;"
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Page 4 '"
",tic
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_8~8888
. CAUTION
V Never allow the disc temperatureto exceed500°F
(260°C). Permanentdamageto the lining material
will result.
Burnishuntil a minimum of seventy-fivepercentlining contactand a bright disc surface

is achieved.To measurethe degreeof contact,setthe brakesandusea .002" feeler
gaugeto probethe perimeterof eachbrakeshoe. If the amountthe feeler gaugewas
ableto probeexceedstwenty-five percentof the lining areathenfurther burnishingis
required. The adequacyof burnishingmust alsobe verified with load testsor stopping
time measurements.If the actualbraketorquedoesnot meetthe ratedbraketorque
then further burnishingis required.
CAUTION
Do not put equipmentinto serviceif ratedbrake
torquecannotbe developed.ConsultJohnson
Industriesfor assistance.
"'-" 2.3 BRAKE DISC
For standardapplicationsthe disc shouldbe manufacturedfrom ASTM A588 or

equivalentmaterial~The disc mustbe suitablydimensionedfor the brakeapplication.
The O.D. must be selectedto providethe desiredtorque,the I.D. must allow enough
radial clearanceto removethe shoesduring liner replacementandthe thicknessmust be
chosento safelyabsorbthe brakeenergyinput. Referto the?ertified drawing at the
backof this manualfor critical dimensions.For bolted connectionsthe locating
diameterof the disc shouldbe machinedto a H8 toleranceclass. The disc shouldbe
balancedto ISO 1940/1gradeG40 for low speedapplicationsandG6.3 for high
speedapplications. The sweptpathof the disc shouldhavea surfacefinish within 32 to
64 rms micro inches. Surfacefinishesin excessof the maximumwill result in rough
braking action andrapid lining wear. Scoredor rough discsmustbe reconditioned,
removingno more than 0.02 inchesper inch of thickness. Facesshouldbe flat and
parallel within 0.004inchesacrossthe sweptface. Lateral andradial run-out should
not exceed0.001 inchesand0.002inchesper 12 inchesof diameterrespectively.
The heatdissipatingcapacityof the disc must not be exceeded.If the brakeenergy

input of the caliper, when usedunderdynamicconditionsof continuousapplicationor a
high duty cycle, exceedsthe energydissipatingcapacityof the disc then the torquemust
v' be limited or the duty cycle reduced.For high duty cycle applicationsASTM A514 or
","
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Page5
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_8~8888
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. equivalent mustbespecifiedfor thediscmaterialandspecialattentionmustbepaidto
the thermalandbrakingstresseson the disc/hubassembly.ConsultJohnsonIndustries
for suchapplications.
WARNING
NEVER APPLY WATER TO A HOT DISC
Permanentdamagein the form of heatcheckingand
warpingwill result.
2.4 AIR GAP
The air gapmustbe inspectedon a regularbasisandadjustedif necessaryfor lining

wear. An excessiveair gap and actuatorextension;
1. increasesthe brakereactiontime becauseof the largervolume of oil to
be charged.
2. reducesthe allowablelining wear asthe actuatorshavea limited amount
of stroke
3. could result in loss of actuatorforce dueto inadequatestroke.
The air gapmust be adjustedback within specificationswheneverit hasgrown out of

\.-I tolerance. The air gapis adjustedby extendingthe actuatorspindle. Begin by
removingthe draw bar and spindleretainer. Inserta shim of equivalentthicknessasthe
desiredair gapbetweenthe disc andthe brakepad on both sidesof the disc. Screwin
the adjustmentspindlesuntil the padscontactthe shim andall the spindlescontactthe
back of the shoes.Onehalf of a turn on the adjustmentspindlesclosesthe air gapby
0.04 inches. Ensurethat the spindleretainerlines up with its mountingholesto install
the retainerandreinstallthe draw bar. Cycle the brakesand~echeckthe air gap. After
adjustingthe air gapthe releaseandwear switchesif suppliedmust be adj'ustedalso
(seesection3.5). The air gapis measuredby pushingone shoeagainstthe disc while
measuringthe distancebetweenthe lining anddisc on the other shoe.
For applicationsthat requirea fasterresponsetime of the brakes,the air gapcanbe

reduced. In thesecasescloseattentionmust be paid to the axial run-out of the disc and
for possibledraggingof the shoes.In applicationswith high axial run-out of the disc the
air gap canbe increasedto compensate.For thesecasesconsultJohnsonIndustriesas
the lateral float capabilityof the brakesis critical.
2.5 LUBRICATION
When adjustingthe air gap,ensurethat the caliperfloats freely. It will be necessary,on

V a regular basis, to remove the bearing pins and clean both pins and slide bearings in the
Page6
"",;, ~
-,
.
_8~8888
. caliper. Although lubricating the slide bearings will reduce the sliding friction, this
""---" practice should be avoided if possible. The lubricant will attract dust and therefore
require more frequent maintenance intervals and possible reduce the life of the bearings.
When replacing linings ensure that the threads of the shoe pins have sufficient anti galling
compound applied and that an EP greaseis also applied to the shank.
2.6 LIMIT SWITCHES
Brake release and lining wear proximity switches are available as an option. The
switches are supplied pre wired to DIN 43650 spadeterminals. If present, both
switches must be adjusted whenever the air gap is adjusted. Failure to adjust the
switches will result in improper indication of pad wear and brake release.
Switch actuation of the brake releaseproximity switch must occur within 1/16 of an
inch of full actuator retraction. Ensure that the switch resets before the pads contact
the disc. The position of the switch in the caliper must be adjusted whenever the air
gap has been adjusted. This procedure is done by releasing the brakes, removing the
connector, loosening the jam nut and turning the switch housing clockwise. Advance
the switch housing until it contacts the shoe plate then retract it one quarter turn.
Secure the setting by tightening the jam nut to 25 foot-pounds.
\-.-
The lining wear limit switch is set to trip at a maximum air gap value of 3/16 of an inch
(4.5 mm). Maintaining the air gap within specified limits is critical to the overall
performance of the brake. It is important that the wear switch is properly adjusted
whenever the air gap is adjusted. The wear switch set point is adjusted in the exact
same manner as the release switch.
When replacinglinings fully retractboth switchesto avoid damagingswitches. Referto

the switch adjustmentproceduresat the back of this manual.
3.0 ACTUA TORS
Sealscanbe safelyreplacedby removing slottednut on the piston rod and

disassembling the actuator. Actuators should be returned to Johnson Industries Ltd. for
routine inspection and reconditioning on a 24 month basis or more frequently for
extreme operating conditions. When replacing seals,ensure that they are installed
correctly and are not damaged.Care must be taken not to allow the actuator interior to
become contaminated or the seal surfaces to become scratched. Recondition or
""-' change the cylinder if the surface finish exceeds 16 rms micro inches. Reconditioning of
Page 7
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_8~_88-
,
\I
" hydraulicactuatorsealingsurfaces
arepermittedsolongastheresultantradial
clearanceafter honing doesnot exceed0.004inches.
3.2 PRESSURESUPPLY
A hydrauliccontrol systemshouldsupplywell filtered, high quality, petroleumbased

fluid having goodlubricity andoxidation resistance.An ISO VG32 hydraulicoil having
a viscosityindex of about200 is recommended.The viscosity must not exceed1000
cSt (4500 SUS)at the minimum ambienttemperature.Bleed air from actuatorand
lines after installationor servicing. Failureto bleedair from hydrauliclines and actuator
will result in slow anderratic actuationandcandamagethe seals.
SYMPTOM CAUSE DIAGNOSIS RECTIFICA TION

4.1 a. Control valve failure Verify no pressurein actuator Replaceor repair
Brakes will control valve
not release b. Shoepins seized
Verify shoepins free lubric.ate
v c. Actuator seized
Verify actuatorresponseto Replaceactuator
pressure
4.2 a. Control valve failure Verify valve pressurizes Replaceor repair
Brakes will actuator defectivevalve.
not apply b. insufficient actuator
stroke Verify actuatorstrokesufficier Adjust air gapor
to closeair gap replacelinings if
necessary.
4.3 a. Aeratedoil Verify no air in oil Bleed actuators
Slow brake
response b. High oil viscosity Verify oil specificationand Replaceoil
servicetemperature
c. Inadequatelysized Verify flow rating of valves Replacevalveswith

valves properly sizedvalves
d. excessiveair gap Verify air gapwith in specs Adjust air gap
V
Page8
'!I{~f,'~i;~;;iI~~ 111111. ;.,;.,
'
'1'!I;,,""'!.i,'~,""j, , ,;"~,,
,:~J~t~4i~ " ~., L
'-
.
_8~8888
.
v 4.4 a. Contaminated Verify linings and disc dry and Clean with non oil base<
Brakes slip linings or disc free from oil solventandburnish.
Checkfor oil leaks.
Cleangroovesif
b. Poor lining contact Verify 75% minimum contact. necessary.Burnish
Verify groovesnot plugged. linings.
Verify gradeof linings Replacelinings

c. Incorrectlinings
Verify caliper doesnot contact Checkbrakemounting
d. Inadequatefloat brakeframe whenbrakesset andcorrectif necessary.
4.5 a. Both shoesdragging Verify no trappedpressure. Replaceor correct

Rapid or on disk control valves
erratic
lining wear b. One shoedragging Verify brakescenteredon disc. Repositionbrakes.
on flange Verify adequatefloat.
Verify surfacefinish within

c. Roughdisc surface specifications Reco~ditionsweptface
\...,.J finish of disc
Verify brakesproperly
e. Linings not fully positionedandmounted. Repositionand/orshim
seatedon disc brakesto fully seat
linings
Measureaxial run-out. Verify
f. High axial run-out adequateair gap andlateral Correctdisc run-outif
co
float. possible. Adjust air gap

to accommodatedisc.
Verify maximumdisc Limit duty cycle of

g. Excessivedisc temperaturenot exceeded. brakes
temperature
5.1 RECOMMENDED SPARE PARTS
The numberandnatureof sparepartsthat shouldbe carriedwill dependon severityof

service,frequencyof cycling and functionalcriticality of the brakes. Partswhich may
V require replacement due to normal wear are:
Page9
. ,
.
_8~8888
v
. 1. Friction linings (c/w rivets)
2. Actuator seals
3. Release& wear switches
4. Slide bearings
For critical applicationswith high duty cycle it may be advantageous
to carry a setof
lined shoes,actuatorassembliesandcaliper pins to reducedown time.
When orderingspareparts,specifycaliper model and serialnumber,andpart number

andquantity of spareparts.
5.2 SERVICE
JohnsonIndustriesoffers field service,supervision,and assistance,

during installation,
maintenance,and tests,at a nominalper diem rate plus disbursementsat costplus a
handlingfee. Under no circumstancesarefield servicesof any kind or commissioning
allowedfor in the pricesof our brakesunlessexpresslyso statedin writing on our
quotations.
JohnsonIndustriesalsooffers shopservicesto reconditionor repair worn brake

assembliesor components.Contacta JohnsonIndustriesrepresentativefor an estimate
of the work desired.
\.-;
5.3 WARRANTY
JohnsonIndustrieswarrantstheir calipersand discsto be of the quality specifiedin our

quotations. We guaranteeour materialsandworkmanshipfor a period of ninety days
from dateof delivery to the end user. Disc and lining performancein regardsto wear,
friction coefficient, andenergydissipationdependon severity,andcondition of the brake
service. Therefore,the purchasershall verify throughadequatetestingthat all linings,
calipersanddiscsperform satisfactorilyin his particularapplication,anywarranty
concerningsuchperformancebeingexpresslyexcludedherefrom. Our liability in respect
of anyfailure of goodssuppliedby us or any loss,injury or damageattributedthereto,
shall be limited to making goodthe repairby replacingandrefitting free of chargeany
goodsor partsthereofwhich areshownto our satisfactionto havebeenproved,under
their intendeduse,defectivein materialsandworkmanshipwithin the ninety day
guaranteeperiod, providedthat suchdefectivepartsarepromptly returnedasdirected
by us, transportationchargesbeingpaid by the purchaser,andprovidedfurther that no
burningor welding or any modificationsof any sort hasbeendoneon any suchdefective
goodsor parts. In everycase,the customershall be chargedfor replacementpartson a
pro ratabasisfor the elapsedportion of the warrantyperiod. In the caseof friction
linings, productsand componentsmanufacturedby others,we extendto the Purchaser
~ the warranties of the manufacturer only. Deterioration, damage, or malfunction caused
Page10
:II,
.
_8~8888
.
, byinadequate
storageor handlingpriorto or aftersaleto theenduserarenot covered
\I by thiswarranty.We reservetherightto makechanges
andaddimprovements
at any
time without incurring any obligationto makesuchchangesandimprovementson
productsalreadyproduced. This warrantyandguaranteeis in lieu of all warranties,
conditions,or liabilities implied by law or expressedby statute.
\.,...;
~
Page 11
~ M30X3.5 X 55 DP
65.0O:t 0.25 FOR LIFTING EYE
1mm CHAMFER
BOTH SIDES
(36) ~42.0
l I
I
~~ 0
SPACED 10.
~
00 OOw I
NO ON-l I
~'1' ~'1'~
- 8 ~0 ~ - L[) I
~2438.0:f:0.5-- --
a r--.:~"-
0 ro
I
N N OJo I
..- ..- I
J i
2mm CHMF THIS SIDE

45.O:t 0.2 6.5mm CHMF OPPOSITE SIDE
INSTALL BOLTS FROM DISC SIDE FOR MATINGTO HUB
PRELOAD BOLTS TO 750 KN-M
TORQUE LOCK NUTS TO 1500 N-M
A
TAG NO'S ORIGINALOTY EXPANSION
OTY
120-CY-OO5 5 1
120-CY-OO6 5 1
120-CY-OO7 3 0
NOTE:
SPECIFICATIONS DISCS SUPPLIED COMPLETE WITH
MATERIAL: QT100 STEEL! ASTM - A514 M39 X 10.9
CLASS 175 AND
BOLTS TO934,
DIN DIN CLASS
931, 10
.
..~
WEIGHT: 1790 KG [3940 LBS]
industries
/ elevanja
NUTS.
02438mm X 65mmTHICK BRAKEDISC

CONVEYORS 120-CV-005, 006, & 007
Th ssen Kru I Minera Los Pelambres
'" 8500 River Rood, Richmond BC Canada V6X 1Y4
Tel 604 273 3737 -- Fax 604 273 9654
BY:
SC:
DJ DATE:
REV.
981210 DWG. NO.
A3859-20.6
Bath Road. Bridgwater Somerset England TA6 4NU PATH'. Pit/lpcnvrs/Ip385920
Tel 0278 456411 -- Fax 0278 429949 J
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115VAC
NE RAL
BRAKE #1
LS1
1 - '" - -/ ~
~ Brake Released
Dr al\o ~oroa~ou
L-
r--
TS1 TS2
- - - -i Lining Temperature O.Kr -
5 6 7 8
LSZ
0---0--- - - - -1 Linings worn I adjust air-gap r-
9 10
&
LS3
BRAKE #2
-1 Brake Released I-
11
14
TS3 TS4
- - - -i Lining TemperatureO.K.f- -
1 20
LS4
0---0- - - - -1 Liningsworn I adjust air-gap r-
21 22
&
SETTINGS LEGEND
TS1, TS2, TS3, TS4: 170'C FALLING LS1,LS3 - BRAKE RELEASE INDICATING PROXIMITY SWITCH
LS1, LS3: FULLY RETRACTED LS2,LS4 - AIR GAPILiNING WEAR INDICATINGPROXIMITYSWITCH
LS2, LS4: 4mm EXTENDING TS1",.4 - DISC TEMPERATUREINTER LOCK SWITCH
.
..~ industries/elevanja
ELECTRICAL SCHEMATIC
2DS2040A & 2DS2040B CALIPER BRAKES
CONVEYORS120-CV-005, -006, & -007
", .
8500 River .
Rood. Richmond
Tel 604 273 3737 --
BC Conodo V6X 1Y4
Fox 604 273 9654
BY:
SC:
di:I DATE: 98/06/02
REV.-4 Y.K, JanJ06
DWG. NO.
Bath Road. Bridgwater Somerset England TA6 4NU

Tel 0278 456411 -- Fox 0278 429949
PAT H
I:
' tli
pj pcnv
rs/r 14/1385918
p a
A385918-2.4
~
PA RTS LI ST
0 0
0 0
ITEM PART NO. QTY DESCRIPTION

1 2DS2040B 1 BRAKE FRAME
2 - - - - 2 CALIPER BRAKE ,..
3 BBP2040H 4 BEARING PIN - HEAVY

4 BKB2040H 8 RETAINER BAR - HEAVY
5 F12C28H5 16 KEEPER BOLT
6 EE22040B 1 ELECTRICAL ENCLOSURE
(FIELD MOUNTED)
.". . . . . .
LEFT HAND SHOWN
(RIGHT HAND OPPOSITE)
...
~
INDUSTRIES LTD.
pjt/lpcnvrs/r14/lp385912
TEL. (604) 273 3737 CUST .

2DS2040B CALIPER BRAKE ASSEMBLY
SECONDARY DRIVE & TAKE-UP PULLEYS
LOS
KRUPP
PELAMBRES
CANADA
CONVEYORS 120-CV-O5. & -06
8500 RIVERROAD.RICHMOND
BC FAX.(604) 273 9654 J/N 3859 SID JAN 99 DWG. NO.
CANADAV6X IY4 TLX.04-357554 S N's A3859- P2
-,
illM PART NO. .Qli DESCRIPTION
1 BHA1040 2 ACTUATOR ASSEMBLY
2 BBFL3859 1 ACTUATOR PLATE
3 BBFC3859 1 CENTER PLATE
4 BBFR3859 1 CALIPER PLATE
5 BS4978 2 SHOE PLATE
6 BFS3859 20 FRICTION LINING - 3 RIVET
. 7 BFSGBK3 20 FRICTION LINING - 2' RIVET
8 BILS3859 1 LINING INSULATER
9 F6R17 100 LINING RIVETS
10 BPSG3859 4 SHOE GUIDE PIN
11 BSRS2050 2 SHOE RETURN SPRING
12 BSB2040 4 SLIDE BEARING
13 F22C248H5 6 CALIPER ASSEMBLY BOLT
14 F22C5N 6 CALIPER ASSEMBLY NUT
15 F18C56S8 8 ACTUATOR MOUNTING BOLT
16 BMBLE16 2 CALIPER LIFTING EYE
17 BMBLE6 4 SHOE LIFTING EYE
18 BLTS3859 2 LINING TEPERATURE SWITCH
19 BRPS3040 1 BRAKE RELEASE SWITCH
20 BWPS3040 1 LINING WEAR SWITCH
21 BHH3859 1 FLOW-THRU LINE HOSE
22 F8DP32 4 DOWELL PIN
ASSEMBLY NOTES
1 APPLY RUST INHIBITOR TO SURFACES OF CENTER PLATE (ITEM 3) BEFORE ASSEMBLY
2 SANDBLAST AND APPLY PRIMER BEFORE MOUNTING ACTUATORS
3 FRICTION LININGS (ITEM 6 & 7) RIVETED TO SHOE PLATES (ITEM5)
4 APPLY NEVER SEIZE TO THREADS OF SHOE GUIDE PIN (ITEM 10)
5 TORQUE ACTUATOR BOLTS (ITEM 15) TO 580 FT-LBS
6 TORQUE CALIPER ASSEMBLY NUTS (ITEM 14) TO 650 FT-LBS
.
..~
7 ALLIGN FLATS OF NUTS AND BOLTS WITH CURVATUREOF FRAME
8 THERMAL INSULATOR APPLIED TO ACTUATOR SIDE ONLY
industries / elevanja
DH2040 CALIPER BRAKE
PARTS
LIST& ASSEMBLY
DETAIL
'" 8500 River Rood. Richmond BC Canada V6X 1Y4
Tel 604 273 3737 -- Fox 604 273 9654
BY: HE
SC:
DATE:NOV 05
REV.
DWG. NO.
Both Rood. Bridgwater Somerset England TA6 4NU

Tel 0278 456411 -- Fox 0278 429949
PATI H. pj"t/ lpcnvrs / r14/ lp385923
' A4978 - P6 .
-~
!DANGER! PARTS LIST
ACTUATOR CONTAINS
COMPRESSED SPRINGS
~ PART NO. W DESCRIPTION ~ PART NO. W DESCRIPTION

1 BHA1040 1 ACTUATORBODY 9 SHRWJ650 1 ROD WIPER
2 BAHAP1050 1 ACTUATORPISTON 10 SHW2654 1 WEAR STRIP
3 BAHAS1050 1 ADJUSTMENTSPINDLE 11 SSL1125 1 SHAFT SEAL
4 BASC1050 1 SPRING COLLAR 12 BARS1050 1 RETURN SPRING
5 FKMFE14 1 LOCK NUT 13 BAHB4S 1 AIR BLEEDER
6 SHP455650 1 PISTON SEAL 14 BAPTR1025 1 SPINDLE RETAINER
7 SHR605300 1 ROD SEAL 15 F4C12CS8 1 RETAINERSCREW
8 SHRWD300 1 ROD WIPER 16 FHP50N-O4 4 PORT PLUG - SKT
. industries /e/evanja Itd BHA 1 040 ACTUATOR

"
Vancouver BC Canada -- Tel: 604 273 3737 fax:
PARTS LIST
604 273 9654 GUST. MINERA LOS PELAMBRES
Toronto ON Canada -- Tel: 416 213 9991 fax: J/N 4978
416 213 9992 SID FEB06 DWG. NO.
Bridgwater SOIAEngland -- Tel:01278456411fax: 01278429949
S N's dbr/ocr/dsoctrs/bho1050.dwg A4978-P2.
~'i~
-;
PA RTS LI ST
A1 BAPH1140 1 ACTUATOR HOUSI~G

A2 BAPPR1040 1 SPINDLE
A3 BAPCB1040 1 ACUTATOR BASE
A4 BAPSG1140 1 SPRING GUIDE
A5 BAPSH 1050 18 DISC SPRING
A6 BAPPN 1040 1 PISTON
A7 BAPCR1040 1 CAGING RING
A8 FST04C24S5 4 END COVER SCREW
A9 BAPCV1040 1 END COVER
A10 FST04C06S5 4 SPINDLE RETAINER SCREW
A11 BAPTR1040 1 SPINDLE RETAINER
A12 BAEG1040 2 END GASKET
A13 BAPSW1140 1 SPRING WASHER
A14 BAPOP1040 1 PISTON SEAL
A15 BAPOR1040 1 ROD SEAL
A16 BAPWR1040 1 ROD WIPER
A17 BAPWB1040 1 BASE WIPER
A18 BAPAB04 1 AIR BLEEDER
'
. .~ dbrjoctjds_octrsj1040osm
industries / elevanja Itd BAH 11 40 ACTUATOR
"
Vancouver BC Canada -- Tel: 604 273 3737 Fax: 604 273 9654 GUST. MINERA LOS
ASSEMBLY
PELAMBRES
Toronto ON Canada -- Tel: 416 213 9991 Fax: 416 213 9992 JjN 4978 SID Mar .20/06 DWG. NO.
Bridgwater SaM England -- Tel:01278,456411
Fax:01278429949S N's BAH1040-418806-1,..-10 A1040-P2.1
-,
D.lE
1.
1 A1
The
shell
of
each
THE
the Con
catalo
numb
the con
curre
ratin
range
and
the the
tem
conta
arran
FEI"t\ftIAl.: THERMOSWITCH@
Contr
that
are
com
Undereco
or
Labo
or liste
by
certi
by
Can
Temperature Controller
Stand
Asso
(CSA
will
also
bea
the
sym
of
"'"\-.,I Installation Instructions
the
appro
agen
"4"
as In
addi
theUL
com
nized
units
awith
temp
firstrec
rang
up
to
500
will
hav
digit
of
Thethe
Cata
Num
fifth
digit
of
the
cata
num
des
whe
con
ATTENTION: To ensure safe and proper performance, read
tacts
open
or
close
on
temp
rise
If
con
ope
these instructions carefully before attempting to install or operate
on
temp
rise,
fifth
digit
of
the
num
is
an
eve
this Fenwal product. Please retain for future reference. Temperature
Adjusting
Sleeve
numb
(1700
If1700
theetc.)
If
cont
ature
rise,
close
on
temp
is
(-
73Low
to
+
204°
can
onebe
hour.clos
on
fourth
digit
is
"2"
or
"7"tem
fifth
digit
is
an
odd
(170
etc.).170
(e.g
170
170
~troffe
is
comp the
con
oper
Comc'
unit
rise
aretha
reco
if~~
ove
antici
temp =
units
[-10
to
+
400
over
to
500(
(26'"
.r~
,!,,
L.
r
iQ 1
~~
.
THER
Cont
headare
sup
in
five
config
- bas
Cartrec
Bloc
Hea
Hexthe
0.1
Heain
di
the
un lo
fro
ro
whp
th
asTp
is
t
C""c'.
Coup
Head
and
Circu
Flan
See
Figu
1.
Th
casty
mb
us
fo
cie
c~ cc' C c",'
To
avoid
restri
shell
expa
whe
tions
in mak
solid
meta inst
block
for
5/8a
0.62
in
0.81
In
13/16
heav
duty
is ser
diam
rea
stand int
a
hol
units
or 11Fe
Blo
reco
SeeHe
(S
the su
m
2)
fol-
the
ca -
M
typ
If
th w
(
in
a
un
is
to
bim
i
aN
n
rn
and high temperature units [-100 to +600°F (- 73 to 3 4 5
lowin
spec
contr
style
listin
for
add
inst
ho
mo
tw
sh
pi
on
ei
so
t
hTh
+316°C)] overrangedto 700°Ffor intervalsnot exceeding
tion
instru pin
sh
res
ag
vensi
rot
of o
t
b t
p
t
He
an
Co
He
(S
3
a
4-
In
l
INSTALLATION
pip
fitt
If
ins
in
a
pi
te
th
te
s b
Figure 1
lar
en
to
all
ad
cot
f
MOUNTING Cartridge (Style 1) - Hole should have a short spline to
1
~ aro the
tem
Se
Ta
1
for
m se
toch
va
INSTALLATION (Continued) 2. When removing controller from a heated system, never
I ~CAUTION I plu~ge it i.nto a colder medium or use an air blast for
I ~"'AU. .un I rapid cooling.
Excessivetorque applied to units may change temperatureset-
tings. Tension or Compression Operated Controllers
Table 1 1. Certain gases or liquids (including water at elevated J'
temperature) could be corrosive and/or cause electro-
THERMOSWITCH
Controller Max.Torque lytic action which could severely shorten life of control-
Standard(5/8in dia) 35 ft-lb* ler. Rate of corrosionor electrolysisis i~fluencedby
(47.5 N-m) many system parameters such as chemical makeup,
. . 70 ft-lb** temperature of solution, stray electrical currents, etc.
Heavy Duty (13/16 In dla) 94.9 Nom) Consult supplier of your chemicals or Fenwal for appli-
*4 ftolb(5.4 Nom)whenTeflontape lubricantis used. cation s~ggestions. Also, note th~t Fenwal offers ~ari-
**8 ftolb(10.8Nom)whenTeflontape lubricantis used. ous platings and Type 321 Stainless steel, hellarc
welded thermowells for added protection.
-
Circular Flange (Style 5) Three holes in flange allow . .. .
easy mounting on any flat surface. 2. Be sure that there IS sufficient but not excessive room
I h..~...~.ft..~1 for the installedcontrollerto expand in diameterand
I ~CAUTIONSI length.
Tens!on Operated Controllers . 3. Insulate head of controller when large ambient temper-
:~nslon op~rated THERMOSWITCH controllers are Id~n.- ature variations may occur. This precaution is not
tlfled by having a number other than 2 or 7 as the fourth digit necessary on junction box type controllers (Series
of their Catalog Number. Applying excess tension on the 17800).
element of a tension operated controller may permanently . . ..
warp the element, and in extreme cases, tear the anchor 4. DO ~OT Imme~s.econtrolle~ Into liquids or gases un-
pin loose. To avoid over-tension, pay close attention to the less It was specified for that job.
following cautions: 5. DO NOT seal controller head with silicone materials.
1. Do not expose controller to temperatures above its 6. DO NOT thermally shield controller from medium being
upper range limit. controlled. ~
~~ 2. Do not expose controller to more than 100Fo (55CO)

~ above its calibration point. Therefore, preset controller
7. DO NOT remove adjusting sleeve or turn it in farther
than necessary for desired operation. This action mar .J
~ to approximate required elevated temperature before in- permanently damage controller.
i serting !t in.to t~e process. Preset by turning adjusting 8. DO NOT oil controller. Oil around adjusting sleeve will
sleeve In direction of arrow on head of controller. See flow inside controller, contaminating contacts.
Table 3.
. 9. DO NOT handleunit with pliersor force it into position
3. If necessary to decrease temperature of a tension oper- either by hand or with tools.
ated controller in a heated system, it may be necessary . .
to do this in several increments. Do not turn adjusting 10. DO NOT subject shell of controller to deformation.
sleeve to achieve more than 100Fo (55°C) temperature WIRING
drop at a time. Wait until controller stabilizes (begins to Connect controller leads in series with the load and power
cycle). Then repeat until desired setting is reached. supply.
Compression Operated Controllers I ~CAUTION I
Compression operated THERMOSWITCH controllers are DO NOTexceed the ratingsindicatedon the controllershell.
identified by having a 2 or 7 as the fourth digit of their
Catalog Number. Applying excess compression on the ele- Capacitors are not required under average conditions.
ment of a compression operated controller may result in However, for smoother control at small loads or to prevent
warping or crushing it. To avoid over-compression, pay contact bounce due to vibration, the capacitance listed in
close attention to the following cautions: Table 2 is recommended. Wire capacitors in parallel with
. .. controller lead connections. Use capacitors rated for a
1. When rotating adjusting sleeve, do not exceed upper . . f 600 VDC .th 120 VAC ' .t d ..
. . minimum 0 WI circul s an a minimum
range limit of controller. of 1000 VDC for 240 VAC circuits.
1- ~
J
!
Table 2 TESTING TEMPERATURE SET POINT
S' Capacitance(fLF) The set point temperatureis the temperatureat which the
Voltage ervlce (nonpolarized) contacts on a THERMOSWITCH Controller just "make"
120VAC Resistance None Required (close). All controllers are set at room temperature [75
V 240 VAC Resistance 0.1 ::t 15°F (24 ::t8°C)] unless ordered with a specific factory
120 VAC Relays 0.001 to 0.01 setting (MOD 3).
240 VAC Relays 0.001 to 0.01 Testing the temperature set point in an application, under
15-25VAC Relays 0.02 conditionswhere the heat source is remotelylocatedfrom
120 VAC Motor Use Relay the controller, or when ambient temperature conditions are
240 VAC Motor Use Relay far below or above 75°F (24°C), may give misleading re-
sults. In some cases, this has led to rejection of controllers
that were within proper setting tolerance. If you require tem-
TESTING AND ADJUSTMENT perature set point testing, Fenwal recommends the Model
The arrow on the head of the controller indicates the direc- 80001-0 Test Kit. If you choose to build your own test
tion to turn the adjusting screw to increase the temperature equipment, .we reco~mend t.hat yo.u contact your Fenwal
setting. Each full turn of the adjusting sleeve will change the representative for guidance In setting up a good thermal
temperature the approximate amount shown in Table 3. test system.
After the controller has been installed, allow the controller

to operate for several cycles to permit the controlled system
to stabilize. Then adjust to the desired temperature. Check
the setting by cooling the system to ambient temperature,
reheating it, and rechecking the temperature. Where ex-
tremely accurate control is desired, several adjustments
may be necessary. However, once adjusted, the accuracy
of the setting will be maintained.
V
~-
;i~~"":;j;$;;;...:j
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- "~1rc
,,"-, Tension Operated CompressionOperated
~ Approx. Fo Approx. Fo
""
Catalog Per Full Catalog Per Full
Number Turn of Number Turn of
Adj Sleeve Adj Sleeve
15050 to 16051 165 - -
17000 to 17352 80-115 17021 to 17323 70-100
17800 125 17821 75
17802 160 17823 90
18000 to 18002 80-100 18021 to 18023 75-90
~
...~ industries / elevanja
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.,
P
~Western Office
8500RiverRoad
RichmondBC
0 EasternOffice
108SkywayAvenue
TorontoON
DEuropeanOffice
BathRoad
BridgwaterSomerset
Canada V6X 1Y4 Canada M9W4Y9 England TA64NU
Tel: 6042733737 Tel: 4162139991 Tel: 01278456411
Fax:6042739654 Fax:4162139992 Fax: 01278429949
INDEX
1.0 INSTALLATION
1.1 GENERAL 1
1.2 MOUNTING 1
1.3 PLUMBING 2
1.4 FLUSHING 2

2.1 LININGS ' '.' '..' '.. 3
2.2 BURNISlllNG 4
2.3 DISC 5
2.4 AIR GAP '.'.'.'...' '.' '..' ' ' '...' 6
2.5 LUBRICATION 7
",,--,,' 2.6 LIMIT SWITCHES : 7
3.0 ACTUATORS
3.1 INSPECTIONAND MAINTENANCE 8
3.2 PRESSURE SUPPLY '..'..' '.' '.' ', 9

4.1 BRAKES Wll.L NOT RELEASE 9
4.2 BRAKES WILL NOT SET " 9
4.3 SLOW BRAKE RESPONSE 10
4.4 BRAKES SLIP 10
4.5 RAPID OR ERRATIC LINING WEAR 11

5.1 RECOMMENDED SPAREPARTS 11
5.2 SERVICE 11
5.3 W ARRANTY 12
F :\dbr\generic_DS_manual" wpd
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1.0 INSTALLATION
1.1 GENERAL
The Johnson Industries 'DS' series caliper brake is a direct acting type of brake
utilizing spring set, hydraulically releasedactuators acting directly onto the brake shoe.
The calipers are mounted in a frame via two bearing pins. Teflon slide bearings in the
caliper allow the brake to float laterally on the bearing pins to compensatefor axial
movement of the disc or lining wear. The 'DS' caliper brakes are available in a large
range of clamping forces and can be selected with various types of friction grades. The
brakes are available in either left or right hand orientation and three different styles of
basesfor horizontal, vertical or inclined mounting. Contact Johnson Industries for
assistancein selecting a brake most suitable for the user's application.
1.2 MOUNTING
Discs are normally installed prior to placement of the caliper. Discs are shipped with a
rust inhibitor coating applied to the exposed surfaces. This coating will permanently
damage the friction linings if allowed to come in contact with the disc. It is imperative to
"'"-" thoroughly remove the rust inhibitor with a cleaning solvent prior to installation of the
calipers. Most calipers are shipped in the released mode for easeof installation.
Before tightening caliper bolts, set the caliper to clamp on the disc. This is done by
removing the caging ring from the actuators. To remove the caging ring, apply enough
pressureto the actuator to fully releasethe brakes (see the certified print at the back of
this manual). With the actuator pressurized, remove the cover and unscrew the caging
ring. Flip the caging ring around to mount the ring in the stowed position and re-install
the cover plate. Refer to the actuator instruction sheet at the back of this manual. The
hydraulic power pack used to manually release the brakes must be limited to a
maximum pressure of 3000 psi and the oil must be filtered to a 10 micron absolute
(ISO 18/15) cleanliness level. With the caliper clamped on the disc verify that the
shoes are parallel with the disc and that the base sits flat. Correct with shims if
necessary. Verify that the pads are fully seatedon the disc and that the assembly is
centered with the disc. Reposition the brakes or shim the base if required.
Once the caliper is properly positioned release the brakes and verify that the caliper has
adequatefloat on both sides of the brake frame. After bolting the brake frame in place,
releasethe caliper and ensure that the caliper floats freely. It is critical that the brakes
have adequateradial clearance between the disc outer diameter and the caliper center
, plate. This clearance must be checked and verified to be a minimum of 3/16 of an inch.
V Once the positioning of the brakes is verified to be correct the brake mounting bolts
Page 1
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must be tightened. Preloadthe mountingbolts to the value specifiedon the certified
drawingor to a maximum of seventy-fivepercentof the bolt proof load. Use either
lock washersor jam nuts to ensurethat the mountingbolts do not work loose. The
brakepedestalmust be designedto allow enoughwrenchclearanceto properlytighten
the mountingbolts.
When operatingtemperaturesexceed300°F (150°C), oversizedbolt holesshouldbe

usedin both disc and hub. It is preferableto drill the disc/hubmountingholestogether
usingthe samesetup.
1.3 PLUMBING
The brakesystemmust be plumbedwith adequatelysizedpiping or tubing, preferably

stainless,suitablyratedfor the operatingpressures.Generally,Y2inch diameterJIC
tubing andY2inch diameterpipe is sufficient for most applications.The piping must be
adequatelysupportedwith pipe clampsevery4 feet for Y2inch and 3/4 inch lines. The
connectionto the brakemust be donewith a flexible hosesuitablyratedfor the
operatingpressure.Before connectingto the brakes,the plumbing must be purgedto
removeall the coarsecontaminants.After connectingto the brakesandhydraulic unit,
\;' thoroughlyflush all hydraulic systemsto a 10 micron absolute(ISO 17/14)cleanliness
level before applyingfull operatingpressure.
When all connectionshavebeenmade,air must be bled from all hydraulicactuators

during initial pressurization.The brakesmust be cycled severaltimesto get all the air
out.
1.4 FLUSHING
For hydraulicallyreleasedbrakesthe systemmust be flushedprior to commissioningthe

equipmentto ensureproper andreliableoperationof the equipment.This procedure
must be doneperiodically or wheneverthe circuit hasbeenbrokento replacea
component.For newly commissionedsystemsthe piping and/orhosesmust alsobe
pre-flushedprior to connectingto the equipmentto removeanycoarsecontaminants.
After plumbing the completesystemcanbe flushedby following the guidelinesbelow.
The oil shouldideally be flushedto an I.S.O. cleanlinesslevel of 17/14. This cleanliness

level canbe achievedby using a ten micron (or finer) filter elementwith a betarating of
75 (or higher). The durationof flushing shouldbe sufficient to allow all the oil in the
reservoirand systemto be circulateda minimum of four timesthroughthe filter.
The setup for flushing shouldinclude a suitablefilter, as specifiedabove,in the return
""-' line portion of the circuit to filter out contaminantsbeforethe oil reachesthe reservoir.
Page2
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It is undesirableto flush the contaminantsinto the reservoirasthey will be picked up by
the pump andpossiblycausedamage.Many hydrauliccontrol units havea return line
filter in which caseit is only requiredthat the elementbe suitablyrated. For thosecases
that do not havea return line filter a spin-onfilter canbe temporarilyaddedto the
circuit for flushing.
Many hydraulicbrakesystemshavereciprocatingflow type circuits whereasflushing

requirescirculatoryflow. For thesecasesa suitablyratedhosemust be plumbed
betweenthe flushing filter andthe secondactuatorport. For flow throughtype circuits
a return line will alreadybe present.
Flushing is bestaccomplishedwith turbulentflow to "blast" the contaminantsout of the

system. For thosehydrauliccontrol units which havea BrakeReleaseSolenoidValve
turbulentflow is createdby cycling the valve. The valve shouldbe left de-energized
long enoughto chargeup the systemaccumulatorbetweencycles. If the H.P.U. does
not have a BrakeReleaseSolenoidValve then a ball valve canbe temporarilyadded
up streamof the flushing filter.
WARNING!
".-I Do not adda shut off valve betweenthe filter and.
reservoirashigh pressurewill burst the filter.
2.1 LININGS
Friction linings carry only the manufacturer'swarrantyandmust be adequatelytested

by the User in his particularapplicationto verify performancecharacteristics.New
linings must be thoroughlyburnishedand seatedon the disc. Ratedtorqueis obtained
when the linings arefully bedded. Contaminatedor burnt linings must be discarded.
Stoppingcapacityof a springappliedcaliper brakeis dependanton the actuator

extension. Wear of the linings increasesthe air gapwhich resultsin an increaseof the
actuatorextension. The lining condition andthickness,aswell asthe air gapmust be
monitoredon a regularbasisto ensureproperbrakeperformance.Seesection2.4 for
adjustingthe air gap.
Allowing oil, grease,slurry etc. to contaminatethe linings will havea severedetrimental

, effect on the stoppingcapacityof the brakes. Ensurethat thereareno sourcesof
\; contaminationnearthe disc or brakes. Lightly contaminatedlinings canbe cleanedwith
Page3
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\-/
."..~
a non oil based solvent and burnished.
When the lining thickness wears down to 0.28 inches the shoesmust be removed and
new linings installed. Allowing the linings to wear further will eventually result in the
rivets contacting and scoring the disc. In dynamic applications, wearing of the linings
beyond the bottom of the lining grooves or allowing the grooves to become packed
with loose debris will have a detrimental effect on the stopping capacity of the brakes.
When installing new linings ensure that the linings are bonded as well as riveted and that
the rivets are all snug. In critical applications it is advantageousto carry a spare set of
lined brakes shoesto avoid down time of operating machinery. Replacement linings
must be as originally specified.
2.2 BURNISHING
Burnishing of friction linings is done to provide good, clean contact between the linings
and disc. The procedure removes minor contamination on the disc or linings as well as
any minor high spots or misalignment of the linings. New linings require burnishing to
fully embed the linings on the disc and periodically over the life of the linings to remove
v any light contamination or oxide film from the swept face of the disc.
Before burnishing, ensure that the disc and linings are free from contamination. If
cleaning is required, use a non oil based solvent. If the swept face of the disc has a
heavy oxide layer then initial burnishing is required to remove it. This stage should be
done at a lower temperature and clamping force. After the rust is removed inspect the
linings and verify that the lining grooves have not become packed with loose debris.
Clean out the grooves if necessary. Heavily contaminated or burnt linings must be
discarded.
In addition to preparing the linings and disc for burnishing, any safety interlocks of the
drive mechanism from the brake system should be bridged to allow the disc to be
driven through the brakes.
To burnish, the clamping force of the brake shoes and disc speed should selected so
that the frictional power generatedis in the range of 0.15 to 4.5 horsepower per square
inch of lining area. The clamping force of the brake shoescan be adjusted by
contr~lling the pressurein the actuators. It is preferable to burnish at the high end of the
range to reduce the burnishing time but ultimately the brake torque while burnishing will
be limited by the torque capacity of the drive. Insufficient lining pressure during
~ burnishing can polish the lining material, resulting in a reduction of the friction coefficient.
If this has happenedthe linings must be removed and sandedmanually to scuff the
Page 4
~
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surface.
The temperature must be monitored through out the burnishing process. The
temperature of the disc should be maintained between 2500P (120°) and 4500P
(230°C). When the upper temperature limit is reached pause burnishing until the disc
has cooled to the lower limit.
CAUTION
Never allow the disc temperature to exceed 5000P
(260°C). Permanent damageto the lining material
will result.
Burnish until a minimum of seventy-five percent lining contact and a bright disc surface
is achieved. To measure the degree of contact, set the brakes and use a .002" feeler
gauge to probe the perimeter of each brake shoe. If the amount the feeler gauge was
able to probe exceedstwenty-five percent of the lining area then further burnishing is
required. The adequacyof burnishing must also be verified with load tests or stopping
time measurements. If the actual brake torque does not meet the rated brake torque
""-" then further burnishing is required.
CAUTION
Do not put equipment into service if rated brake
torque cannot be developed. Consult Johnson
Industries for assistance.
2.3 BRAKE DISC
For standard applications the disc should be manufactured from ASTM A588 or
equivalent material. The disc must be suitably dimensioned for the brake application.
The O.D. must be selected to provide the desired torque, the I.D. must allow enough
radial clearance to remove the shoesduring liner replacement and the thickness must be
chosen to safely absorb the brake energy input. Refer to the certified drawing at the
back of this manual for critical dimensions. For bolted connections the locating
diameter of the disc should be machined to a H8 tolerance class. The disc should be
balanced to ISO 1940/1 grade G40 for low speedapplications and G6.3 for high
speed applications. The swept path of the disc should have a surface finish within 32 to
64 rms micro inches. Surface finishes in excess of the maximum will result in rough
~ braking action and rapid lining wear. Scored or rough discs must be reconditioned,
Page 5
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removingno morethan0.02 inchesper inch of thickness.Facesshouldbe flat and
parallel within 0.004inchesacrossthe sweptface. Lateral andradial run-out should
not exceed0.001inchesand0.002 inchesper 12 inchesof diameterrespectively.

input of the caliper,whenusedunderdynamicconditionsof continuousapplicationor a
high duty cycle,exceedsthe energydissipatingcapacityof the disc then the torquemust
be limited or the duty cycle reduced. For high duty cycle applicationsASTM A514 or
equivalentmust be specifiedfor the disc materialand specialattentionmust be paid to
the thermalandbraking stresseson the disc/hubassembly.ConsultJohnsonIndustries
WARNING
warpingwill result.
2.4 AIR GAP

~
The air gapmust be inspectedon a regularbasisand adjustedif necessaryfor lining
wear. Excessiveair gapwill result in excessiveactuatorextensionand a significantloss
of brakingtorque. An excessiveair gapand actuatorextension;
1. reducesthe clampingforce andthereforethe braking torquebecauseof
the lossof springforce associatedwith actuatorextension.
be discharged. .,.,

of stroke
4. could result in loss of actuatorforce due to inadequatestroke.
The air gapmustbe adjustedback within specificationswheneverit hasgrown out of

tolerance.The air gapis adjustedby extendingthe actuatorspindle. Begin by
removingthe backcover and spindleretainer. Apply releasepressureto the actuators
andinsert a shim of equivalentthicknessasthe desiredair gapbetweenthe disc andthe
actuatorsidebrakepad. Ensurethat the caliperis shifted over so that all the air gapis
on the actuatorside of the caliper. Screwin the adjustmentspindlesuntil the pads
contactthe shim and all the spindlescontactthe back of the shoe. One full turn on the
adjustmentspindlesclosesthe air gapby 1/16of an inch. Ensurethat the spindle
~ retainerlines up with its mountingholes. After lining up the spindleretainerholesinstall
the retainerandbackcover then removethe shim. Cycle the brakesandrecheckthe
Page6
!g.!i~
"
\,
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removingno more than0.02 inchesper inch of thickness.Facesshouldbe flat and
parallel within 0.004inchesacrossthe sweptface. Lateralandradial run-out should
not exceed0.001 inchesand0.002inchesper 12 inchesof diameterrespectively.

input of the caliper, when usedunderdynamicconditionsof continuousapplicationor a
high duty cycle, exceedsthe energydissipatingcapacityof the disc thenthe torquemust
be limited or the duty cycle reduced. For high duty cycle applicationsASTM A514 or
equivalentmust be specifiedfor the disc materialand specialattentionmust be paid to
the thermalandbraking stresseson the disc/hubassembly.ConsultJohnsonIndustries
WARNING
warping will result.
2.4 AIR GAP

"
\,
The air gapmust be inspectedon a regularbasisandadjustedif necessaryfor lining
wear. Excessiveair gapwill result in excessiveactuatorextensionand a significant loss
of braking torque. An excessiveair gapand actuatorextension;
1. reducesthe clampingforce andthereforethe brakingtorquebecauseof
the loss of spring force associatedwith actuatorextension.
be discharged.
of stroke
4. could result in loss of actuatorforce dueto inadequatestroke.
The air gapmust be adjustedbackwithin specificationswheneverit hasgrown out of

tolerance.The air gapis adjustedby extendingthe actuatorspindle. Begin by
removingthe back cover and spindleretainer. Apply releasepressureto the actuators
andinsert a shim of equivalentthicknessasthe desiredair gapbetweenthe disc andthe
actuatorsidebrakepad. Ensurethat the caliper is shiftedover so that all the air gapis
on the actuatorsideof the caliper. Screwin the adjustmentspindlesuntil the pads
contactthe shim and all the spindlescontactthe back of the shoe. One full turn on the
adjustmentspindlesclosesthe air gapby 1/16of an inch. Ensurethat the spindle
.-. retainerlines up with its mountingholes. After lining up the spindleretainerholesinstall
~ the retainerandback cover thenremovethe shim. Cycle the brakesandrecheckthe
Page6
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air gap. After adjusting the air gap the release and wear switches must be adjusted also
(see section 3.5). The air gap is measuredby pushing one shoe against the disc while
measuring the distance between the lining and disc on the other shoe. Refer to the air
gap adjustment procedures (drawing DSPS-Ol) at the back of this manual.
WARNING
Adjusting the air gap without releasepressurein the
actuator will result in damage to the actuator spindle.
For applications that require a faster responsetime of the brakes, the air gap can be
reduced. In these casesclose attention must be paid to the axial run-out of the disc and
for possible dragging of the shoes. In applications with high axial run-out of the disc the
air gap can be increased to compensate. For these casesconsult Johnson Industries as
the lateral float capability of the brakes is critical.
2.5 LUBRICA TION
"-- When adjusting the air gap, ensure that the caliper floats freely.' It will be necessary,on
a regular basis, to remove the bearing pins and clean both pins and slide bearings in the
caliper. Although lubricating the slide bearings will reduce the sliding friction, this
practice should be avoided if possible. The lubricant will attract dust and therefore
require more frequent maintenance intervals and possible reduce the life of the bearings.
When replacing linings ensure that the threads of the shoe pins have sufficient anti galling
compound applied and that pins on the actuator side also haS'an EP greaseapplied to
the shank.
2.6 LIMIT SWITCHES
Brake release and lining wear proximity switches are available as an option. The
switches are supplied pre wired to DIN 43650 spadeterminals. If present, both
switches must be adjusted whenever the air gap is adjusted. Failure to adjust the
switches will result in improper indication of pad wear and brake release.
Switch actuation of the brake release proximity switch must occur within 1/16 of an
inch of full actuator retraction. Ensure that the switch resetsbefore the pads contact
the disc. The position of the switch in the caliper must be adjusted whenever the air
V gap has been adjusted. This procedure is done by releasing the brakes, removing the
connector, loosening the jam nut and turning the switch housing clockwise. Advance
Page 7
II.
v
."..~
the switch housinguntil it contactsthe shoeplatethen retractit one quarterturn.
Securethe settingby tighteningthejam nut to 25 foot-pounds.
The lining wear limit switch is setto trip at a maximumair gapvalue of 3/16 of an inch
(4.5 mm). Maintaining the air gapwithin specifiedlimits is critical to the overall
performanceof the brake;an excessiveair gapresultsin insufficient braking torque. It
is importantthat the wear switch is properlyadjustedwheneverthe air gapis adjusted.
The wear switch setpoint is adjustedin the exactsamemannerasthe releaseswitch.
Whenreplacinglinings fully retractboth switchesto avoid damagingswitches. Referto

the switch adjustmentproceduresat the backof this manual.
3.0 ACTUATORS
If the actuatorneedsto be removed,releasethe caliper andmechanicallycagethe

springs. Referto the actuatorinstructionsheetat the back of this manualfor actuator
cagingtechnique.
"-'
DANGER
Spring actuatorscontaincompressedspringsand are
dangerous.Referto actuatorinstructionsheetbefore
servlcmg.
Sealscanbe safelyreplacedusing the disassemblyprocedureoutlined in actuator

instructionsheet. Actuatorsshouldbe returnedto JohnsonIndustriesLtd. for routine
inspectionandreconditioningon a 24 monthbasisor morefrequentlyfor extreme
operatingconditions. When replacingseals,ensurethat they areinstalledcorrectlyand
arenot damaged.Caremust be takennot to allow the actuatorinterior to become
contaminatedor the sealsurfacesto becomescratched.Reconditionor changethe
cylinder if the surfacefinish exceeds16rms micro inches. Reconditioningof hydraulic
actuatorsealingsurfacesarepermittedso long asthe resultantradial clearanceafter
honing doesnot exceed0.004 inches.
After servicingapply pressureto measurehold-off andreleasepressuresand verify

actuatorperformance.Use a dial indicatoron the actuatorpiston and a valve that
allows accuratepressurecontrol to measurehold-off andreleasepressures.The
L actuator rod should be totally retracted at the specified releasepressure and begin
extendingat the specifiedhold-off pressure.Refer to the certified print at the backof
Page8
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this manual for the specified release and hold-off pressures. The measuredvalues must
be within plus or minus ten percent of the specified pressures.
3.2 PRESSURE SUPPL Y
A hydraulic control system should supply well filtered, high quality, petroleum based
fluid having good lubricity and oxidation resistance. An ISO VG32 hydraulic oil having
a viscosity index greater then 200 is recommended. The viscosity must not exceed
1000 cSt (4500 SUS) at the minimum ambient temperature. Bleed air from actuator
and lines after installation or servicing. Failure to bleed air from hydraulic lines and
actuator will result in slow and erratic actuation and can damage the seals.
\,-
V ;:;~
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."'"
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."..~
SYMPTOM CAUSE DIAGNOSIS RECTIFICATION

4.1 a. Control valve failure Energizevalve and verify valv Replaceor repair
Brakes will actuation control valve
not release
b. Systempressuretoo Verify systempressuregreater Adjust pressuresettings
low than specifiedreleasepressure
c. Actuator seized Verify actuatorresponseto Replaceactuator

releasepressure
4.2 a. Control valve failure De-energizevalve andverify Replaceor repair
Brakes will valve actuation. Verify contro defectivevalve. Open
not set valve is fail safedesign. Verif all valvesblocking
no other valvesclosed. pressureat actuator.
b. Actuatorscagedout Verify cagingring in stowed .

"'-' position Apply releasepressure
andremovecagingring~
c. Actuator spring
failure Verify hold-off pressurewith i Replaceactuator
specification
d. Insufficient actuator
i
~ stroke Verify ac~uator
strokesufficienAdjust~r ~ap~r
,i ,.
~;,. to closeaIr gap replacel1mngsIf
necessary.Remove
actuatorjam nuts and
releaseactuator.
4.3 a. Aeratedoil Verify no air in oil Bleed actuators
Slow brake
response b. High oil viscosity Verify oil specificationand Replaceoil
servicetemperature
c. Inadequatelysized Verify flow rating of valves Replacevalveswith

valves properlysizedvalves
v
Page10
-,~C,
-~..~
V
4.4 a. Contaminatedlining Verify linings and disc dry and Cleanwith solventand
Brakes slip or disc free from oil burnish. Checkfor oil
leaks.
b. Poor lining contact Verify 75% minimum contact. Cleangroovesif

Verify groovesnot plugged. necessary. Burnish
linings.
Verify hold-off pressurewithi
c. Failed actuator specification Replaceactuator
spnngs
Verify air gapwithin tolerance
d. Excessiveair gap Adjust air gapto
Verify gradeof linings specification
e. Incorrectlinings Verify caliperdoesnot contact Replacelinings

brakeframewhenbrakesset
f.lnadequatefloat Checkbrakemounting
andcorrectif necessary.
Replacelinings if worn.
"'-" 4.5 a.Bothshoesdragging Verifybrakereleasepressure. Adju~tsystempressure
Rapid or on flange to specification
erratic
lining wear b. One shoedragging Verify brakescenteredon disc. Repositionbrakes.
on flange Verify adequatefloat. Verify bearingconditior
R¥,conditionsweptface
c. Roughdisc surface Verify surfacefinish within of disc
finish specifications
Repositionand/orshim
. e. Linings not fully Verify brakesproperly brakesto fully seat
seatedon disc positionedand mounted. linings
Correctdisc run-out if
f. High axial run-out Measureaxial run-out. Verify possible. Adjust air gap
adequateair gap and lateral to accommodatedisc.
float.
Limit duty cycle of
brakes
g. Excessivedisc Verify maximumdisc
V temperature temperaturenot exceeded.
Page11
~""""'~,'x*c'"
-"..~
V
5.1 RECOMMENDED SPARE PARTS
The numberandnatureof sparepartsthat shouldbe carriedwill dependon severityof

service,frequencyof cycling andfunctionalcriticality of the brakes. Partswhich may
requirereplacementdue to normal wear are:
1. Friction linings (c/w rivets)
2. Actuator seals
3. Release& wear switches
4. Slide bearings
For critical applicationswith high duty cycleit may be advantageous to carry a setof
lined shoes,actuatorassembliesandcaliperpins to reducedown time.
When orderingspareparts,specifycalipermodel and serialnumber,and part number

andquantityof spareparts.
5.2 SERVICE
"-'" JohnsonIndustriesoffers field service,supervision,and assistance,

during installation,
maintenance,andtests,at a nominal per diem rateplus disbursementsat cost plus a
handlingfee. Under no circumstancesarefield servicesof anykind or commissioning
allowedfor in the pricesof our brakesunlessexpresslyso statedin writing on our
quotations.
JohnsonIndustriesalsooffers shopservicesto reconditionor repairworn brake

assembliesor components.Contacta JohnsonIndustriesrepresentativefor an estimate
of the work desired.
5.3 WARRANTY
JohnsonIndustrieswarrantstheir calipersanddiscsto be of the quality specifiedin our

quotations. We guaranteeour materialsandworkmanshipfor a period of ninety days
from dateof delivery to the end user. Disc andlining performancein regardsto wear,
friction coefficient, andenergydissipationdependon severityandcondition of the brake
service. Therefore,the purchasershall verify throughadequatetestingthat all linings,
calipersanddiscsperform satisfactorilyin his particularapplication,any warranty
concerningsuchperformancebeingexpresslyexcludedherefrom. Our liability in respect
of any failure of goodssuppliedby us or any loss,injury or damageattributedthereto,
~ shall be limited to making goodthe repairby replacingandrefitting free of chargeany
Page12
I,
-"..~
V
goods or parts thereof which are shown to our satisfaction to have been proved, under
their intended use, defective in materials and workmanship within the ninety day
guaranteeperiod, provided that such defective parts are promptly returned as directed
by us, transportation chargesbeing paid by the purchaser, and provided further that no
burning or welding or any modifications of any sort has been done on any such defective
goods or parts. In every case,the customer shall be charged for replacement parts on a
pro rata basis for the elapsedportion of the warranty period. In the case of friction
linings, products and components manufactured by others, we extend to the Purchaser
the warranties of the manufacturer only. Deterioration, damage,or malfunction caused
by inadequate storage or handling prior to or after sale to the end user are not covered
by this warranty. We reserve the right to make changesand add improvements at any
time without incurring any obligation to make such changesand improvements on
products already produced. This warranty and guaranteeis in lieu of all warranties,
conditions, or liabilities implied by law or expressedby statute.
~
Page 13
-'-'"""-,"",,,y.~c
,
GAP ADJUSTMENT PROCEDURE

1. Ensure that the hoist drive is locked out and that the hoist drum is dogged or held
by another brake while the adjustments are being made;
2. Remove back covers G) and retaining plate @ to access the air gap adjustment spindles (i)
3. Apply full release pressure to the brake to open it to its maximum air gap;
Option 1: .
A. Place appropriate shims @ between the disc @) and brake pads @ to provide
the desired air gap. Total thickness of shims to be equal to desired air gap.
B. Screw the adjustment spindles (?) in evenly, using the flats (t), until the pads @ contact
the shim @). Do not force spindle against shims such that shims cannot be removed.
C. Ensure that screw holes on spindle retainer @ line up. Adjust if necessary.
Option 2:
A. Mount a dial indicator @ on the caliper to sense the disc. Push caliper over so that
opposite shoe contacts disc and zero dial indicator. Push caliper back so that near
shoe contacts disc and read displacement from dial indicator.
B. Screw the adjustment spindles ~
in evenly, using the flats (t) , to correct air gap if
necessary. (spindles have a .016" per quarter turn adjustment resolution)
~ For brakes with two or more actuators per side ensure that linings are
parallel to the disc after adjustment.
C. Ensure that screw holes on spindle retainer @ line up. Adjust if necessary.
5. Reinstall spindle retainers @. If screw holes do not line up, release brakes, readjust
and remeasure.
6. Stow caging ring (@) and reinstall adjustment access covers CD
7. Return the brake to its set condition and remove any dogging means employed to
secure the hoist while the gap adjustment was made.
.
..~ industries
/ elevanja
AIR GAP ADJUSTMENT PROCEDURE
" 8500 River Rood.RichmondBC CanadaV6X 1Y4

Tel 604 273 3737 -- Fax 604 273 9654
BY:
SC:
NAJ
'os' SERIES CALIPERBRAKE
DATE:
REV.
940930
000204
DWG. NO.
Bath Rood. Bridgwater Somerset England TA6 4NU

Tel 0278 456411-- Fax 0278 429949
PATH' db /h
. r
/d
Sp
d.
sgpa J
0SPS-. 0 1 6
I
PAD WEAR PROXIMITY SWITCH
SHOWN BEFORE ADJUSTMENT
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BRAKE RELEASE PROXIMITY SWITCH

SHOWN CORRECTLY ADJUSTED
BRAKE RELEASE AND PAD WEAR LIMIT

SWITCH ADJUSTMENT PROCEDURE
Switches should be adjusted whenever brake linings are changed or actuators adjusted
for wear. Failure to adjust switches as indicated will result in improper indication of
pad wear and brake release.
1. Ensure that the conveyor drive is locked out and that the conveyor is dogged or held
2. Remove electrical connectors CD from rear of switches;
3. Loosen jam nuts (2) on switch body Q) ;
4. Rotate switch body Q) counter-clockwise until switch nose @) is recessed in brake base ~ ;
5. Apply full rel.ease pressure to braKe;
6. Screw the switch body ~
in until switch nose @ contacts rear of brake shoe @ ;
7. Back switch housing out 1/4 turn and tighten jam nuts (2) ;
8.. Replace electrical connectors G) ;
9. Return the brake to its set condition and remove any dog gin means employed to secure the hoist
while the switch adjustment was made.
WARNING: Before removing brake shoe @ for lining replacement recess switch nose @)fully.
Impact -to switch nose will damage switch.
WARNING: The position of the switch inside the housing (J) is factory set.
DO NOT ADJUST.
. 'OS' SERIES BRAKE RELEASE AND WEAR LIMIT

..~ industries / elevanja SWITCH ADJUSTMENT PROCEDURE
~ 8500 River Rood. Richmond BC Canada V6X 1Y4
Tel604 2.733737-- Fox604 273 9654
BY:
SC:
DCA DATE:
REV.
950622 DWG. NO.
DSSA- 01 2
Both Rood. Brldgwater Somerset England TA6 4NU
Tel 0278 456411 -- Fox 0278 429949
PATH' db /h
. r Sp
/R14/3859d d.
ssensa J
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BRAKE SHOE REP~CEMENTPROCEDURE

Shoes should be removed and re-lined whenever the linings show excessive wear
«5 mm thickness.) or damage. Never allow friction lining rivets to contact the disc.
Replacement linings are much less expensive than replacing or re-machining a scored disc.
1. Ensure that the conveyor drive is locked out and that the conveyor is dogged or held
2. Fully release brake and cage actuators, remove temperature switches;
3. Retract actuator spindles per drawing DSPSS-01 and switches per drawing DSSA-01;
4. Secure brake shoes with hoist rings ; ~
5. Remove shoe guide pins Q) and return springs <2) on actuator side;
6. Remove brake shoes, reline and reinstall or replace with newly lined shoes;
7'. Replace shoe guide pins G) being sure to install return springs (?) on actuator side. Insure that
shoe pins are fully threaded into shoe;
8. Adjust actuator spindles per drawing DSPSS-01 and switches per drawing DSSA-01;
9. Return the brake to its set condition and remove any dogging means employed to secure the
conveyor while the shoe replacement was made.
.
..~ industries/ elevanja
'OS' SERIES BRAKE SHOE REPLACEMENT
PROCEDURE
" 8500 River Road, Richmond BC Conada V6X 1Y4
Tel 604 2.73 3737 -- Fax 604 273 9654
BY:
SC:
DCA DATE:
REV.
950622
950911
DWG. NO.
0 S P R - 0 1 2
Both Rood. Brldgwater Somerset England TA6 4NU
Tel 0278 456411 -- Fax 0278 429949 PAJH'. dbr /h Sp/R 14/3859d spr .
-
WARNING
Spring brake actuators store energy and can be dangerous.
Handle with caution. Follow proper procedure.
Always loosen assembly bolts uniformly.
To properly remove tropped air, an air

bleeder must be located at highest position.
With the air bleeder open, fill the
actuator under low pressure. Allow
oil to escape until clear of air or foam.
Cycle actuator several times and repeat.
Actuator lines must be bled whenever
a hydraulic line has been opened.
C With loss of release pressure, the
brake may be released by removing
the actuator attachment bolts.
Loosen attachment bolts uniformly
to allow safe spring expansion.
A = 1.22:1:
0.01
Caging ring (shown in stowed

position) is used to hold actuator Actuator disassembly
in released position. To cage tool
actuator remove end cover, gaskets
and caging ring. Pressurize
actuator to extend piston and scre
on caging ring.
When servicing actuators, re-pack

springs using high pressure
molybdenum grease.
Orientation of spring stack must
be maintained at re-assembly.
ACTUATOR DIS-ASSEMBL Y INSTRUCTIONS:
1. Cage and remove actuator from the caliper brake (note assembly weight);
2. Pressurize actuator and remove cover plate and caging ring;
3. De-pressurize actuator and remove spindle retainer and spindle;
4. Compress springs in press with allowance to access spring guide at actuator base end.
Unscrew spring guide approximately 0.5" using actuator disassembly tool.
5. Slowly release the press, allowing the springs to safely release to their free height;
6. Upon assembly, reverse above procedures. Verify dimension" A" , hold off pressure,
release pressure ,and stroke per specification.
J:JQJf;. SPECIFICATIONS:
To check integrity of spring 1. HOLD-OFF PRESSURE: 2000 psi
pack, verify release and hold-off 2. RELEASEPRESSURE: 1850 psi
pressures are as per 3. SPRINGPRELOAD: 950 psi
specification. 4. ACTUAJORSTROKE: 0.438 in
5. ASSEMBLYWEIGHT: 175 Ibs
. BAH1040 ACTUATOR
"..~ industries
/elevanja
8500 River Rood. Richmond BC Canodo V6X 1Y4
Tel 604 273 3737 -- Fax 604 273 9654
BY:
SC:
H.EPKENS
SERVICE
INSTRUCTIONS
DATE:MAR 1/01
REV.
DWG. NO.
Bath Road. BridgwaterSomersetEnglandTA6 4NU

Tel 0278 456411-- Fax 0278 429949 PATI H'. dbr / hs p/ ds gcage A1 040 - S1 .
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~"~~"..
ITEM PART NO, QTY DESCRIPTION
~ 1 BAH1140 2 ACTUATOR ASSEMBLY
2 BBFL3859 1 ACTUATOR PLATE
3 BBFC3859 1 CENTER PLATE
4 BBFR3859 1 CALIPER PLATE
~ 5 BS4978 2 SHOE PLATE
~ 6 BFS3859 20 FRICTION LINING - 3 RIVET
7 BPSG3859 4 SHOE GUIDE PIN
8 BSRS2030 2 SHOE RETURN SPRING
9 BSB2040 4 SLIDE BEARING
10 F22C248H5 6 CALIPER ASSEMBLY BOLT
11 F22C5N 6 CALIPER ASSEMBLY NUT
12 F18C56S8 8 ACTUATOR MOUNTING BOLT
13 BMBLE3859 2 CALIPER LIFTING EYE
14 BPS3040 4 SHOE LIFTING EYE
15 BLTS3859 2 LINING TEPERATURE SWITCH
16 BRPS3040 1 BRAKE RELEASE SWITCH
17 BWPS3040 1 LINING WEAR"SWITCH
18 BHH3859 1 FLOW-THRU LINE HOSE
19 F16F2J 2 PROX SWITCH LOCK NUT
20 F8DP32 4 DOWELL PIN
21 BILS3859 1 LINING INSULATOR
~ 22 F6R17 100 LINING RIVETS
6 BFSGBK3 20 FRICTION LINING - 2 RIVET
.
..~ industries
/ elevanja KRUPP CANADA /
OS2040 CALIPER BRAKE ASSEMBLY
" 8500
. .
River Road, Richmond BC Canada V6X 1Y4
Tel 604 273 3737 -- Fax 604 273 9654
BY: HE
SC:
LOS PELAMBRES
DATE:JULY 30/98
REV,
DWG. NO.
Tel 0278
Bath Road, Fax 0278
456411 Somerset
Bridgwater --, 429949
Englond TA6 4NU PATH: pj' t/l pcnvrs / r 14/1p 385923 A3 8 5 9 - P5 .
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A company

VOLUME 1 MECHANICAL (ENGLISH)

SECTION 3 VENDOR MANUALS

VOLUME 2 MECHANICAL (SPANISH)

SECTION 4 MANUAL DE VENDEDOR

Los Pelambres – Power Upgrade, Bechtel 25100-220-POA-MHCB-0001

SECTION 10 CONTROL DESCRIPTION

BINARY ELEMENTS, DELAY ELEMENTS, STORING

LOS PELAMBRES UPGRADE PROJECT

Krupp / Siemens / Conveyor Dynamics, Inc.

1.1 General System Description

2.1 Control System Architecture

3.1 PLC Control

3.1.1 PLC 5 Control Functions

3.2 AFD Drives control

3.2.1 General Description

3.3 Alarm Handling

3.3.1 PLC Alarms

3.3.2 AFD Alarms

4.1 Mode Selection

4.2 Control Modes - Conveyors

4.2.1 Remote-Automatic Mode

4.2.1.1 System Commands

1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 2 of 96

4.3 Maintenance Workstations (OP37)

5.1 Graphics Screens

6.1 General Considerations

6.2.1 Remote-Automatic Mode

6.2.1.1 Feeder Selection

6.2.2 Local-Automatic Mode

6.3 Automatic Speed setback

6.5.1 General Considerations

6.5.2.1 Remote-Automatic Mode

7.1 General Considerations

7.5.1 PLC to PLC Interlocks

1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 3 of 96

7.10.1 AFD Stop (level 2)

7.11 Stopped State Controls

8.1 Normal Operation

9.1 General Considerations

9.1.1 Emergency Circuit

9.2 General Description

9.3.1 Pressure Generation

10.1 General Considerations

1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 4 of 96

11.1 General Description

11.2.1 Remote-Automatic Mode

12.1 General Interlocks

12.2.1 Remote-Automatic Mode

13.1 Dust Suppression Systems

13.1.1 Fogger Systems

13.2 AFD Houses

13.2.1 Air Conditioning Units

13.3 Miscellaneous Equipment

14.1 Redundant CPU

A. General Layout Drawings

1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 5 of 96

1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 6 of 96

The system control is performed by several PLC’s interconnected by a system wide

1.1 General System Description

The system consists of four belt feeders (120-FE-005, 120-FE-006, 120-FE-007

Conveyor 120-CV-005 is 5,905 meters long with a negative elevation of 536

The head of conveyor CV-120-007 is equipped with a moveable shuttle. The

1. Lsp-ctrl-phil-u2.doc Control Philosophy - Section 1 Page 7 of 96