M-020 Volume 2 Manual Belt Feeders

Aker Kvaerner
San Cristobal Project

Belt Feeders
Operation and
Maintenance Manual
VOLUME 2
Prepared by:
ThyssenKrupp Robins
December 2005
HYDRAULIC DRIVE SYSTEM
OPERATION AND INSTRUCTION
MANUAL
CUSTOMER INFORMATION
Name THYSSENKRUPP ROBINS
Purchase Order 0 507 001 57 27
Reference
Notes B E LT F E ED ER
HÄGGLUNDS INFORMATION
Project 2 005 033
Sales Order 2 005 302 2
Notes
(2/2001) Engineering Group-Hägglunds North America www.hagglunds.com

2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
1 Project Specifications
Bill of Materials
Test Reports
2
Hydraulic Motor
Motor Accessories
3
Hägglunds Drives Inc. Hydraulic Power Unit
2275 International Street
Columbus, Ohio 43228 USA
Phone: (614) 527-7400

Fax: (614) 527-7401
4
www.hagglunds.com Spider Control Documentation
5
Project Drawings
6
Spanish Documentation
Documentacion Espanol
NORTH AMERICAN SALES OFFICES
United States Regional Offices Canadian Regional Offices
NORTHEAST EASTERN
1273 Bound Brook Road 87B Marie-Victorin
Suite 11 Suite 202
Middlesex, New Jersey 08846 Candiac, Quebec J5R 1C3
(732) 469-0411 (450) 659-4244
(732) 469-8047 (fax) (450) 659-3792 (fax)
MIDWEST CENTRAL
2275 International Street 5040 Mainway, Unit #7
Columbus, Ohio 43228 Burlington, Ontario L7L 7G5
(614) 527-7400 (905) 319-6338
(614) 527-7401 (fax) (905) 319-6615 (fax)
NORTHWEST WESTERN
19219 West Valley Highway #3 7201-72 Street
Suite M-101 Delta, British Columbia V4G 1H2
Kent, Washington 98032 (604) 940-8281
(425)-251-9661 (604) 940-8241 (fax)
(425)-251-9280 (fax)
SOUTHEAST
4335 South Lee Street
United States Headquarters
Suite F Hägglunds Drives Inc.
Buford, Georgia 30518 2275 International Street
(770) 945-6223 Columbus, Ohio 43228
(770) 945-6246 (fax) (614) 527-7400
(614) 527-7401 (fax)
NORTH-CENTRAL
(262) 594-3762 Canadian Headquarters
(262) 594-3764 (fax)
Hägglunds Drives (Canada) Inc.
CENTRAL 5040 Mainway, Unit #7
(913) 515-8047 Burlington, Ontario L7L 7G5
(913) 322-6910 (fax) (905) 319-6338
(905) 319-6615 (fax)
SOUTH-CENTRAL
220 Spring Hill Drive Worldw ide Headquarters
Suite 200 Hägglunds Drives AB
Spring, Texas 77386 SE-890 42
(281) 292-6700 Mellansel, Sweden
(281) 292-6768 (fax) +46 660 870 00
+46 660 871 60 (fax)
SOUTHWEST
(602) 790-4632
(480) 474-1039 (fax)

PROJECT SPECIFICATIONS
Project No.: 2005033
Revision: B Date: 11/21/2005
PROJECT INFORMATION
Hägglunds Salesperson: CHUCK SEITZ
Customer Name: THYSSENKRUPP ROBINS
Address: 7730 E. BELLEVIEW AVE. SUITE 404
GREENWOOD VILLAGE, CO. 80111
Contact Name: PETER SEHL
Phone: 303 793-2605 Fax: 303-770-8233
E-mail: SEHLP@KRUPPROBINS.COM
Customer P.O. : 0507 001 5727 Customer Ref.: 507 001
Customer Spec. No. Copy Attached: yes/no
Spec. Exceptions List YES Copy Attached: yes/no
Equipment : BELT FEEDER 210-FE-001
Description :
Location : SAN CRISTOBAL, BOLIVA
NEMA Classification NEMA 4X (IP-65)
Ambient Temp. Range -10.3 C TO 21.6 C
Cooling Water Temp. N/A
Elev. Above Sea Level 3900 M
DESIGN INFORMATION
Drive Speed, Run 0-6.97 RPM
Drive Speed, Max 6.97 RPM
Nominal Torque 36,315 Ft. Lbs.
Starting Torque 62,337 Ft. Lbs.
Duty Cycle CONT
Flow Range: 43.7 GPM
Motor Case Flushing: 0.98 GPM
Nominal Pressure: 2484 PSI
Peak Pressure: 4203 PSI
Horsepower Installed: 100 HP, 1470 RPM
High Pressure Switch Setting: PSI
Max Volume Stop : GPM (Forward) GPM (Reverse)
Uni / Bi-Directional Drive: UNI W/JOG REVERSE
Port "A" of Pump to Port A MOTOR
SCOPE OF SUPPLY
Hydraulic Motor CB-400-320-C-A-O-N-O 178-5041-2602
Hydraulic Power Unit PBC-0202-073/XXX-100/XXX-21-1110-11B-0000-0-0380/50
Elec. Control System SPIDER II
Torque Arm TCA-40-2 278-5014-602
Mounting Tool MTMB 378-0846-801
Shaft Adaptor N/A
Speed Encoder SPDB-3600 378-5036-802
Encoder Mounting Set SMCB 178-5049-801
Axial Locking Set N/A
Customer Supplied
Hägglunds Drives, Inc.; 2275 International Street, Columbus,OH 43228; Tel: 614-527-7400; Fax: 614-527-7401
Page 1 of 4 Form No.: F10400-4 | Release Date: 04-Nov.-04 l Revision: F

DESCRIPTION OF OPERATION
xx
xx LONG TERM STORAGE REQUIRED
xx PACKING FOR SEAWORTHY EXPORT
xx SPECIAL TAGGING REQUIREMENTS,PER SPEC AAPPENDIX B, AND M-020, 7.5
xx AND GD-11
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
HYDRAULIC NOTES
xx 25 FT. HOSE KITS REQUIRED
xx
xx
xx
xx
ELECTRICAL NOTES
xx
xx
xx
xx
xx
MECHANICAL NOTES
xx
xx
xx
xx
xx
DOCUMENTATION NOTES
Drawings: 2 copies For Approval and 2 copies of For Construction. Please specify other requirements.
Drawing Due Date: 3 weeks after receipt of Tech Clarified order
Manuals: TOTAL 8 MANUALS, IN ENGLISH, 8 MANUALS SPANISH
Manuals Due Date: 1 week after the ship date

Revision: B Designation System
Date: 11/21/2005 POWER UNITS, North America
PB C - 0 2 0 2 - 0 7 3 / X X X - 1 0 0 / X X X - 2 1 - 1 1 1 0 - 1 1 B - 0 0 0 0 - 0 - 0 3 8 0 / 5 0
PAC
PBC
PHS Electric Motor Frequency
PAX 60 Hz
50 Hz
Tank Size
Liter(Gallon) Voltage
1000 (264) = 100 200 (53) = 020 460/575 VAC
1200 (317) = 120 400 (106) = 040 2300/4160 VAC
Other (Specify) 600 (159) = 060
800 (211) = 080 Electric Motor Supplied By
1 = Customer
Number of Doors 0 = Hägglunds
2
3 000 = Standard Design
001-999 = Special Design
Pump Displacement
Left Door/Right Door Accumulator Package
cu. cm/rev cu. in./rev 1 = With
SP-40 = 040 P6S = 060 0 = Without
SP-71 = 071 P7S = 073
SP-125 = 125 P11S = 110 Control Box Voltage
SP-180 = 180 P14S = 140 A = 24 VDC
SP-250 = 250 P24S = 240 B = 110 VAC
SP-355 = 355 P30S = 300 C = 220 VAC
SP-500 = 500 9A2 Pump Stroker(5A2/9A2 for Denison, EP for SP pumps)
SP-750 = 750 1 = Air/ Oil Cooler
0 = Water/Oil Cooler
Electric Motor Size Water Valve Voltage X
Left Door/Right Door Air Cooler EM Voltage X
kW HP
22 = 022 30 = 030 1 = Oil Heater
30 = 030 40 = 040 0 = Without
37 = 037 50 = 050 Oil Heater Voltage 220V
45 = 045 60 = 060
55 = 055 75 = 075 1 = Duplex Filters
75 = 075 100 = 100 0 = Single Filters
90 = 090 125 = 125
110 = 110 150 = 150 1 = Cabinet Feet
132 = 132 200 = 200 0 = Without
160 = 160 250 = 250
200 = 200 300 = 300 1 = High Pressure Switch
250 = 250 350 = 350 0 = Without
315 = 315 400 = 400
450 = 450 1 = Pressure Transmitter
500 = 500 0 = Without
HP Specify HP or kW
Control Box Mounting
Control Box Options 0 = Shipped Loose
None = 0 1 = Mounted Inside Power Unit
Driver Card = 1 2 = Mounted in Power Unit Door
Spider = 2 3 = Supplied as Separate Item, with Bracket
Other = 3 4 = Supplied as Separate Item, with Flange
5 = Mounted outside of Power Unit (Specify)

XX ft.
XX ft.
XX ft.
XX ft.

Bill of Material No.: HB2005033
Bill Of Material
Date Issued : 31-May-2005 Hägglunds Drives Inc. Latest Rev. : Customer Ref(s) :
Issued By: JFDIII 2275 International Street; Columbus, Ohio 43228, USA E P.O. 0507 001 5727
Checked By: Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN : -
TITLE: ECN-00000643 Assembly Ref(s) :
Revised By : HS-2005 033
Power Unit Model JFDIII GA-2005 033
PBC-202-073-100-21-1110-11B-0000-0-380/50 Rev. Date : Project No. :
21-Nov-2005 2005 033
C
Item O Hägglunds Description Manufacturer Manufacturer Part. No. Purchase Purchase Landed Weight Source P.O. P.O. Required Prom'd Rcd'
No. Qty. D Part No. Cost, Each Cost, Ext Cost, Ext No. Date Date Date Date
E
K 8 * MM2005033-E OPERATION AND INSTRUCTION MANUALS, ENGLISH HDI MM2005033-E 65.99 527.92 554.32
J 8 * MM2005033-S OPERATION AND INSTRUCTION MANUALS, SPANISH HDI MM2005033-S 65.99 527.92 554.32
I 1 * HDE-30826-0 ORIFICE FITTING 1/2" BSP X 1/2" JIC WITH 4MM ORIFICE, CB HDI HDE-30826-0 7.60 7.60 7.98 Mid State
H 1 * HK2005033-0 HOSE KIT, 25 FT. LONG, PBC-200 W/ MAINLINE,DRAINLINE,AHDI HK2005033-0 2274.00 2274.00 2387.70
G 1 * HAS-10392-0 LONG TERM OIL FILLING, ALL COMPACT MOTORS HDI HAS-10392-0 80.00 80.00 84.00
F 1 * 178 5049-801 ENCODER MTG. SET, SMCB-1, For All CA and CB motors HDM 178 5049-801 224.00 224.00 246.40
E 1 * 378 5036-802 SPDB-3600 HDM 378 5036-802 413.00 413.00 454.30
D 1 * 378 0846-801 MOUNTING TOOL, MTMB-Swedish HDM 378 0846-801 48.00 48.00 52.80
C 1 * 278 5014-602 TORQUE ARM, For CB-280 & CB-400, TCA-40-2, w/ Pivot AttacHDM 278 5014-602 1009.00 1009.00 1109.90
B 1 * 178 5041-2602 HYDRAULIC MOTOR, CB 400-320 C A 0 N 0 HDM 178 5041-2602 18780.00 18780.00 20658.00
A 1 HB2005033 PBC-202-073-100-21-1110-11B-0000-0-380/50 HB2005033
1 1 HAS-10534-100 POWER UNIT FRAME ASSEMBLY PBC-202 HDI HAS-10534-100 1930.00 1930.00 2026.50 MID OHIO
1a 1 FM-2005033-0 POWER UNIT FRAME MODIFICATION HDI FM-2005033-0 999.99 999.99 1049.99 MID OHIO
2 1 HAS-10723-100 RESERVOIR ASSEMBLY, 200 LITER, 2" SUCTION HDI HAS-10723-100 2271.02 2271.02 2384.57 195.00 PROTO
3 1 517-00054-0 GATE VALVE FOR RESERVOIR DRAIN, 1" NPT MALANO M-300-1" NPT 5.13 5.13 5.39 McJunkin Corp
4 NOT USED 0.00 0.00 0.00 0.00
5 4 * 229-10120-0 CABINET FEET, 600 KG. FOR PAC/PBC-202/203 TRELLEBORG TF-600 9.00 36.00 37.80 TRELLEBORG
6 1 237-00023-0 BASE PLATE, 24.5 X 24.5 FOR PAC/PBC-202/203 HDI 237-00023-0 299.30 299.30 314.27 MID OHIO
7 4 H606-25309-0 SHOCK MOUNTS, PAC/PBC TRELLEBORG C 100/55 SH60, P/N 66983 18.00 72.00 75.60 TRELLEBORG
1 L 023-07706-0 HYDRAULIC PUMP #P7S-2R1A-9A2-B00-0A1-M2-07706, W/ TB-006 DENISON 023-07706-0 3922.00 3922.00 4118.10 335.00 DENISON
8a 2 038-58361-0 1-1/2" CODE 62 PROTECTIVE COVER WITH SEAL E&S SALES SPX-24 3.38 6.76 7.44 E&S SALES
8b 2 H492-15407-0 TEST POINT, SAE-4, VA AND VB PORTS HYDAC 6003735 4.28 8.56 9.42 HYDAC
8c 1 H492-15408-0 TEST POINT, SAE-6, DG PORT HYDAC 6003737 4.28 4.28 4.71 HYDAC
9 1 H513-50391-0 CHARGE PRESSURE CHECK VALVE, 3/4", 65 PSI, FOR P6/P7/P11/P14 PUMSNAPTITE 6C 12 EF EF 65 23.20 23.20 24.36 15.00 SUNSOURCE
10 1 H171-00233-0 PUMP/MOTOR ADPT., 444/445 TSC TO P6/P7, SIZE 55/70 HDI H171-00233-0 757.00 757.00 794.85 BSF
11 COUPLING CONSISTING OF 11a, 11b, 11c:
11a 1 S H212-85283-0 E-MOTOR HALF: 2-3/8" X 5/8", Frame: 444/445/447/449 TSC, SIZE 55-02 CASKTR 602-055310-0020 55.54 55.54 58.32 16.00 KTR
11b 1 S H212-85284-0 PUMP HALF: 1-1/4" X 5/16", PUMP: P6S & P7S, SIZE 55-01 CAST IRON KTR PROTO 1328, Snap Ring L=1.57 70.45 70.45 73.97 16.00 KTR
11c 1 S H212-85258-0 INSERT, 92 SHORE A, SIZE 55, YELLOW SPIDER (104 HP) KTR 502-055100-0001 14.00 14.00 14.70 1.00 KTR
12 1 L H135-80534-0 ELECTRIC MOTOR, 100 HP, 1500 RPM, 380V/3/50, 444TSC TOSHIBA 5842.00 5842.00 6134.10 530.00 TOSHIBA
TEFC, PREM. EFF., SF=1.15, NEMA DESIGN B,VERTICLE SHAFT DOWN MTG
40° C CLASS F INSULATION, FOOTED FRAME, RATED FOR 3900 MASL
13 2 H506-85473-0 SINGLE FILTER ASSY', SIZE 160, 10 µm, W/ ELEMENT & 30°C THERMAL LOHDI FLN BN/HC 160 DE 10 LE 1.0/1 120.00 240.00 252.00 15.00 HYDAC
13a 1 HDE-30561-0 MOUNTING BRACKET, SHORT, FOR FLN FILTERS AEM HDE-30561-0 12.00 12.00 12.60 15.00 AEM
13b 1 HDE-30562-0 MOUNTING BRACKET, LONG, FOR FLN FILTERS AEM HDE-30562-0 11.40 11.40 11.97 15.00 AEM
14 2 *M 478 3233-620 FILTER REPLACEMENT CARTRIDGE, SIZE 160, 10 µm HDI 0160 DN 010 BN3HC /-VPN-SO 29.00 58.00 60.90 3.00 HYDAC
15 2 S H502-00228-0 PRESSURE GAUGE, 0-6000 PSI, 2-1/2" DIAL, SYSTEM PRESSURE PIC 201L-254S 6.50 13.00 13.65 1.00 PIC
1/4" NPT, LOWER MOUNT LIQUID FILLED
16 2 S H502-00227-0 PRESSURE GAUGE, 0-1000 PSI, 2-1/2" DIAL, CHARGE & SERVO PRESSUR PIC 201L-254M 6.50 13.00 13.65 1.00 PIC
17 1 502-00001-500 GAUGE MANIFOLD ASSEMBLY, W/ NEEDLE VALVE HDI 502-00001-500 198.91 198.91 208.86 HYDAC
18 1 502-00001-501 NAME PLATE, GAUGE MANIFOLD, DENISON PUMPS HDI 502-00001-501 15.05 15.05 15.80 SPECIALTY
19 1 H503-80003-0 OIL LEVEL INDICATOR, 10" HYDAC FSA-254-1.1/-T12, P/N 0070007 6.00 6.00 6.30 1.00 HYDAC
20 1 M 506-85181-0 FILTER AIR BREATHER, 10 MICRON AND 3/4" NPT ADAPTER HYDAC HBRM-3/4NPT-10-1-2 6.75 6.75 7.09 2.00 HYDAC
21 NOT USED 0.00 0.00 0.00 0.00
22 1 S H170-00213-0 TEMP/ LEVEL ASSEMBLY, 20-32VDC INPUT, IP 65, , TEMPERATURE RANG HYDAC ENS-3118-5-0205-400 203.00 203.00 213.15 2.00 GEMS
ANALOG OUTPUT: 4-20mA, SWITCHING OUTPUTS: 2 ADJUSTABLE LEVELS, 1.2A MAX EACH
22a 1 H492-30042-0 1" NPT ADAPTER FOR HYDAC ENS-3000 TEMP/LEVEL ASSEMBLY HYDAC ZBM 20. p/n 02701672 20.00 20.00 22.00 0.50
22b 1 H115-15220-0 ELECTRICAL CONNECTOR, M12, 5-POLE CANFIELD RC12B-F1F0501 16.00 16.00 16.80 1.00 Voelker Controls
23 NOT USED 0.00 0.00 0.00 0.00
24 1 492-15321-0 QUICK DISCONNECT COUPLING PARKER H6-62 + H6-63 + H6-65M + H6-6 33.77 33.77 35.46 5.00 HERSH
25 1 HDE-30570-0 QUICK DISCONNECT COUPLING BLOCK MID STATE 6801-20-20 W/ #12MP 31.07 31.07 32.62 2.00 MID STATE
26 1 HDE-30571-0 QUICK DISCONNECT 45° FITTING MID STATE 5503-12-12 3.79 3.79 3.98 1.00 MID STATE
27 1 L H505-65337-0 AIR COOLER, WITHOUT ELECTRIC MOTOR AKG AC 70-0 700.99 700.99 736.04 125.00 AKG
27a 1 L H135-80542-0 ELECTRIC MOTOR, 3/4 HP, 1500 RPM, 380V/3/50, 145TC TOSHIBA 562.99 562.99 591.14 530.00 TOSHIBA
28 1 513-50133-0 COOLER BYPASS CHECK VALVE, 1 1/4 SAE SNAPTITE 3C 20 EF EF 65 45.49 45.49 47.76 4.00 PABCO
29 NOT USED 0.00 0.00 0.00 0.00
30 1 S H115-15218-0 CHARGE PRESSURE SWITCH, 0-1000 PSI, IP 65, 18-35 VDC Input, 4-20 mA HYDAC EDS 3476-3-1000-400 217.00 217.00 227.85 2.00 HYDAC
30a 1 S H115-15212-0 ELECTRICAL CONNECTOR, M12, 4-POLE HYDAC ZBE 06 8.00 8.00 8.40 1.00 HYDAC
31 1 S H115-15219-0 HIGH PRESSURE SWITCH, 0-6000 PSI, IP 65, 18-35 VDC Input, 4-20 mA OutpHYDAC EDS 3476-3-6000-400 217.00 217.00 227.85 2.00 HYDAC
31a 1 S H115-15212-0 ELECTRICAL CONNECTOR, M12, 4-POLE HYDAC ZBE 06 8.00 8.00 8.40 1.00 HYDAC
32 1 S H130-15209-0 OIL IMMERSION HEATER 0.5 kW, 240 VAC, 1 PH, EXP. RESISTANT, BUILT ICHROMOLOX ARMTO-500T4E2, P/N 292998 276.60 276.60 290.43 15.00 ANDERSON BOLDS
33 1 H517-00343-0 BUTTERFLY VALVE 2" CODE 61 WITH LIMIT SWITCH, M12 x 1.75 pitch MET IC FLUID POWER AB 16 S 50-HE 244.81 244.81 257.05 IC FLUID POWER
34 NOT USED 0.00 0.00 0.00 0.00
35 1 HDE-31397-0 SUCTION LINE MANIFOLD, FOR P6-P14 PUMPS HDI HDE-31397-0 399.99 399.99 419.99 MID OHIO
36 NOT USED 0.00 0.00 0.00 0.00
37 NOT USED 0.00 0.00 0.00 0.00
38 CB2005033-0 CONTROL BOX CONSISTING OF 38a, 38b, 38c:
38a 1 CB2005033-A CONTROL BOX HDM CB2005033-A 1750.00 1750.00 1837.50 ISI
38b 1 276 0023-801 SPIDER II CONTROLS, 1 PUMP - SINGLE DRIVE HDM 276 0023-801 1750.00 1750.00 1925.00 HDM
38c 1 576 7942-025 RUBBER FLANGE FL21 (USED WITH EVERY SPIDER II) HDM 576 7942-025 19.00 19.00 20.90 HDM
38d 1 HAS-10778-0 CONTROL BOX MOUNTING BRACKET AEM HAS-10778-0 315.00 315.00 330.75 AEM
38e 1 276 0003-001 MOUNTING FRAME (FOR DOOR OR BOX MOUNTED SPIDER II) HDM 276 0003-001 52.00 52.00 57.20 HDM
38f 1 HU3 3872-801 HEATER ASSEMBLY HDM HU3 3872-801 92.00 92.00 101.20 HDM
39 1 HDE-30988-0 MTG ANGLE, DRAIN/FLUSHING CONNECTION HDI HDE-30988-0 12.70 12.70 13.34 MID OHIO
40 1 HDE-30569-0 CHECK VALVE MANIFOLD, PAC/PBC 200-400 UNITS, 1-1/4" SAE HDI HDE-30569-0 60.12 60.12 63.13 8.00 MID OHIO
41 NOT USED 0.00 0.00 0.00 0.00
42 1 513-50133-0 CHECK VALVE, 1-1/4" SAE, 65 PSI SNAPTITE 3C 20 EF EF 65 51.34 51.34 53.91 PABCO
43 NOT USED 0.00 0.00 0.00 0.00
44 NOT USED 0.00 0.00 0.00 0.00
45 1 TAG-2005032-0 LOT OF LAMACOID TAGS PER CUSTOMER SPEC HDI 99.99 99.99 104.99 0.00
46 1 SP-2005032-0 ENGRAVED PLATE OF HYDRAULIC SCHEMATIC: HS-2005032 (11 X 17) HDI 99.99 99.99 104.99 0.00
47 2 HDE-30576-1 1/2" CONDUIT BRACKET PROTO HDE-30576-1 5.78 11.56 12.14 4.00 PROTO
48 1 HDE-30576-2 3/4" CONDUIT BRACKET PROTO HDE-30576-2 5.78 5.78 6.07 4.00 PROTO
49 1 038-54612-0 S/N PLATE HDI 038-54612-0 6.54 6.54 6.87 SPECIALTY NAMEPLATE
50 NOT USED 0.00 0.00 0.00 0.00
51 1 HAS-10014-0 LONG TERM OIL FILLING, GOLDCUP P6 THRU P14 AND HAGGLUNDS SP25HDI HAS-10014-0 123.70 123.70 129.89
52 1 EXPORT CRATING, 200 UNIT HDI 0 595.00 595.00 624.75
0.00
* - Indicates Items supplied loose to be installed by Customer

M - Indicates Recommended Maintenance Spares
S - Indicates Recommended Shelf Spares
L - Indicates Recommended Long Term Spares
TOTAL: 26268.42 1868.50
hb2005033e.xls, Date Printed: 11/29/2005 Form No.: F10203-1 | Releae Date: 4/6/2001 | Revision: A
Bill of Material No.: CB2005033
Bill Of Material
Date Issued : 7-Jun-2005 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: RHW 2275 International Street; Columbus, Ohio 43228, USA P.O. 0507 001 5727
Checked By: Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: Assembly Ref(s) :
CONTROL CONSOLE Revised By : CC-2005 033
HYDRAULIC POWER UNIT CS-2005 033
2005 033
C
Item O Hägglunds Description Manufacturer Mfg. Part. No.
No. Qty. D Part No. Vendor
E
1 1 CB2005033-A CONTROL PANEL Industrial Solutions IP05-xxx
2 1 276 0023-801 SPIDER 2 CONTROL, FULL FUNCTION HDM 276 0023-801
3 1 H103-20469 ENCLOSURE NEMA 4X, 24 X 24 X 12 HOFFMAN C-SD242412SS
4 1 H103-20420 PANEL FOR ABOVE ITEM HOFFMAN C-P2424
5 1 H103-20394 ENCLOSURE MOUNTING KIT HOFFMAN C-MFKSS
6 1 H103-20415 DOOR LOCK KIT FOR ENCLOSURE HOFFMAN C-WHK
7 1 H153-15301 PUSHBUTTON, GREEN FLUSH HEAD, 1 N.O., 1 N.C. CONTACTS ALLEN BRADLEY 800T-A1A
8 1 H153-15302 PUSHBUTTON, RED EXT. HEAD, 1 N.O., 1 N.C. CONTACTS ALLEN BRADLEY 800T-B6A
9 1 H153-10363 INDICATING LIGHT, GREEN, FULL VOLTAGE, 120VAC ALLEN BRADLEY 800T-Q10G
10 1 H151-15318 MUSHROOM HEAD PUSH/PULL MAINTAINED PUSHBUTTON, 2 N.O. CONTACTS ALLEN BRADLEY 800T-FX6A5
11 1 155-10060 LEGEND PLATE, GRAY, E-MOTOR START ALLEN BRADLEY 800H-W100
12 1 155-10055 LEGEND PLATE, RED, E-MOTOR STOP ALLEN BRADLEY 800H-W100
13 1 H155-10487 LEGEND PLATE, GRAY, E-MOTOR STARTED ALLEN BRADLEY 800H-W100
14 1 155-10057 JUMBO LEGEND PLATE, RED, EMERGENCY STOP
15 62 123-75144 TERMINAL, UKK5 PHOENIX 2774017
16 6 123-75048 END ANCHOR, E/UK PHOENIX 1201442
17 4 ft. 123-75047 MOUNTING RAIL, NS 35/7.5 PHOENIX 0801681
18 3 123-75146 END COVER D-UKK 3/5 PHOENIX 2770024
19 3 123-75147 SPACER PLATE, DP-UKK 3/5 PHOENIX 2770794
20 3 H123-75421 END SPACER COVER, DG-UKK 3/5 PHOENIX 2770817
21 10 H123-75422 PARTITION PLATE, ATP-UKK 3/5 PHOENIX 2778521
22 10 H123-75453 ISOLATING BRIDGE BAR, ISSBI 10-6 PHOENIX 0301505
23 10 H123-75465 BRIDGE BAR ISOLATOR, IS-K 4 PHOENIX 1302338
24 2 H123-75477 DOUBLE TERMINAL BLOCK, UDK 4 PHOENIX 2775016
25 1 H123-75478 END COVER FOR DOUBLE TERMINAL BLOCK, D-UDK-4 PHOENIX 2775113
26 2 H123-75489 UNIVERSAL GROUNDING DOUBLE TERMINAL BLOCK, UDK-4-PE PHOENIX 2775184
27 2 123-75069 MARKER STRIP, 11-20
28 2 123-75070 MARKER STRIP, 21-30
29 2 123-75077 MARKER STRIP, 91-100
30 2 123-75086 MARKER STRIP, 121-130
31 2 123-75089 MARKER STRIP, 151-160
32 2 123-75126 MARKER STRIP, 301-310
33 2 123-75127 MARKER STRIP, 311-320
34 2 H123-75467 MARKER STRIP, 331-340
35 2 H123-75468 MARKER STRIP, 341-350
36 2 123-75162 MARKER STRIP, 401-410
37 2 123-75163 MARKER STRIP, 411-420
38 2 H123-75493 MARKER STRIP, 421-430
39 2 H123-75495 MARKER STRIP, 441-450
40 2 123-75139 MARKER STRIP, 501-510
41 2 123-75141 MARKER STRIP, 521-530
42 2 H123-75427 MARKER STRIP, L, N, GND
43 10 ft. 104-25020 WIRE DUCT, 2" X 3", WHITE HOFFMAN A 200 300 WH
44 10 ft. 104-25021 WIRE DUCT COVER, 2", WHITE HOFFMAN A 200 CWH

CB2005033.xls Form No.: F10203-2 | Release Date: 4/12/2000 | Revision: ORIG

Control Box Test Report
Hägglunds Drives Inc.
Columbus, Ohio 43228
Job Number: 2005 033 Serial Number: 517-2-21190

Control Box Part Number: CB 2005033
Type of Control Device

Jupiter 900:
Jupiter 500:
Spider Controller:
Model Code: B104-01000-1
Serial Number: E01P-X10-2347
Full Function:
Monitoring Function:
Other:
List all drawings used and their revision levels:
CS-2005 033 Rev. A
CD-2005 033 Rev. A
CC-2005 033 Rev. A
Rev. -
Rev. -
If Control Device has any other special options please list in “NOTES” section of this report.
Installation
All Terminal Markers Installed: Function
All wires bundled and tied: Continuity Test:
Control Box P/N Tag Installed: Functional Check of Switches:
All Bill of Material Items Installed: Functional Check of Lights:
Grounding Lug Properly Installed: Functional Check of Pushbuttons:
Other Items
Control Voltage: 120 VAC
Make of Power Supply: HDI
Model of Power Supply: SPIDER
Power Unit Switch Indications

Max Oil Temp: High Oil Temp: Min Oil Level:
Low Oil Level: Low Charge Pressure: Return Filter Clogged:
Drain Filter Clogged: Suction Line Closed: High System Pressure:
Other (List):
Spider Controller
Jumpers are in correct position:
All Parameters checked:
If the Spider is supplied as a loose item, is it temporarily wired to the Power Unit:
If there are any Parameter changes please list them all in the "NOTES" section of this report.
Page 1
F10208-2 l Revision: Orig.l Date: 10/10/02 www.hagglunds.com
Jupiter 900 Driver Card (S20-14078)
SW SW SW SW
Input Command: 1A 1B Ramp 1C 1D
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA
PWM Driver Soft Stop Emergency Stop

C C C
JP2: JP3: JP4:
A A A
REMOTE VOLTAGE & CURRENT INPUT CONFIGURATION

Input SW1
Input Command: Input Type: SEG RET 1 2 3 4 5 6 7 8
± 5VDC Single-Ended 6 9
± 10VDC 6 9
± 0-20mA 8 7
± 4-20mA Differential 8 7
12 ± 8mA 8 7
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Bi-Directional Output
Unidirectional Output
Inputs and Outputs

Input Signal Type (0-20mA, 4-20mA, 0-10VDC): 4-20 mA
Electrically Centered: x
IA Maximum or I+: Pump 1=315ma
IA Minimum or I-: Pump 1=183ma
IB Maximum or I+: Pump 1=305ma
IB Minimum or I-: Pump 1=175ma
Customer remote connections checked for correct operation:
Page 2
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Miscellaneous
Password ( If Spider is used): 0533
Tested By: WK
Date: 16SEP05
Engineering Release and Approval for Shipment:
Approval By:
Date:
Notes:
Page 3
Power Unit Test Report

Power Unit Model Code: PBC-202-073-100-21-1110-11B-0000-0-380/50
Electric Motor No. 1

Manufacturer: TOSHIBA Serial Number: 050801743
Frame : 444TSC Power: 100 HP
Frequency: 50 Hz Voltage: 380 VAC
Current (FLA): 144 Amps Speed: 1485 RPM
Does Motor Have Space Heater: Yes No

If yes, what Wattage and Volts is heater rated for: 200 Watts 110Volts
Does Motor Have bearing RTD’s: Yes No

If Yes how many: 2
Type (3 or 4 wire, platinum, 100 Ohm, etc.): 3 Wire
Does Motor Have stator RTD’s: Yes No

If Yes how many: 6
Does motor have grease fittings installed: Yes No

Bearings lubricated prior to start up: Yes No
Verify shaft coupling fit and set screws are tight: Yes No
If motor has any other special options please list in “NOTES” section of this report.
Pump No. 1
Manufacturer: DENISON Model No. P7S 2R1A 9A2 B00 0A1 M2
Serial Number: 01043475 Part No.: 023-07706-0
Rotational Check: Left Hand (CCW looking at input shaft) Right Hand (CW looking at input shaft)
Mechanical Centering: OK, Re-center

Electrical Centering: OK, Re-Adjust
Internal Charge Relief valve setting: 450 psi Servo Pressure with Pump in Neutral: 480 psi
Charge Pressure with Pump in Neutral: 300 psi Servo Pressure at 50% max. flow: 400 psi
Charge Pressure at 50% max. flow: 220 psi
Compensator Setting: Port A: 4200 psi, Port B: 4200 psi

Current setting “I” A min: 183 mA “I” B min: 175 mA
Current @ Max Flow: “I” A max: 315 mA “I” B max: 305 mA
Max Flow Setting: Port A: 51 gpm, Port B: -10% / 5 gpm
Mechanical Volume Limiter: Port A: FULL gpm, Port B: FULL gpm
Pump Shaft Seal Leak Check OK

Overall Pump Leak Check OK
If pump has any other special options please list in “NOTES” section of this report.
Page 1
F10208-1 l Revision: Al Date: 7/31/02 www.hagglunds.com
Power Unit Hydraulic Components

Cooler Type: Air/Oil Water/Oil
Manufacturer: AKG Model No.: AC70-0
Serial Number: BG
Cooler E-motor Data: Manufacturer: TOSHIBA Serial Number: 050901371
Frame: 143T Power: .75 HP
Current (FLA): 1.4 Amps Speed: 1445 RPM
Verify fan coupling fit and set screws are tight: Yes No
If Water/Oil cooler, water valve voltage 120 VAC, Frequency 60 Hz
Water Valve function verified: Yes No
Water/Oil Cooler checked for water leaks: Yes No
If cooler motor has any special options please list in the “NOTES” section of this report.
Hoses, couplings, and fittings checked for oil leaks: OK

Reservoir checked for Oil leaks: OK
Check valves inspected for proper flow direction: OK
Oil Heater model no. (if installed): Chromalox: 156-119144-012 / .5KW / Date: 024AP
Oil Heater Voltage: 240VAC Thermostat included in heater: Yes No
Heater Function verified: Yes No
Power Unit Electrical Function Check

Is unit supplied with control system: Yes No
If yes, what type: Spider Control, If Spider or Jupiter Card Fill out separate test report for control system
Control system tested with power unit: Yes No
Verify all wires are connected properly: Verify all wires are marked properly:
Verify all terminals have labels: Verify all cables are marked properly:
Temperature Switch Max. Temp.: 140 °F, Normally Closed, Opens on temp rise
Temperature Switch High. Temp.: 131 °F, Normally Closed, Opens on temp rise
Temperature Switch Cooler. Temp.: 104 °F, Normally Open, Closes on temp rise
Oil Level Switch, Min Level: Yes Normally Open, closes on rising oil level
Oil Level Switch, Low Level: Yes Normally Open, closes on rising oil level
Filter Switch, Return (Hot Oil Shuttle) Pump 1: Normally Closed, opens on high diff. pressure
Filter Switch, Charge Pump 1: Normally Closed, opens on high diff. pressure
Filter Switch, Pump/Motor Drain: Normally Closed, opens on high diff. pressure
Suction Line Switch Pump 1: Yes Normally Open, with ball valve closed
Charge Pressure Switch Pump 1: 150 psi Normally Open, closes on rising pressure
Charge Pressure Switch Pump 2: psi Normally Open, closes on rising pressure
High Pressure Switch Pump 1: 4000 psi Normally Closed, opens on rising pressure
High Pressure Switch Pump 2: psi Normally Closed, opens on rising pressure
Analog Pressure Transmitter Pump 1 Hydac model: Hydac EDS 3476-3-6000-400 S/n 524D030726
Pressure range 0-6000 psi, scaled to 6000 psi.
Output signal type: 4-20mA, calibrated to input pressure signal and checked at 0, 50, &100%: Yes, No
Analog Pressure Transmitter Pump 2 Rosemount model:
Pressure range 0-10,000 psi, scaled to psi.
Page 2
F10208-1 l Revision: A l Date: 7/31/02 www.hagglunds.com
Miscellaneous
Torque Seal applied to reservoir breather and all pressure switches: Yes No
Serial Number Plate installed: Yes No
Documentation Used for testing:
General Arrangement Rev. A Hydraulic Schematic Rev. A
Electrical Schematic Rev. - Power Unit Bill of Material Rev. B
List all other drawings used and their revision levels:
CS-2005 033 Rev. A
CD-2005 033 Rev. A
CC-2005 033 Rev. A
Rev. -
Rev. -
Rev. -
Rev. -
Tested By:WK Date:16SEP05

Approval By: Date:
Notes:
*PS-1 (Charge): Hydac EDS 3476-3-1000-400 / Rng.1000 Psig / Art No:908841 / S/n 517D026559
*PS-4 (High System Pressure): Hydac EDS 3476-3-6000-400 / Rng.6000 Psig / Art No:908598 /
S/n 524D030726
*TT-1 / LS-1,LS-2 :FLUID LEVEL TEMP. SENSOR / Version 2.03

MODEL: HYDAC: ENS 3118-5-0205-400-P
ART.NO.: 908578 / S/N: 417A000488
TEMPERATURE RANGE: -25 TO 100 C / 4 - 20 MA
"POWER UNIT TESTED WITH 250 HP TEST MOTOR @ 460 VAC / 60 HZ / 3 PHASE / 1770 RPM"
Page 3
COMPACT CB MOTOR MANUAL
Installation and Maintenance Manual
Compact CB 280-840
EN683-2h 2002
Preface Installation and Maintenance Manual, Compact CB
Preface
Hägglunds Drives is one of the worlds leading manufacturers of large hydrau-
lic Drive Systems. A leading position, made possible by unbeatable service
spirit and of continuing development of both products and markets all over the
world. Our drives are to be found in most industrial and marine segments,
where there are extremely high demands for efficiency and reliability. Our main
office and production plant is in Mellansel, Sweden and we have our own
sales- and representation offices in some 40 different countries.
Our high quality Drive Systems, are based upon our unique hydraulic piston
motors, developed through a wealth of experience accumulated over 30 years
in marine and industrial areas.Today this ongoing development work has
resulted in the powerful COMPACT CB industrial motor. New, as well as esta-
blished technical solutions, contribute to the creation of this product. The most
desirable features and operating reliability have been designed in this hydrau-
lic motor.
This manual provides necessary information for installation and maintenance

of the motor. In order to find particular information, just search for the wanted
section as listed in the table of contents. However, changes in the equipment
may occur. We therefore reserve the right to introduce amendments in the
manual as we deem necessary without notice or obligations.
This Installation and Maintenance Manual is valid

for motors manufactured after 02-01-01.
Original EN683-1h, 2001
2
Installation and Maintenance Manual, Compact CB Contents
Contents
1. GENERAL ....................................................................................................................... 4
1.1 Safety precautions .. ........................................................................................................ 4
1.2 Motor data ........................................................................................................................ 5
1.3 Functional description ...................................................................................................... 6
2. TECHNICAL DATA .......................................................................................................... 7

2.1 Recommended charge pressure ...................................................................................... 7
2.2 Sound from a complete installation .................................................................................. 8
2.3 Choice of hydraulic fluid ................................................................................................... 9
Environmentally acceptable fluids .................................................................................. 10
3. INSTALLATION ............................................................................................................. 11
3.1 Mounting instructions ..................................................................................................... 11
Thread for mounting tool ................................................................................................ 12
Spline ............................................................................................................................. 12
3.1.1 Lifting methods ............................................................................................................... 13
Standing the motor on a flat surface ............................................................................... 14
3.1.2 Mounting the coupling onto the motor shaft .................................................................... 15
3.1.3 Fitting the torque arm to the motor . ................................................................................ 17
3.1.4a Mounting the motor onto the driven shaft - shaft coupling .............................................. 18
3.1.4b Mounting the motor onto the driven shaft - splines ......................................................... 21
3.1.5 Removing the motor from the driven shaft ..................................................................... 22
3.1.6 Mounting the reaction point . .......................................................................................... 23
3.2 Oil connections .............................................................................................................. 24
3.2.1 Direction of rotation of motor shaft ................................................................................. 26
3.2.2 Draining and venting the motor ...................................................................................... 36
3.2.3 Flushing .......................................................................................................................... 27
4. OPERATING INSTRUCTIONS .................................................................................... 28

4.1 Storage ........................................................................................................................... 28
4.2 Before commissioning .................................................................................................... 28
4.3 Commissioning .............................................................................................................. 29
4.4 Periodic maintenance ..................................................................................................... 29
Maintenance chart ......................................................................................................... 29
Motor .............................................................................................................................. 30
Filters ............................................................................................................................. 31
Oil ................................................................................................................................... 31
4.5 Oil inspection ................................................................................................................. 31
5. FAULT FINDING............................................................................................................ 32
DECLARATION OF CONFORMITY ............................................................................ 33
3
General Installation and Maintenance Manual, Compact CB
1. GENERAL
1.1 Safety precautions
It is of high importence that the Safety precautions are always followed, if you are
unsure about something, please don´t hesitate to contact your nearest HD-office
for advice.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will
cause personal enjury or substantial property damage. Depending on the probability of the hazard,
and how serious the injury or property damage could be, there are three levels of classification.
DANGER is used to indicate the presence of a hazard

which will cause severe personal injury, death, or
substantial property damage if the warning is ignored.
WARNING is used to indicate the presence of a hazard

which can cause severe personal injury, death, or
CAUTION is used to indicate the presence of a hazard

which will or can cause minor personal injury or property
damage if the warning is ignored.
Application area
All new and rebuild applications, should always be approved and supervised by Hägglunds
personel.
Mounting
Carefully follow the instructions and be aware of the high weights and forces during lifting.
Before starting up
Before starting up new, rebuild or just worked on applications, all accessories and safety
arrangements functions, should be controlled/tested.
Periodic maintenance
Notice the intervals in maintenance chart (4.4) and keep a record.
Dismounting
4
Installation and Maintenance Manual, Compact CB General
1.2 Motor data
Table 1.1
Metric
Specific Rated * Max. Max. ** Max. Max. power 3)
Displacement
torque speed 1) speed pressure torque 2) Intermittently
Motor type
Vi Ts n n p
kNm kW
cm3/rev Nm/bar rev/min rev/min bar
CB 280-240 15 100 240 53 68 350 79 530
CB 280 17 600 280 44 58 350 92 530
CB 400-240 15 100 240 94 125 350 79 970
CB 400-280 17 600 280 73 105 350 92 950
CB 400-320 20 100 320 71 94 350 110 970
CB 400-360 22 600 360 59 82 350 120 960
CB 400 25 100 400 58 75 350 130 970
CB 560-440 27 600 440 49 65 350 140 930
CB 560-480 30 200 480 48 62 350 160 970
CB 560-520 32 700 520 41 57 350 170 960
CB 560 35 200 560 40 53 350 180 970
CB 840-600 37 700 600 30 45 350 200 880
CB 840-640 40 200 640 28 41 350 210 850
CB 840-680 42 700 680 27 40 350 220 890
CB 840-720 45 200 720 25 37 350 240 870
CB 840-760 47 800 760 23 34 350 250 840
CB 840-800 50 300 800 23 34 350 260 890
CB 840 52 800 840 21 32 350 280 870
US
Displacement speed 1)
torque speed pressure torque 2) Intermittently
Motor type Vi Ts n n p
lbf·ft/1000 lbf·ft hp
in3/rev psi rev/min rev/min psi
CB 280-240 920 12 200 53 68 5000 57 000 710
CB 280 1070 14 200 44 58 5000 67 000 710
CB 400-240 920 12 200 94 125 5000 57 000 1300
CB 400-280 1070 14 200 73 105 5000 67 000 1300
CB 400-320 1230 16 300 71 94 5000 76 000 1300
CB 400-360 1380 18 300 59 82 5000 86 000 1300
CB 400 1530 20 300 58 75 5000 95 000 1300
CB 560-440 1690 22 400 49 65 5000 100 000 1300
CB 560-480 1840 24 400 48 62 5000 110 000 1300
CB 560-520 1990 26 400 41 57 5000 120 000 1300
CB 560 2150 28 500 40 53 5000 130 000 1300
CB 840-600 2300 30 500 30 45 5000 140 000 1200
CB 840-640 2450 32 500 28 41 5000 150 000 1100
CB 840-680 2610 34 600 27 40 5000 160 000 1200
CB 840-720 2760 36 600 25 37 5000 170 000 1200
CB 840-760 2910 38 700 23 34 5000 180 000 1100
CB 840-800 3070 40 700 23 34 5000 190 000 1200
CB 840 3220 42 700 21 32 5000 200 000 1200
*) Related to a required pressure of 12 bar/175 psi for motors in braking mode. (Special considerations regarding
charge pressure, cooling and choice of hydraulic system for speeds above rated, 4 ports must be used for higher
speed).
**) The motors are designed according to DNV-rules. Test pressure and peak pressure 420 bar/6000 psi is allowed.
1
) Special considerations regarding charge pressure, cooling and choice of hydraulic system for speed above rated.
2
) Calculated as : Metric= Ts·(350-15)·0,98 US= Ts·(5000-218)·0,98.
3
) Valid for minimum permissible oil viscosity 20 cSt in the motor case.
5
1.3 Functional description

Hägglunds hydraulic industrial motor Oil main lines are connected to ports A and C
COMPACT CB is of the radial-piston type with in the connection block and drain lines to ports
a rotating cylinder block/hollow shaft and a D1, D2, D3 or D4 in the motor housing.
stationary housing. The cylinder block is
The motor is connected to the shaft of the dri-
mounted in fixed roller bearings in the housing.
ven machine through the hollow shaft of the
An even number of pistons are radially located
cylinder block.The torque is transmitted by
in bores inside the cylinder block, and the valve
using a mechanical shaft coupling, or alterna-
plate directs the incoming and outgoing oil to
tively by splines.
and from the working pistons. Each piston is
working against a cam roller.
Valid patents
When the hydraulic pressure is acting on the
pistons, the cam rollers are pushed against the US 4522110, US 005979295A, SE 456517,
slope on the cam ring that is rigidly connected EP 0102915, JP 83162704, GB 1385693,
to the housing, thereby producing a torque.The EP No 0524437.
cam rollers transfer the reaction force to the
piston which are guided in the rotating cylin- Quality
der block. Rotation therefore occurs, and the
torque available is proportional to the pressure To assure our quality we maintain a Quality
in the system. Assurance system, certified to standard ISO
9001, EN 29001 and BS 5750; Part 1.
Fig. 1 The COMPACT CB motor
1
1. Cam ring
2. Cam roller
2 A, C
3. Piston
3
D 4. Shaft coupling
4 8
5. Cylinder block /
hollow shaft
5 6. Cylinder block / spline
7. Front end cover
8. Cylindrical roller bearing
11 9. Connection block
10. Valve plate
6 11. Axial bearing
7 9 A = inlet or outlet port »A«

10 C = inlet or outlet port »C«
D = drain port
6
Installation and Maintenance Manual, Compact CB Technical data
2. TECHNICAL DATA
2.1 Recommended charge There are two distinct cases:
pressure Case 1:
The hydraulic system must be such that the The motor works in braking mode. Required
motor will recieve sufficient charge pressure charge pressure at the inlet port is according
at the low-pressure port. This applies to all to diagram below.
types of installations.
Case 2:
The motor works in driving mode only. Required
back pressure at the outlet port corresponds
to 30% of value given in diagram below, but
may not be lower than 2 bar (29 psi).
In hanging load applications, charge

pressure at motors connection must
be according to graph below under
all conditions.
Table 2.1a Charge pressure

RECOMMENDED CHARGE PRESSURE - COMPACT CB MOTORS
Single port connection (2 ports) oil viscosity 40 cSt / 187 SSU
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 400 / CB 400-360
CB 560 / CB 560-520
CB 280-240
CB 400-320
CB 840-720
CB 840-600
CB 840
CB 280
20
18
250
16
Recommended charge pressure [bar]
Recommended charge pressure [psi]
14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80
Recommended charge pressure - CB 280-840 2-port connection Speed [rpm]
Note:
The diagram is valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge
pressure must be increased accordingly. The graph is valid when 4 ports are used. Max casing
pressure is 3 bar (43,5 psi)(for 1% of the operation time evenly divided, pressure peaks of max 5
seconds upto 8 bar (116 psi) are allowed). Max permitted case pressure at stand-still is 8 bar (116
psi).
7
Technical data Installation and Maintenance Manual, Compact CB

Double port connection (4 ports) oil viscosity 40 cSt / 187 SSU
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
Table 2.1b Charge pressure
CB 560 / CB 560-520
CB 400 / CB 400-360
CB 840-720
CB 840-600
CB 280-240
CB 400-320
CB 840
CB 280
20
18
250
16

14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
2.2 Sound from a complete installation
Background noise
Pump Pipe Hydraulic Noise from

motor noise motor driven unit
Foundation and construction noise
Remarks:
Background noise
Hydraulic motor
The background noise can not normally be
influenced but is usually known or easy to The hydraulic motor is a known noise level.
measure. (Tables of sound data - see subsection 4.9 in
the Engineering Manual).
Pump unit
Driven unit
The pump unit is a known noise level.
The driven unit is an unknown sound source
(for us) but can through certain information
Pipe noise probably be obtained from the supplier. When
The pipe noise is probably the source of the securing the torque arm of a hydraulic motor
majority of mistakes in installations: all pipe to the foundation or casing of a driven machine,
clamps should be of vibration insulating type it is highly important to study the construction
secured to concrete ceiling, wall or floor. of the foundation or casing. This may well be
Securing to non-rigid metal structures or the most important factor to consider, since
structures is likely to give resonance and many structures may give rise to resonance,
should be avoided. resulting in severe noise problems.
8
2.3 Choice of hydraulic fluid

The Hägglunds hydraulic motors are primarily designed to operate on conventional petroleum based
hydraulic oils. The hydraulic oil can be chosen in consultation with the oil supplier of your local
sales office, bearing the following requirements in mind:
GENERAL
The oil shall have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354). The oil must
also contain inhibitors to prevent oxidation, corrosion and foaming. The viscosity of mineral oil is
highly dependent of the temperature. The final choice of oil must depend on the operating tempera-
ture that can be expected or that has been established in the system and not in the hydraulic tank.
High temperatures in the system greatly reduce
the service life of oil and rubber seals, as well RECOMMENDED VISCOSITY AT
as resulting in low viscosity, which in turn prov- OPERATING TEMPERATURE
ides poor lubrication. 40-150 cSt/187-720 SSU.
Content of water shall be less than 0,1%.
Temperature limits
In Industrial applications with high demands
for service life, the content of water shall be Normal operating temperature should be less
less than 0,05%. than +50°C (122°F)
Viscosity limits Nitrile seals (std motor) -35°C to +70°C

Viton seals -20°C to +100°C
= 100 recommended
Viscosity index = 150* for operation
with large temperature
Nitrile seals (std motor) -31°F to +158°F
difference
Viton seals -4°F to +212°F
Min. permitted in continuous duty 40 cSt/187 SSU
Min. permitted in intermittent duty 20 cSt/98 SSU**
Max. permitted 10000 cSt/48000 SSU
* Many hydraulic fluids with VI-improvers are subject to temporary and permanent reductions of the viscosity.
** Low viscosity gives reduced service life for "COMPACT CB".
Fire resistant fluids

OPERATING WITH FIRE RESISTANT FLUIDS
The following fluids are tested for Hägglunds motors: (ISO/DP 6071)
Fluid Approved Seals Internal paint
HFA: Oil (3-5%) in water emulsion No - -
HFB: Inverted emulsion 40-45% water in oil Yes Nitrile (std motor) Not painted*
HFC: Water-glycol Yes Nitrile (std motor) Not painted*
HFD synthetic fluids

HFD:R - Phosphate esters Yes Viton Not painted*
HFD:S - Chlorinated hydrocarbons Yes Viton Not painted*
HFD:T - Mixture of the above Yes Viton Not painted*
HFD:U - Other compositions Yes Viton Not painted*
* Must be specified in the order.
IMPORTANT!
Down rating of pressure data and service life must be considered when using fire
resistant fluid. The Hägglunds company or its authorised representative must always
be contacted for approval in the case of these types of fluids.
9
Environmentally acceptable fluids
Vegetable */** Nitrile

Yes -
Fluid HTG (std motor)
Synthetic ** Nitrile
Yes -
Esters HE (std motor)
* Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids
must be controlled every 3 months and temperature shall be less than +45° (113°F) C to give good service life for
the fluid.
** Environmental acceptabel fluid gives the same servicelife for the drive, as mineral oil.
Filtration Explanation of
"GRADE OF FILTRATION"
The oil in a hydraulic system must always be
filtered and also the oil from your supplier has Grade of filtration β 10=75 indicates the
to be filtered when adding it to the system. The following:
grade of filtration in a hydraulic system is a β 10 means the size of particle ≥10µm that will
question of service life v.s. money spent on filt- be removed by filtration.
ration.
=75 means the grade of filtration of above
In order to obtain stated service life it is mentioned size of particle. The grade of filt-
important to follow our recommendations ration is defined as number of particles in the
concerning contamination level. oil before filtration in relation to number of
When choosing the filter it is important to particles in the oil after filtration.
consider the amount of dirt particles that the Ex. Grade of filtration is β 10=75.
filter can absorb and still operate satisfactory.
For that reason we recommend a filter with an Before the filtration the oil contains N number
indicator that gives a signal when it is time to of particles ≥10µm and after passing the filter
change the filter cartridge.
once the oil contains number of particles
Filtering recommendations ≥10µm.
Before start-up, check that the system is This means that number of
thoroughly cleaned.
particles have been filtered (=98,6%).
1. In general the contamination level in our
motors should not exceed ISO 4406 19/15.
(NAS 10)
2. For heavy-duty industrial applications the
contamination level should not exceed ISO
4406 16/13. (NAS 7)
3. When filling the tank and motor housing, we
recommend the use of a filter with the grade
of filtration β 10=75.
10
Installation and Maintenance Manual, Compact CB Installation
3. INSTALLATION
3.1 Mounting instructions Design of driven shaft end on heavily-
loaded shaft
If the motor is to work properly it must be
installed with the greatest possible precision. Where the driven shaft is heavily loaded and
Every item connected to the motor that does is subject to high stresses, for example on
not meet the requirements of the following changes in the direction of rotation, it is
instructions may result in stresses that recommended that the driven shaft should
adversely affect the service life of the motor. have a stress relieving groove; see Fig. 3.1 and
tables 3.1 and 3.4.
Normally the motor must be completely filled
with oil. When the motor is installed with the
shaft in the horizontal plane, the drain ports G
must be positioned vertically. The higher of the F
four ports must be used: see fig. 3.25. Fig. 3.1 Max R 3,2
a
When the motor is mounted with the shaft in

the vertical plane, see 3.2.2 "Draining and ven-
ting the motor".
C
A
D
The drain line must be dimensioned so that
E
max. 3 bar (43.5 psi) motor housing pressure 30°
is not exceeded.
6±0,5 R 50
(0,24±0,02) (R 1,97)
The max housing pressure is 3 bar (43.5 psi). B±0,5
(B±0,02)
Brief peaks during operation up to 8 bar (116
psi) are permissible. The permitted housing
pressure when the motor is stationary is 8 bar Normally-loaded shaft
(116 psi). In drives with only one direction of rotation
The motor must always be connected in such where the stresses in the shaft are moderate,
a way as to give a sufficient boost, make-up the shaft can be plain, see Fig. 3.2 and tables
flow at the low pressure connection. This is 3.1 and 3.5
particularly important at high speeds and with Fig. 3.2
rapid reversing, see 2.1 "Recommended
charge pressure".
Max
Table 3.1 Valid for couplings
Dim CB 280 CB 400 CB 560/840

A Table 3.2
-0,014 -0,015 -0,017
mm 180 -0,054 200 -0,061 260 -0,069 Unidirectional drives
-0,00055 -0,00059 -0,00067
in 7.0866 -0,00213 7.8740 -0,00240 10.2362 -0,00272
B Steel with yield strength Relmin= 300 N/mm2

106 117 153
mm
4.17 4.61 6.02 Bidirectional drives
in
C Steel with yield strength Relmin= 450 N/mm2
174 194 254
mm
6.85 7.64 10
in
Note! The dimensions are valid for +20°C (68°F)
11
Installation Installation and Maintenance Manual, Compact CB
Spline Thread for mounting tool

The splines shall be lubricated, either oiled with To make it easier to mount the motor on the
hydraulic oil at assembly, or filled with trans- driven shaft end or to remove the motor from
mission oil from the connected gearbox. To the shaft it is recommended that a hole (Table
avoid wear in the splines, the installation must 3.5) should be drilled and tapped in the centre
be within the specified tolerances in fig. 3.3. of the shaft for a mounting tool; see 3.1.4
"Mounting the motor onto the driven shaft", and
For production of the shaft, see 278 5023, 278 3.1.5 "Removing the motor from the driven
5024, 278 5025 and 278 5026. For control of shaft".
spline see table 3.4.
The tool has both a UNC thread and a metric
Table 3.3 thread, so that the hole can be drilled and
Unidirectional drives tapped to conform to one of the two alternatives
given in table 3.5.
Steel with yield strength Relmin= 450 N/mm2
Bidirectional drives

Table 3.5 Alternative thread (Fig.3.1 and 3.2)
CB 280 - 840
Table 3.4
D M20 UNC 5/8"
Motor CB 280/400 CB 560/840
E >17 (0,67) >13,5 (0,53)
F 25 (0,98) 22 (0,87)
Toth profile and G 50 (1,97) 30 (1,18)
DIN 5480 DIN 5480
bottom form
Tolerance 8f 8f
Guide Back Back
Pressure angle 30° 30°

Fig 3.3
Module 5 5
Number of teeth 38 50 A
Pitch diameter ø 190 ø 250

ø
ø
0 0
Minor diameter ø 188 ø 248
-1,201 -1,201
0 0
Major diameter ø 199 ø 259
-0,290 -0,320
-0,088 -0,103
Measure over
210,158 270,307
measuring pins -0,157 -0,181 0,15 A
(0,006) 0,4 A
Diameter of
ø 10 ø 10 (0,015)
measuring pins
Addendum
+2,25 +2,25
modification X M
12
3.1.1 Lifting methods

Always make sure where the centre of gravity
is before any lifting. Always make sure where
the centre of gravity is
Fig. 3.4a before any lifting. Never
stand below a hanging
motor or torque arm.
Fig. 3.5
Fig. 3.4b Fig. 3.4c
13
Standing the motor on a flat surface
When the motor is placed on a flat surface

Table 3.6
such as a floor, it must stand either on its outer
Motor with
diameter or on the suitably protected end face
shrink disc and of the hollow shaft (see Fig. 3.6 and 3.7).
Motor torque arm
kg lb
CB 280 928 2042 Fig. 3.6
CB 400 1288 2834
CB 560 1514 3331
CB 840 1844 4057
Support
Table 3.7
Weight
Torque arm
kg lb
TCA 40 128 282

Fig. 3.7
TCA 84 224 493
Lifting straps must be

chosen with reliable saftey
margin over the total weight
of the lifted object.
Support
NOTE:
The motor must not be placed on the end face
of the hollow shaft when the coupling is fitted,
since this may cause damage to the coupling.
When in storage, the motor must always be
placed on the end face to the hollow shaft. It is
also advisable to provide supports at the
mounting surface of the motor; see Fig. 3.7.
14
3.1.2 Mounting the coupling onto the motor shaft

Before the motor is mounted there are some preconditions which must be fulfilled:
- You should note that the couplings are from the factory lubricated with MoS2 (Molycote) on the
conical surfaces and the bolts,see fig. 3.8. This lubricants shall remain on those surfaces but:
Molycote must under no circumstances be

trans-ferred to the surfaces between the
driven shaft and the motor.
It is therefore important that you clean your hands free from Molycote. If those conditions are
fullfilled you may start the mounting.
- Clean the driven shaft and the out- and inside of the Compact motor hollow shaft.
- Remove the spacers between the two clamping rings of the coupling.
- Mount the coupling on the hollow shaft of the motor. The coupling must be pushed right up to the
stop of the shaft. Use a screwdriver to open the coupling ring for easier mounting.
Never tighten the coupling screws until the

motor has been mounted onto the driven
shaft.
- Mount the motor onto the driven shaft by following the instruction in the section 3.1.4. (With or
without using the mounting tool).
Remember:
-The conical surface between the coupling ring and the clamping rings + the bolts shall be coated
with MoS2 (Molycote), see Fig. 3.8. This is done from the factory at delivery! When a motor has
been in for overhaul or service and shall be reassembled it may be necessary to relubricate those
surfaces with Molycote again but remember only the specified surfaces!
-Absolutely No Molycote on the surfaces between shaft-motor. Clean the driven shaft and the
inside of the motor hollow shaft.
- Alignment of the motor on the shaft. (Dimensional check).
- Minimum variation in the gap between the clamping rings (Dimensional check).
- Right torque on the bolts. (Use torque wrench).
Before starting the motor, check

that the rotating coupling can not
cause damage.
15
Clamping rings
Fig. 3.8
Seal Coupling ring
Washer - - - - - = Coated surface
Motor hollow Cleaned surface

shaft
Centre of motor
16
3.1.3 Fitting the torque arm to the motor

The torque arm is fitted to the motor before the Fig. 3.9 CB 280/400
motor is mounted on the driven shaft.
- Clean the spigot surface on the torque arm
and motor with trichlorethylene or similar sol-
vent.
- Oil the screws.
- Make sure that the torque arm will be pointing
in the right direction when the motor is
mounted in place on the machine. To achieve
the highest possible oil level in the motor
housing, the motor must be turned until the
drain outlets are positioned according to fig
3.12.
- Line up the torque arm on the motor by
using the screws with washers.
- Tighten the screws to the torque stated in the
table below.
Fig. 3.9a CB 560/840
Do not weld, drill, grind or

carry out any similar work on
the torque arm without
Hägglunds approval.
Table 3.8
Tightening torque
Number
Motor Screw dimension
of screws
Nm lbf·ft
CB 280/400 M20 Strength class 10.9 34 540 400

Note: Use torque wrench and oiled screws!
17
3.1.4a Mounting the motor onto the driven shaft - shaft coupling
The motor can be mounted onto the driven shaft with or without a mounting tool, but the use of a
mounting tool is recommended since it makes the work easier.
It is important to arrive at the correct clamping length between the driven shaft and the hollow shaft
of the motor.
Ensure that the full clamping length is used by, for example, measuring and marking the driven
shaft. This is of particular importance if the duty is so severe that a stress relieving groove has
been made on the driven shaft. See Fig. 3.11, 3.11a and the table 3.9.
Mounting the motor with a mounting tool (Fig. 3.10a)

- Remove the End cover together with screws and washers.
- Align the motor with the driven shaft.
- Locate the existing plastic washer between the nut on the mounting tool and the bearing retainer.
- Pass the mounting tool through the centre of the motor, and screw it into the driven shaft to
stated depth by using the key handle in the end of the tool.
- Pull the motor onto the shaft by turning the nut on the mounting tool until the length B is obtained;
see Fig. 3.11, 3.11a and table 3.9. Push and pull the end of the torquearm for easier mounting.
- Tightening the shaft coupling see table 3.10.
- Remove the mounting tool.
- Refit the plug.
- Refit the end cover and tighten the screws together with washers. Torque 80 Nm (59 lbf·ft).
Fig.3.10b
Clean the driven shaft and the

inside of the motor hollow
shaft.
Fig. 3.10a Mounting the CB 280...840
2 1; Bearing retainer
2; Plastic washer
3; Nut
4; Mounting tool
3
4
18
Fig. 3.11 Without stress relieving groove Fig. 3.12
Fig. 3.11a With stress relieving groove
Mounting the motor without a

mounting tool
The motor can be mounted onto the driven
shaft without using a mounting tool, though this
is more difficult and takes longer time. However,
it is easier to mount the motor if during
mounting the compressed air trapped within
the hollow shaft is evacuated. To do this,
remove the End cover as described in
"Mounting the motor with a mounting tool"
Align the motor with the driven shaft using an
overhead crane or lifting truck and press it
carefully onto the shaft so that the length
stated in the table beside is obtained, see
Table 3.9 Fig. 3.11.
Length To achieve the highest possible oil level in the

Motor motor housing, the motor must be turned until
B mm B in the drain outlets are positioned according to
fig 3.12.
CB 280 106 4.17
CB 400 117 4.61
CB 560
153 6.02
CB 800
19
Tightening of shaft coupling
However for the tightening of the coupling Mark the screw heads at 12 oćlock with a pen
screws the following must be observed: or paint so that you can follow the turning
sequence of the screws.
Keep tension in your lifting wires to avoid
a skew setting of the motor on the shaft Set the torque wrench for the specified maxi-
during the tightening of the screws. mum torque. Tightening torque of the coupling
Wobbling caused by a skew setting of the screws; see the sign on the coupling, or table
motor gives extra forces on the main 3.10.
bearings.
Now start tightening the screws in sequence
In order to avoid the misalignment of the two shown in Fig. 3.14.
clamping rings during the screw tightening, the
Keep on doing this until you have reached the
gap between the rings must be measured in
stated torque. Several passes are required
several places during the process, see Fig.
before the screws are tightened to specified
3.14. The difference between the measured
torque. Keep checking the alignment of the
gaps must never vary more than 1 mm (0,04")
coupling. (15-20 passes may be necessary).
during any stage of the tightening process.
When the specified torque is reached it is
Pre-set the coupling screws in opposite pairs
important that all screws are tightened with
(12-6-3-9 oćlock) until you reach max. 50%
specified torque and that no further movement
of the torque specified for the screws. It is very
can be observed.
important that when you reach this stage the
misalignment is controlled as described above.
Table 3.10
Tightening torque
Motor No of Screw Strength Type of
type screws dim class head
Nm lbf·ft
CB 280 12 M20x80
CB 400 15 M20x90
10.9 490 362
Hexagon
CB 560 20
M20x100
CB 840 20
Note 1 Uncoated screws greased with MoS2.

Note 2 There is a metallic sign on every coupling with a tightening torque stamped on it.
This torque is always to be used.
Note 3 Tightening torque value is critical. Use calibrated torque wrench.
20
Fig. 3.14
Fig. 3.14a
3.1.4bMounting the motor onto the driven shaft - splines
Flange mounted motors

o-ring
For flange mounted motors, the spline shall
normally not be subject to radial load.With no
radial load, the splineshaft can be greased before
mounting the motor. If the motor is subject to radial
load, the splines shall be filled up with oil.
- Mount motor on to the shaft.
- Bolt the motor to the flange. Tightening torque,
see Table 3.10.
Axial clearance min 5 (0.2)
Oil to be filled before
tightening G1 plugg
- Fill up hydraulic oil to the G1 plug.
If oil here, it can be
used for the spline. - Torque the G1 plug. MV=125 Nm/90 lbf.ft.
Then take away
the o-ring. - Mount the end cover. MV=80 Nm/59 lbf.ft.
o-ring 10 (0,4) during Torquearm mounted motors

filling of oil
Motors that carry radial load, must have the
splines filled up with oil.
Spacer
- Mount the spacer on the shaft. MV=450 Nm/300
lbf.ft.
- Fill hydraulic oil to the G1 plug.
- Mount special designed bolt.
- Torque the bolt. MV=385 Nm/280 lbf.ft.
tightening bolt M20 - Mount the end cover. MV=80 Nm/59 lbt.ft.
L=100 mm
21
3.1.5 Removing the motor from the driven shaft

Before dismounting the motor from the driven Removal by using the mounting tool
shaft the oil in the motor housing must be drai-
ned through the lower draining hole. - Slacken the shaft coupling screws gradually;
The motor can be removed from the shaft with see Fig. 3.14 and 3.14a. Each screw should
or without the mounting tool. The operation is be slackened only about a quarter of a
easier if the tool is used. turn each time. Thus tilting and jamming of
the collars or thread stretching will be
avoided. The screws must be slackened until
the coupling ring is fully released.
- Remove the End cover and Bearing retainer
together with screws and washers; see Fig.
Never stay below the mo-
3.15
tor during disassembly
- Locate the existing plastic washer outside the
mounting tool nut.Then pass the tool
through the centre shaft, and screw it into
Always make sure that the the driven shaft to stated depth.
lifting equipment is strong - Screw in the nut of the tool until the Bearing
enough to handle the retainer can be refitted, torque 136 Nm (100
weight of the motor lbf·ft)
- Remove the motor from the driven shaft by
unscrewing the nut of the mounting tool.
- Remove the Bearing retainer and mounting
tool. Finally, refit the removed Bearing retai-
ner, torque 136 Nm (100 lbf·ft) and End cover,
Fig. 3.15 Removal of Compact CB 280...840 torque 80 Nm (59 lbf·ft) as before.
Removing the motor without using the

mounting tool
1 - Slacken the screws of the shaft coupling, see

2 above "Removal of motors by using the
mounting tool".
- Remove end cover and plug to allow air to
enter the space in the hollow shaft of the mo-
tor; see “Mounting the motor without a
mounting tool“. After removal of the motor, refit
3 the removed components as before.
4
- Carefully pull the motor off the driven shaft
supported by an overhead crane or a lifting
truck.
1; Bearing retainer
2; Plastic Washer
3; Nut
4; Mounting tool
22
3.1.6 Mounting the reaction point

Fig. 3.16 Mounting of pivoted attachment
x = ±2 mm (0,079) misalignment in installation.
x ≤ ±15 mm (0,59) movement when in use.
Alternative
Note: The toggle bearing must position
be dismounted during welding.
Steel:
EN 10113S355N
DIN St E39
BS 4360 Grade 50 C
Protected against corrosion, after welding.
Fig. 3.18
DANGER ZONE
Fig. 3.17 In case of failure of
torque arm installation
Make sure that the foundation

can withstand the forces from
the torque arm.
23
Installation Installation and Maintenance Manual, Compact
3.2 Oil connections

When using (heavy wall) piping and in frequent Fig. 3.25a
reversal drives, it is recommended to fit flexible
hoses between the motor and piping to avoid
damage due to vibration and to simplify instal-
lation of the motor. The length of the hoses
should be kept fuirly short.
Fig. 3.25
T4
Table 3.11
Connection Description Remarks
If C is used as the inlet, the motor shaft rotates clockwise,

C1, C2 Main connection
viewed from the motor shaft side.
If A is used as the inlet, the motor shaft rotates counter-
A1, A2 Main connection
clockwise, viewed from the motor shaft side.
D1 Drain outlet Normally plugged at delivery.
D2, D3, D4 Alternative drain outlets Normally plugged at delivery.
F1,F2 Flushing connection For flushing of radial lip seal. Normally plugged.
F3 Flushing connection For flushing of axial bearing and motor case.
Used to measure pressure and/or temperature at the main

T1 Test connection
connections.
T2, T3 Test connection Used to measure pressure and/or temperature in drain oil.
T4 Pressure connection Connection for double ended torque arm.
Table 3.12
D1, D2, F1, T1, y y x x
Motor A** C** D4 F3 T3 T4
D3 F2 T2 mm in mm in
1 1/4" 1 1/4" G 1/4" 223 8.78 99 3.90

CB 280...840 G 1 1/4" G 1 1/4" G 1/4" G 1/2 " G 1/4" G 1/2"
1 1/2" 1 1/2" M16 223 8.78 101 3.98
**SAE coupling J 518 C, code 62, 414 bar (6000 psi). 1 1/4" or 1 1/2" can be used.
*** A2-connection and C2-connection is blocked at delivery. They are able to withstand max pressure.
24
Main connection A, C
Fig. 3.25b
Table 3.13
a c
Motor Connection b
mm (in) mm (in)
1 1/4" UNC 1/2" 27 (1.06)

CB 280 - 840 31 (1.22)
1 1/2" UNC 5/8" 35 (1.38)
Drain connection D1, D2, D4 Test connection T

Fig. 3.25c Fig. 3.25d
3/4"
G1 1/4"
∅ 65
(2,56)
G
BSP
25
3.2.1 Direction of rotation of

motor shaft Fig. 3.26
With the inlet pressure supply connected to A

port, the motor shaft rotates in the direction A1
C1
shown by the arrow, anti-clockwise viewed from
the motor shaft side.
With the inlet pressure supply connected to C
port, the motor shaft rotates clockwise viewed
from the motor shaft side.
3.2.2 Draining and venting the motor

Horizontal mounting
When the motor is installed with the shaft in the horizontal plane. The highest of the four drain
outlets D1, D2, D3 or D4 must always be used; see Fig. 3.28.
Drain line must be connected direct to the tank with a minimum of restrictions, to ensure that the
maximum housing pressure is not exceeded.
Vertical mounting
When the motor is mounted vertically, the highest of the four drain outlets D1, D2, D3 or D4 must
be used. Flushing of radial seal from low pressure is necessary.
Motor shaft pointing downwards

The motor must be connected to one of the drain connections in the connection block; see
Figure 3.29. The flushing connection F2 shall be connected to low pressure connection.
Orifice must be installed.
Motor shaft pointing upwards

The motor must be connected to the drain line connection on the shaft end housing; see Figure
3.30.
The flushing connection F1 on the shaft end housing should be connected to the low pressure
connection. With bi-directional drives, use the connection with lowest average pressure. (Connec-
tion to high pressure will increase the motor drain flow). This gives flushing of the radial lip seal. It is
advisable to fit the nipple and the hose to the motor before fitting the torque arm.
Make sure that this

checkvalve is connected
in the correct direction.
26
Fig. 3.28 Fig. 3.29
Orifice Ø1,0 (0.04)
Drain line
Low pressure
connection
Drain line
connection
Fig. 3.30 G 1/4", Flushing

Fig. 3.31
connection F1

Drain line
connection
G 1/2", Flushing
Low pressure connection F3
3.2.3 Flushing
Flushing of motor case Max. power without flushing

To avoid high temperature in the motor case the CB 280 120 kW (160 hp)
heat must be removed, because high temperature CB 400/560/840 170 kW (227 hp)
gives lower viscosity and that gives reduction in
basic rating life/service life. For calculation of required flushing, please contact
your Hägglunds representative.The flushing oil shall
- For continuous duty in applications with an be drained in the normal drainline. See 3.2.2.
ambient temperature of +20°C (68°F), the motor
case must be flushed when the output power Connect the input line for flushing in F3, see Fig
exceeds the values shown beside. 3.31.
27
Installation and Maintenance Manual, Compact CB Maintenance
4. OPERATING INSTRUCTIONS
4.1 Storage
The motor is delivered with internal protection in the form of an oil film and external protection in the form of an
anti-rust film. This provides sufficient protection for indoor storage in normal temperatures for about 12 months.
Note: the anti-rust protection must be touched-up after transport and handling.
If the motor is stored for more than 3 months in uncontrolled environment or more than 12 months in controlled
environment, it must be filled with oil and positioned as shown in Fig. 3.7.
Place the motor as shown in fig 4.1, fill the motor with filtered oil in the following order: D1, A1, C1. See 2.3,
"Filtration" and table 4.1.
Take extreme care to ensure that no contamination enters the motor.
Seal connections A and C with the cover plate fitted to the connection surface at delivery. Check that the O-
rings or rubber seals are in postion in the cover plate.
Fit the plug to D1, D2, D3 and D4, the table below states the amount of oil needed to fill the various types of
motors.
4.2 Before commissioning

Check the following points before commissioning the motor, i.e. before starting the first time:
- Check that the motor is connected to give the correct direction of rotation (see 3.2 "Oil connections" and
3.2.1 "Direction of rotation of motor shaft").
- Select the hydraulic fluid in accordance with the recommendations (see 2.3 "Choice of hydraulic fluid").
- Fill the motor housing with hydraulic fluid via a filter into the drain outlets D1, D2 or the vent hole (depending
on how the motor is mounted), see table 4.1.
- Check the drain line to ensure that excessive pressure does not build up in the motor housing; see 3.1
"Mounting instructions" and 3.2.2. "Draining and venting the motor".
- Check that the motor is protected from overloads (see 1.1 "Motor data").
- Check that the charge pressure conforms to the
charge pressure curve (see 2.1 "Recommended
Fig. 4.1 charge pressure").
- Check that all hydraulic couplings and plugs are
properly tightened to prevent leakage.
- Make sure that the torque arm is sufficiently faste-
ned, see 3.1.3 and 3.1.6.
Table 4.1
Oil volume approx.
Motor
Litres US gal.
CB 280 15 4.0
CB 400 21 5.6
CB 560 19 5.0
CB 840 25 6.6
28
Maintenance Installation and Maintenance Manual, Compact CB
4.3 Commissioning 4.4 Periodic maintenance

- During initial star ting and the period When a hydraulic system has been in service
immediately after it, any hydraulic installa- for some time, it must undergo periodic
tion must be regularly and carefully checked maintenance and servicing at intervals which
at frequent intervals. depend on the equipment and the type of duty.
- The working pressure and charge pressure This periodic maintenance must include the
must be checked to ensure that they following operations:
correspond to the contracted values. - Check the hydraulic system for leakage.
- The pressure in the drain line measured at Tighten the screws, replace faulty seals and
the motor must be less than 3 bar (43,5 psi). keep the drive clean.
This pressure limit is important for the life of - Inspect and clean all air, oil and magnetic
the motor seals. filters; replace all filter cartridges for which a
- If leakage occurs, correct the fault and carry filter clogged indication has been given;
out new measurements. inspect tank, pump, filters etc. and clean if
necessary.
- Check all lines, connections, screws, etc. and
correct if necessary. - Check the pressure and temperature of the
hydraulic fluid and carry out routine opera-
- Check other possible leakage points and tions. Adjust valves etc. if necessary.
replace faulty parts.
- Check the hydraulic fluid; see the Section
- During the start up period, dirt particles in headed "Oil".
the system are removed by the filters. The
filter cartridges have to be changed after the - Check that no dirt or other contaminations
first 100 working hours and after that enter the system during inspection.Check
according to the maintenance chart. see 4.4 that the outside of the hydraulic motor in an
note to check the "filter clogged" indicators. installation is kept free of dirt; thus leakage
and faults will be detected earlier.
A not run-in motor in combination with dirt
particles in the oil can badly affect the sliding - We recommend that a running log be kept
surfaces in the motor. This is valid during the and that planned inspections are carried out
first 100 working hours. at set intervals.
- Maintenance checks and operations are as
follows:
Maintenance chart
Oil Torque
In operation Oil
filters arm
After the first

100 hours
Rpl. Insp.
After 3
months or Rpl.
500 hours
Once every 6
months
Rpl. Insp. Insp.
Once every
12 months
Rpl = Replacement Insp = Inspection
29
Motor Filters
If the motor is to be stored stationary for a Filters must be changed after the first 100
longer period than about 1 month, it must be working hours and the second change is to be
protected from internal rust. This can be done carried out after 3 months or 500 working hours
as follows: whichever is earlier. They must then be
1. Mix anti-rust additive with the hydraulic changed at regular intervals of 6 months or
fluid of the system. Use 5% of Rust Veto 4000 working hours.
Concentrate (manufactured by E F
Houghton & Co, Philadelphia, USA). This Oil (Se also 2.3)
additive gives rust protection for up to
about 1 year, after which time the motor Analysis
must be turned a few revolutions.
It is recommended that the oil should be analy-
2. If no additives are used, the motor must sed every 6 months. The analysis should cover
be regularly turned a few revolutions. viscosity, oxidation, water content, additives
3. If it is not possible to turn the motor, plug and contamination.
all connections, open drain outlet D1 or D2 Most oil suppliers are equipped to analyse the
on the port end housing (or if the motor is state of the oil and to recommend appropriate
mounted vertically, Flushing connection F1 action. The oil must be replaced immediately if
on the shaft end housing) and fill the motor the analysis shows that it is exhausted.
with hydraulic fluid.(See Fig. 4.3 and Fig.
4.3a). Viscosity
Many hydraulic oils become thinner with
Fig. 4.3
increasing use, and this means poorer
lubrication. The viscosity of the oil in service
must never fall below the minimum recom-
mended viscosity.
Oxidation
Hydraulic oil oxidizes with time of use and
temperature. This is indicated by changes in
colour and smell, increased acidity or the for-
mation of sludge in the tank. The rate of oxida-
Fig. 4.3a tion increases rapidly at surface temperatures
above 60°C (140°F), and the oil should then
be checked more often.
The oxidation process increases the acidity of
the fluid; the acidity is stated in terms of the
"neutralisation number". Typical oxidation is
slow initially and increases rapidly later.
A sharp increase (by a factor of 2 and 3) in the
neutralisation number between inspections is
a signal that the oil has oxidized too much and
should be replaced immediately.
30
Water content
Contamination of the oil by water can be Another method is to install an inline particle
detected by sampling from the bottom of the counter direct in your hydraulic system which
tank. Most hydraulic oils repel the water, which give you the contamination level according to
then collects at the bottom of the tank. This the international rules, the disadvantage with
water must be drained off at regular intervals. this method is that you only get the
Certain types of transmission oils and engine contamination level in the oil.
oils emulsify the water; this can be detected
by coatings on filter cartridges or a change in General
the colour of the oil. Obtain the advice of your The intention is to verify the condition of the oil
oil supplier in such cases. during operation.The motors should be running
Degree of contamination at normal operation while the sample is taken.
The cleanliness is extremely important during
Heavy contamination of the oil causes sampling.
increased wear of the hydraulic system Always use bottles adapted to oil samples,
components. The cause of the contamination they can be ordered from any fluid analysis
must be immediately investigated and re- laboratory.
medied. Never try to clean your own bottle if you want
a true value of the result.
The sample should be taken by using a mini-
mess hose connected to a mini-mess
coupling.
Always clean the connections carefully before
All hydraulic fluids are affected you connect the mini-mess hose to the
differently. Obtain the advice of coupling.
your oil supplier or by nearest Be careful when connecting the mini-mess
Hägglunds representative. hose because the oil beam can be dangerous
and should never point against any person or
other sensible object.
Check and be aware of the pressure you
4.5 Oil inspection mayhave on the connection before you
Purpose connect.
The purpose to take an oil sample is to check
the condition of the oil. How to do
With scheduled oil analysis, wear products can Bottle samples
be identified and corrective action can be taken The sample shall be taken at the mini-mess
before failure occurs. Oil analysis can indicate coupling on the charge pressure side of the
when an oil change is required, point out motor in the closed loop system. Never out of
shortcomings in maintenance and keep repair the tank using the ball valves.
cost to a minimum. Using oil analysis can Clean the coupling and the hose carefully.
create a “window of opportunity”, allowing the Connect the mini-mess hose to the coupling
user to schedule re-fittings or overhauls, but be careful and be aware of the direction of
maintenance or repairs, thus saving money on the oil beam.
equipment repairs and downtime. Let minimum 2 litres (0,6 gallon US) of oil flush
The most used method is to take samples in a into a bucket before you fill the bottle.
special bottle and send it to a fluid laboratory Remove the cap of the bottle as late as
for an analysis and from the laboratory you possible and don’t let any contamination be in
get a repor t, which follow a specific touch with the cap, bottle or the mini-mess hose
international standard. when the sample is taken.
You have to select what analysis the laboratory In dirty air area, use a soft plastic foil (normal
should take, but the most used analysis are as protection in laboratory bottles between
particle count, water content, oxidation and bottle and cap).
viscosity.
31
Fault finding Installation and Maintenance Manual, Compac CB
Do not remove the foil, prick the end of your Inline measure
mini-mess hose through the foil into the bottle The sample shall be taken at the mini-mess
and fill. coupling on the charge pressure side of the
To get a reliable result the system must run motor in of the closed loop system. Clean the
without moving any valves and the mini-mess coupling and the hose carefully.
hose should not touch the bottle. Connect the hoses according to the particle
Only ¾ of the bottle shall be filled because the counters manual.
laboratory has to shake the sample to get a To get a true value the contamination readings
mixed fluid when they analyse it. Minimum have to be stable about 10 min before you stop
200ml are needed for a good analysis. to measure.
When the bottled is filled close the cap as soon
as possible to prevent contamination from the
air that might enter the bottle and give you a
wrong result.
5. FAULT FINDING
Hydraulic motor
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pressure has
risen to the relief valve setting, remove the
load from the drive.
The motor does not deliver Investigate the pressure level in the system
enough torque because the and correct the setting of the pressure limiting
pressure difference across the valve if necessary.
motor is not great enough for
the load.
Insufficient or no oil being Check the hydraulic system. Check the

supplied to motor. external leakage of the motor.
(The D connection)
Motor rotates in wrong Oil supply connections to Connect the oil supply correctly.
direction. motor incorrectly connected.
Motor runs jerkily. Pressure or flow fluctuations Find the cause in the system or in the driven
in the hydraulic system. unit.
Noise in the motor. The motor is being operated Adjust the charge pressure to the correct
with the charge pressure too level. See 2.1 "Recommended charge
low. pressures".
Internal faults in the motor. Investigate the drain oil, if necessary. Put a
magnetic plug in the oil flow and check the
material that sticks to the magnet. Steel
particles indicate damage. Note that fine
material from the castings may be deposited
and does not mean internal damage in the
motor.
External oil leakage on The radial lip seal is worn. Replace the radial lip seal.
the motor.
32
Deklaration of conformity Installation and Maintenance Manual, Compact CB
DECLARATION OF CONFORMITY
Example of the Declaration of Conformity given by Hägglunds Drives AB
178 XXXX-XXX CB 280 XXXXXX
The DECLARATION OF CONFORMITY above, is available on request for deliveries from

Hägglunds Drives AB. Translations into other languages are also available.
33
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
740
4
THROUGH HOLE 110 AVAILABLE

A A
A,A1 C,C1 (29,134)
(0,157)
RO
N TA
ATIO TIO
RO
T N
C1 40 H
A1 (1,575)
(4,331)
(26,772 -0,0062)
45°
-0,0013
A
-0,024
-0,149
H (2:1)
B D1 30 B
C C (1,181)
D4 B B
680
223 (2x)
(8,780)
174 (4x)
(6,850)
(17,008 +0,00078)
C C
+0,00235
)
(29,213 -0,024)
+0,0029
+0,063
432 +0,023
+0,072
+0,023
6x15
742 ±0,6
(17,323)
(0,236)
440
200 0
(7,874 +0
117
(4,606)
D D
D2 T3
E A2 Not 1. E
A
C2 Note 1.
T4 A M20 (34x)
T4 1/2"UNC (16x) 31 (4x)
(1,220)
38
Equ 9° A
ally (1,496)
(1,063)
F F
(1,457)
divi 207 (4x)
27
ded
37
(8,150) 237 425
(9,331) (16,732)
489
782 101 (19,252)
G (30,787) G
B-B (1 : 1) (3,976)
250 224 = = = = A1 C1
25° 55°
(9.843) (8,819)
5/8"UNC (16x) T1 T1
D3 F1 D1 D3
H H
(1,378)
(1,772)
D4
35
45
F2
A F3
D2 F1
(3,346)
(2,874)
85
= = = =
73
T2
C-C (1 : 1)
I T3 I
99 A (1 : 2)
T4 T4
(2,126)
(3,898)
54
MOMENT OF INERTIA = 18.3 Kgm² / 434 lbxft² A2 C2

WEIGHT = 1160 Kg / 2555 lb
(12,047)
306
(13,976)
CONNECTION DECRIPTION PORT CONNECTION

355
J A1 MAIN CONNECTION SAE 1¼" AND 1½" ** J

therof must not be imparted to a third party
nor be used for any unauthorized purpose.
The contents of this drawing are subject to change

This document must not be copied without
our written permission, and the contents
(17,559)
C1 MAIN CONNECTION SAE 1¼" AND 1½" ** without notice or obligation, unless certified
Contravention will be prosecuted.
446
A2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** referring to a certain purchase order.
C2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** Information contained herin should be confirmed
before placing orders.
D1 DRAIN CONNECTION BSP 1 ¼"
D2, D4 ALTERNATIVE DRAIN CONNECTION BSP 1 ¼" Measurements within brackets indicates
D3 ALTERNATIVE DRAIN CONNECTION BSP 1" measurements in inches.
K T1, T2 TEST CONNECTION M16 x 2 NOTE 1: For tightening torque see installation manual. K
T3 TEST CONNECTION BSP ¼" Must be verified on actual name plate.
A T4 PRESSURE CONNECTION BSP ½"
T1 T1 FLUSHING CONNECTION BSP ¼"
F1, F2 Item No. Qty Article No. Material, type, etc Dimensions Name of item
Part of
FLUSHING CONNECTION BSP ½"

Weight kg
A F3 Tolerances for length, corner radii,

chamfers angles and threads Indicates Ra in µm
Reference
according to
SS-ISO 2768-1, class m Scale Presiding drawing no Control code
SS-ISO 965, class 6.
Other not indicated tol. 1:2.5
F2 ** SAE coupling J 518 C, code 62, 414 bar (6000 psi) Cad type
SW
Sheet size
A0
Drawn by
Knight/DVN
Description (English)
HYDRAULIC MOTOR CB 400

Part group
A40P
Prepared both for 1¼" and 1½". Accepted for prod by Iss by Dept. Year Week Description (Own language)
SHRINK DISC VERSION

Type design/group
L
T2 99 A F3 Both UNC 1/2" for SAE 1¼" and UNC 5/8" for SAE 1½" Drawing checked by
D52 01 22 CB400
Rev ind Sheet
Similar drawing No.
1
(3,898) A 620 060 LFN 02 05
D52/BLL
Design checked by
078 5003 A No. of sheets
Rev.Ind. Revision Appd. Year Week D5/BHN 1

A0 - Landscape ver. 2.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Bill of Material No.: HK-2005033
Bill Of Material
Issued By: JFD 2275 International Street; Columbus, Ohio 43228, USA - -
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: - Assembly Ref(s) :
HOSE KIT Revised By : -
25 FT. LONG, PBC-200 with 1 x P6S/P7S to 1 x CB-280/400 -
WITH MAINLINE, AND DRAINLINE HOSES Rev. Date : Project No. :
- 2005 033
C
Item O Hägglunds Description
No. Qty. D Part No.
E
1 2 Hose Assembly, 1-1/2" 5000 PSI Hose with,

1-1/2" Code 62 Flange 90° One End,
1-1/2" Code 62 Straight Flange Other End, 25 Ft. Lg.
(Main Lines, Motor to Power Unit)
Gates : 24G5K-24FLH-24FLH90M-300".
Parker: 78C-6N-6A-24-24-24-300"
2 1 Hose Assembly, 1-1/4" Low Pressure Hose with

1-1/4" JIC 37° Straight Swivel One End,
1-1/4" JIC 37° Swivel 90° Other End, 25 Ft. Lg.
(Motor Case Drain to Power Unit Drain)
Gates : 20G1(C1T)-20FJX-20FJX90M x 300"
Parker: 381-06-39-20-20-20-300"
3 4 Split Flange Kit, with Bolts/Washers

1 1/2" Code 62
Gates : 24FHHS
Parker: HFHFHK-24
4 1 Hose Assembly, 1/2" Low Pressure Hose with

1/2" JIC 37° Straight Swivel One End,
1/2" JIC 37° Swivel 90° Other End, 25 Ft. Lg.
(Motor Case Flushing)
Parker: 381-06-39-08-08-08-300"
NOTE: Clean and cap hoses.
HK2005033.XLS Form No.: F10203-2 | Release Date: 4/6/2001 | Revision: A

Date Issued: Checked By: Hägglunds Drives, Inc. HAS-10392
5/31/2005 CBH BILL OF MATERIALS
Rev.: Prepared By : Hägglunds Drives, Inc.
A JFDIII 2275 International Street, Columbus, OH. 43228
TITLE: Assembly Reference:
LONG TERM OIL FILLING
COMPACT MOTORS (ALL SIZES) Installation/Project:
Item Qty Part No. Description
1 7 - HYDRUALIC OIL, SHELL TELLUS-68, WITH

5% RUST VETO CONCENTRATE
2 1 - LABOR TO UNCRATE MOTOR AND FILL WITH OIL
NOTES:
Fill up motors all the way with following amount of oil and make
sure all drain and vent ports have metal plugs with o-rings:
Compact CA-50 - 0.53 gallons
Compact CB-280 - 4.0 gallons
Rev. By Date Description
HAS10392a.XLS
Bill of Material No.: HAS-10014
Bill Of Material
Date Issued : 10-Mar-1993 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: CBH 2275 International Street; Columbus, Ohio 43228, USA B
Revised By :
Long Term Storage Flange Kit, 1½" HDR
Used for Goldcup P6, P7, P11, P14 and Hagglunds SP250 and SP355 pumps Rev. Date : Project No. :
11-Apr-2008
C
No. Qty. D Part No.
E
1 2 038-58361-0 1-1/2" CODE 62 PROTECTIVE COVER WITH SEAL
2 NOT USED
3 3 HYDRAULIC OIL, SHELL TELLUS-68 WITH 5% RUST VETO
4 1 LABOR TO UNCRATE PUMP AND INSTALL PROTECTIVE COVERS AND FILL WITH OIL
5 8 306-24180-0 HEX HEAD CAP SCREW, 5/8-11 UNC x 1.25" LONG
NOTE:
Install Items 1, 2 and 5 onto pump and then fill with oil
according to the following chart:
Goldcup P6 & P7 - 0.8 gallons
Hägglunds SP-250 - 2.6 gallons
HAS10014c.XLS Form No.: F10203-2 | Release Date: 4/6/2001 | Revision: A

Compact CA & CB AC-3.4
Engineering manual ACB-3.4
Accessories
04-03-30, Replaces 03-06-12
Mounting set SMCB1 for speed encoder

Speed encoder kit for Compact CA50-CA210 and
Compact CB280-CB840 motors where the speed
encoder is enclosed and well protected.
The mounting set can be used for both spline and

shrink disc motors.
The encoder is used for detection of speed by

pulse- frequency or/either direction of rotation by
pulse-train.
Ordering code: See AC-1.4, ACB-1.4
CB280-CB840 with SMCB1 CA50-CA210 with SMCB1
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 1(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
Speed encoder SPDB1:
Digital incremental hollow shaft encoder with torque
arm mounting.
Pulse rates: 1000 and 3600 ppr.

Recommendations:
1000 pulses for speed 6 rpm and above.
3600 pulses for speed below 6 rpm.
- Possibility to read direction of rotation from

encoder.
- Encoder is equipped with zero pulse.

Output signal:
ELECTRICAL SPECIFICATION
Supply voltage + EV DC 24V (9-30V) The output signal contains of two pulse trains with
Polarity protected 1000 or 3600 pulses/rev. and inverted signals to
these. When pulse 1 becomes low, pulse 1-inv.
Current consumption at 65mA @ 24V Max 75mA
no load becomes high same for pulses 2 and 2-inv.
Pulse-train 1 and 2 are displaced 1/4 pulse, (90º
Pule rates 1000, 3600 ppr
el) according to each other so direction can be
Accuracy detected. Direction is measured by detection which
Dividing error ± 50° el pulse comes first (see fig. page 3).
Channel seperation 90° ± 25°el
Outputs Short circuit protected There is a zero-pulse on the turn. This pulse becomes
Load max ± 40mA high (pulse 0) or low (pulse 0-inv), when marking on
Max cable length 200m shaft end (cut in hollow-shaft) is in line with cable
Uhigh (at 10mA load) > +EV -2,0V outlet on speed encoder.
Zero pulse length is 1/4 of ordinary pulse length
Ulow (at 10mA load) < 1,15V
(1/4000 or 1/14400 turn).
Female cable connector HD art.no. 5217 5322-150
EMC approval EN 50081-1, EN 50082-2
MECHANICAL SPECIFICATION
Shaft, Stainless steel Hollow-shaft ø 12mm
Moment of inertia 5,4 x 10-6 kgm2
Load max Same direction as motor
Radial 20 N - clockwise
Axial 10 N
Speed max 6000 rpm
Code disc Unbreakable acrylic glass
Temperature
Operating -25°C...+70°C
Storage -25°C...+70°C
Housing Aluminium, anodized
Weight Approx. 250 g
Protection class IP 65 according to IEC 529
Vibration <100 m/s2 (50...2000 Hz)
Shock <1000 m/s2 (11 ms)
AC-3.4
Clockwise, seen from shaft side
360º el. (1 period)
1 inv
2 inv
90º el. (channel separation)

0
0 inv
Connection:
Encoder must be connected with shielded cable, max 0.5 mm2 which is to be solded in connector-pins.
The shield connects to connector-shell.
Connection female cable connector

1 inv 1 PINNING 12 pin contact
Function Pin
0V 1 8
+EV
+EV 12
10 12 0V 10
0 2 inv 1 8
3 6
1 inv 1
4 5
2 5
0 inv 2 2 inv 6
0 3
0 inv 4
Connector seen from solder side.
T-contact:
To be used for external measuring.
HD art. no: 378 5043-801
AC-3.4
F/A converter:
- Frequence to Analogue converter is available as option.
- Analog output signal 4-20 mA.
- F/A-converter must be mounted externally. Technical data
Supply voltage DC 24 V (12-50 V)
HD art. no: 576 4057-001
Power consumption 3W
Operation temp. -20°C...+60°C
Humidity 0-90% RH, non condens-
ing
Temp. coefficient <0,01%/°C
Accuracy better than 0.3%
Resolution 0.1%
Mounting NS35 DIN rail
Size w45 x d70 d h117 mm
Electrical connections
Pulse input:
- Input high Vin > 15 V
- Input low Vin < 6 V
4-20mA output max. output load 500 Ohms
SW1
EMC approval EN 50081-1, EN 50082-2 SW2-1 on
Safety EN 60730 SW2-2 off
LED1 power on
Settings of SW1 for different type of

encoders and rpm range
Rpm for 4-20mA signal
Settings SW1 1000 ppr 3600 ppr

0 0 - 0,1 rpm 0 - 0,03 rpm
1 0 - 0,2 rpm 0 - 0,06 rpm
2 0 - 0,5 rpm 0 - 0,14 rpm Connection diagram
3 0 - 1,0 rpm 0 - 0,28 rpm
4 0 - 2,0 rpm 0 - 0,56 rpm
5 0 - 5,0 rpm 0 - 1,39 rpm +24 V (15-30 V)
6 0 - 10,0 rpm 0 - 2,78 rpm 0V
7 0 - 20,0 rpm 0 - 5,56 rpm
8 0 - 6,0 rpm 0 - 1,67 rpm
Encoder
9 0- 12,0 rpm 0 - 3,33 rpm

A 0 - 30,0 rpm 0 - 8,33 rpm
4-20 mA out
B 0 - 60,0 rpm 0 - 16,67 rpm
C 0 - 120,0 rpm 0 - 33,33 rpm F/A 4-20 mA ret.
D 0 - 300,0 rpm 0 - 83,33 rpm
E 0 - 600,0 rpm 0 - 166,67 rpm
F 0 - 1200,0 rpm 0 - 333,33 rpm
1 2 3 4 5 6 7 8
+0,009
635 M20 (40x)
68 - 0,021
A +0,00052 (25,000) A
(2,677 -0,00066)
(1,417)
(1,575)
A-A
36
40
1250
(49,213)
1330
(52,362)
1721
(67,756)
B B
R410
(16,142)
(12,070)
C
307
C
A A
19
(0,748) (29 742
,21
3)
D D
B
57 485 429
(2,244) (19,080) (16,890)
(17,717)
(21,457 -0,277)
+0,273

450
without notice or obligation, unless certified

545 ±7
150
E referring to a certain purchase order. E
(5,906)
Information contained herein should be confirmed
Figures within brackets indicate Item No. Qty Article No. Material, type, etc Dimensions Name of item
measurements in inches. Tolerances for length, corner radii,

Part of Weight kg
Reference
according to
SS-ISO 2768-1, class m Scale Preceding drawing no Control code
40
Other not indicated tol. 4 (0,157) SS-ISO 965, class 6.
Other not indicated tol. 1:5
(0,787)
Cad type Sheet size Drawn by Description (English) Prod group

(1,575) TORQUE ARM TCA40
20
210
Weight: 128 kg / 282 lb (arm) SW A2 Knight/DVN A00A
(8,268) Accepted for prod by Iss by Dept. Year Week Description (Own language) Type design/group
135 Weight: 34 kg / 75 lb (Piv.att.) D52 01 24 MOMENTARM DIM.RITN. TCA 40 F

(5,315) Drawing checked by Rev ind Sheet
Similar drawing No.
D522/TKN 1
B-B
Rev.Ind. Revision Appd. Year Week
Design checked by
D52/BLL 278 5016 No. of sheets
1 TCA 40
1 2 3 4 5 6 7 8
PBC POWER UNIT MANUAL
Installation and
Maintenance Manual
PBC
Preface Installation and Maintenance Manual, Power Unit PBC
Preface
Hägglunds Drives is one of the world’s leading manufacturers of low speed,
high torque and heavy-duty hydraulic drive systems. We supply a durable
drive system that will work under the toughest conditions with a minimum
level of maintenance requirements. We have industrial and marine custom-
ers all over the world. They know that when they seek solutions, support or
service, they can trust Hägglunds Drives to be there. The Hägglunds Drives
main office and manufacturing plant is located in Mellansel, Sweden. In
addition, there are sales and service offices in 40 countries worldwide.
Our high quality drive systems are based upon our unique hydraulic piston
motors, which were developed through experience accumulated over 30
years in marine and industrial areas. Today this ongoing development work
has resulted in our PBC power unit product line. This is what powers our
drive systems. New, as well as established technical solutions contribute to
the creation of this product. The most desirable features and operating reli-
ability have been designed into this power unit, PBC.

of the PBC. In order to find particular information, just search for the appli-
cable section as listed in the table of contents. However, changes in the
equipment may occur. Therefore, we reserve the right to introduce amend-
ments in the manual, as we deem necessary without notice or obligations.
Before starting the installation and/or maintenance, the manual must be read
and thoroughly understood in all respects. All involved personnel shall read
and acknowledge the safety precautions that are stated in section 1.1.
The content in this manual is subject to change without notice or

obligation. Therefore, information contained herein should always
be confirmed with Hägglunds Drives or its representatives.
Original AM326-1A 1999
2
Installation and Maintenance Manual, Power Unit PBC Contents
Contents
1. GENERAL ........................................................................................................................ 4
1.1 Safety precautions ........................................................................................................................4
1.2 Operating principle ........................................................................................................................6
2. TECHNICAL DATA .......................................................................................................... 7
2.1 Operating conditions .....................................................................................................................7
2.2 Cooling water ................................................................................................................................7
2.3 Requirements for hydraulic fluid cleanliness .................................................................................7
2.4 Choice of hydraulic fluid ................................................................................................................8
2.5 Power unit monitoring....................................................................................................................9
3. HANDLING OF THE PACKED POWER UNIT .............................................................. 10
3.1 Storage of the packed power unit ................................................................................................10
3.2 Lifting the packed power unit .......................................................................................................10
4. INSTALLATION ............................................................................................................. 11
4.1 Installation directions ................................................................................................................... 11
4.2 Lifting methods and weights ........................................................................................................12
4.3 Positioning the power unit ...........................................................................................................13
4.4 Mounting of the cabinet feet ........................................................................................................14
4.5 Mounting of electric motor ...........................................................................................................14
4.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................15
4.7 Hydraulic connections .................................................................................................................15
4.8 Electric connections ....................................................................................................................16
4.9 Pipe work ....................................................................................................................................16
4.10 Extra filtration prior to start up ...................................................................................................19
4.11 Commissioning......................................................................................................... 20
4.11.1 Prior to commissioning ...........................................................................................................20
4.11.2 Filling up the system with hydraulic fluid .................................................................................20
4.11.3 Initial start up procedure .........................................................................................................22
4.12 Pump settings and adjustments ................................................................................................24
5. PREVENTIVE MAINTENANCE ..................................................................................... 25
5.1 Maintenance log ..........................................................................................................................25
5.2 Maintenance chart .......................................................................................................................25
5.3 Filter change ...............................................................................................................................26
5.4 Inspection of hydraulic fluid .........................................................................................................27
5.5 Lubrication of electric motor ........................................................................................................28
5.6 Air breather change .....................................................................................................................28
5.7 Cleaning of Air-Oil cooler.............................................................................................................29
5.8 Power unit out of service .............................................................................................................29
6. CORRECTIVE MAINTENANCE .................................................................................... 29
6.1 Common ......................................................................................................................................29
6.2 Change of hydraulic pump/electric motor assembly ....................................................................30
6.3 Troubleshooting ...........................................................................................................................31
7. DISPOSING OF POWER UNIT ..................................................................................... 32
3
General Installation and Maintenance Manual, Power Unit PBC
1. GENERAL
It is of extreme importance that the safety precautions are always followed. If you are unsure about
anything, please contact your nearest Hägglunds Drives representative for advice.
Warning signs
In this manual, you will find the following signs, which indicate a potential hazard that can or will cause
personal injury or substantial property damage. There are three levels of hazard classification:
DANGER
! DANGER is used to indicate the presence of a hazard, which will
cause severe personal injury, death, or substantial property damage
if the warning is ignored.
WARNING
! WARNING is used to indicate the presence of a hazard, which can
!
CAUTION
CAUTION is used to indicate the presence of a hazard, which will or
can cause minor personal injury or property damage if the warning is
ignored.
General
Limit access to the equipment only to authorized personnel. Only perform measures on the PBC when
you are completely familiar with the function of the power unit (including the control system) as well as
the complete drive.
Service and repair of the electrical, hydraulic, and the mechanical functions require professional ser-
vice personnel who are aware of risks involved.
Safety equipment necessary for the prevention of accidents during the mounting and maintenance
must be used in accordance with the regulations prevailing in the local country.
4
Installation and Maintenance Manual, Power Unit PBC General
Prior to troubleshooting
• Use the order code and other attached technical documentation to identify the features of your
unique power unit and system.
• Read the attached technical documentation (this manual included) and make yourself familiar
with the PBC (control system included) as well as the complete drive.
• Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection.
• Always ensure that there is no accumulated energy in the system prior to maintenance.
• Ensure that all electric power is off and locked out.
• Ensure that there is no entrapped pressure in the hydraulic system.
• Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,
for example loads on the shaft or winch drum.
• If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be
secured, or in the rest position (hanging load).
• Ensure that all accumulators are discharged.
Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in accordance with the
regulations prevailing in the local country.
All electrical supply levels shall be within the limits that the equipment is constructed for, see technical
documentation and maximum rating plates.
Mounting
Carefully follow the instructions and be aware of the large weights and forces involved during lifting.
Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause
personal injury or property damage.
Before starting up
Before starting up new, rebuilt or serviced drive systems, all accessories and safety arrangement
functions need to be checked and tested.
Maintenance and service
Follow the maintenance intervals for your specific PBC or the maximum intervals on the maintenance
chart (section 5.2 “Maintenance Chart”) and keep a maintenance log. Regular and correct mainte-
nance is necessary for reliable and safe operation.
Only use spare parts recommended and supplied by the Hägglunds Drives organization.
Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment.
Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain
noxious contaminates. We recommend using the service of a professional oil company for supply and
disposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.
Bell housing
Note that there are rotating parts inside the bell housing during operation. Be careful during inspection
through the inspection hole. Replace inspection cover when finished.
Hot surfaces
Temperatures in the hydraulic system above 158° F (70° C) will create hot surfaces.
Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an emergency situa-
tion. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.
5
Operating Principle Installation and Maintenance Manual, Power Unit PBC
1.2 Operating principle 17
18
Main components
1. Hydraulic pump AIR
FLOW
2. Drain valve 20
3. Sight glass 19
8
4. Charge pressure gauge
5. Servo pressure gauge
6. Main pressure gauge ‘B’ port
7. Main pressure gauge ‘A’ port
8. Air breather 11
11 6
9. Drain filter 7 4
10. Return filter 5 5
4 7
11. Electric motor 6
12. Filter switch 12 3
13. Suction valve limit switch 14

12
14
12
14. Charge pressure switch 15 9
15. Electrohydraulic stroker 10 10

16
16. Oil heater 13
17. Terminal box 15
18. Oil Cooler 1 2

19. Temperature switch D D
20. Level switch
Note: Changes from the picture and

main components table above may
occur.
Function
The function of the power unit is to provide the hydraulic motor(s) (or other hydraulic systems) with the
required flow of oil and pressure at the right time. All included parts are assembled in one (or more)
compact cabinet(s). The PBC has one or more pumps driven by one or more electric motors. The
main pump is an axial piston pump with variable displacement for closed loop systems. The electric
motor is totally enclosed fan cooled. Two different control systems are available.
Control systems available
Spider: A small, compact and configurable con- The PBC is a very flexible product with a wide
trol system. It can health monitor the power unit range of options. This makes it possible to select
and can control one or two pumps with three pre- a standard power unit to fulfill the features needed
programmed functions: in many different applications. This installation and
maintenance manual is intended to cover all stan-
• Basic, for most of our drives can be config-
dard options. It may not cover all details on spe-
ured for speed feedback control and power
cial power units, which differ from the standard PBC
limitation.
concept.
• Shredder, for shredder applications.
• Synchro, for friction and synchronized drives.
It is important to check the
MCA: For special control functions, normally based other attached technical
on PLC and control cards.
Note: It is also possible to control the PBC from
!
CAUTION
documentation to identify
the features of your unique
external control systems provided by the customer. power unit.
6
Installation and Maintenance Manual, Power Unit PBC Technical Data
2. TECHNICAL DATA
2.1 Operating conditions
The standard PBC unit is designed for the conditions listed below. If the requirements are outside of
the conditions listed below, contact your Hägglunds Drives representative with your specific require-
ments for special design considerations.
Ambient temperature: Minimum 32° F (0° C) to a maximum 85° F (30° C).
Altitude: Maximum 3,300 feet (1000 m).
Classified Location: Unit is designed for a standard location. Units can be built for use in
classified hazardous locations. Contact your Hägglunds Drives representative for more details.
2.2 Cooling water

The cooling system is primarily designed to operate with clean water.
When there are particles in the water, larger than 0.02 in. (0.5 mm), a water filter must be used.
It is important to:
• Maintain the water filter (if any) in a correct way, this is to get the required flow of water through
the water oil cooler.
• Ensure you have the required flow, pressure and temperature of the cooling water (see attached
technical documentation).
• Check the temperature in the hydraulic system, according to the maintenance intervals for your
specific power unit or the maximum intervals on the maintenance chart.
• Clean the cooling system if the temperature in the hydraulic system is above the specified limits.
• Clean and empty the cooling system (waterside) before periods of inactivity (especially if the
cooling water is not totally clean).
If cooling capacity is too low, the service life of hydraulic motor, the main
components in power unit, and the hydraulic fluid will be reduced.
2.3 Requirements for hydraulic fluid cleanliness

The PBC is equipped with filters on the drain and return line(s). In order to obtain rated service life it is
important to follow recommendations concerning cleanliness levels and maintenance requirements.
Cleanliness recommendations
• The system must be flushed before start up (section 4.11 “Flushing before start up”).
• When filling the tank with hydraulic fluid it is important to fill through the quick connection (sec-
tion 4.11.2 “Filling up the system with hydraulic fluid”).
• The particle contamination level in the system should not exceed ISO/DIS 4406 16/13 (NAS
1638, class 7).
• The water content shall be <0.1% and in individual applications with high demands for service
life, <0.05%.
• Always use filter elements recommended and supplied by the Hägglunds Drives organization.
• The hydraulic fluid should be analyzed according to the special maintenance intervals for your
specific PBC or the maximum intervals on the maintenance chart (section 5.2 “Maintenance
Chart”). You should be particularly careful when removing equipment for repairs or maintenance
so that dirt cannot enter the system. Components should be cleaned and free of dirt prior to
disassembly.
Do not reuse hydraulic fluid that has leaked out.
7
Technical Data Installation and Maintenance Manual, Power Unit PBC

The power unit is primarily designed to operate on conventional petroleum based hydraulic fluids.
Consultation with a Hägglunds Drives service representative is recommended when choosing your
hydraulic fluid.
The hydraulic fluid has to fulfill the following requirements:
• Have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354).
• Contain inhibitors to prevent oxidation, corrosion and foaming.
• Have a viscosity within the prescribed interval for both PBC (see below) and hydraulic motor at
operating temperature (measured in the motor case).
• Have a water content of <0.1% and in individual applications with high demands for service life,
<0.05%.
For other hydraulic fluids, please contact your Hägglunds Drives representative when:
• You may need other seals within the pump and other components.
• The service life, maximum pressure and maximum speed for the pumps may be reduced.
Viscosity limits RECOMMENDED VISCOSITY at

Recommended 100 VI operating temperature 40-150
Viscosity index VI For operation with large
150 VI cSt (187-720 SSU)
temperature difference
Minimum continuous 40 cSt (187 SSU) At cold start the maximum
Minimum intermittent 20 cSt (98 SSU) permissible viscosity is 1600
Viscosity v cSt (7400 SSU) run with low
Maximum continuous 150 cSt (720 SSU)
Maximum intermittent 1600 cSt (7400 SSU) pressure and low flow.
Temperature ºF (measured in the motor case)

50 100 150 200
1000 Viscosity v SSU
Viscosity v cSt
150 720
100 RECOMMENDED
VISCOSITY
40 187
VG VG
VG 100 150
46
VG
68
10
0 10 20 30 40 50 60 70 80 90 100
Temperature ºC (measured in the motor case)
• Check caution sign on container or consult the supplier.

• Avoid prolonged contact of hydraulic fluid with your skin.
!
WARNING
• Use services of a professional oil supplier for disposal of used fluids,
and filter elements.
• Never dump hydraulic fluid into drainage or water supplies.
• Clean hydraulic fluid spills from floors immediately to prevent injury.
8
2.5 Power unit monitoring

If the monitoring function is not included in a control system supplied with the PBC, the following
function must be fulfilled in the system.
MONITORING SWITCHES EXTERNAL FUNCTIONS
POWER UNIT
Maximum oil
Temperature switch
1
Minimum oil
Temperature switch
1
Minimum oil
level switch
Closed suction
1 1 STOP HYDRAULIC MOTOR
line switch
1
1s 0s STOP ELECTRIC MOTOR
Low charge Time delay off
pressure switch Time delay on
0s 0.5s
1
5s 0s
&
Time delay on
Electric motor started
Warning oil
temperature switch
1
Low oil
level switch
1
Return filter Time delay off
switch
Drain filter
0s 5s
1 1 WARNING INDICATION
Time delay off
switch
0s 5s
1
High pressure Time delay off
switch
0s 5s
1
The monitoring of the power unit switches are grouped in two levels according to the above logic
diagram.
The warning indication is to inform about a problem in the PBC but does not need an immediate action.
The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulic
motor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stop
the electric motor.
The low charge pressure switch must be interlocked during stop and start-up of the electric motor, to
avoid alarm and give the pump time to build up the charge pressure after start.
9
3. HANDLING OF THE PACKED POWER UNIT

3.1 Storage of the packed power unit
At delivery, the hydraulic components are protected internally by an oil film (containing rust preventing
additives). This provides sufficient protection for indoor storage in air conditioned premises for up to
12 months.
The PBC and included parts should be stored indoors, in dry, vibration free and dust free conditions. It
should not be stored for more than three months in non-air conditioned premises. (That also includes
parts belonging to the power unit that are delivered separately).
Place the power unit where it will not be exposed to direct sunlight or extreme cold to avoid condensa-
tion.
If storage time exceeds the above mentioned limits, then the power
unit must be operated so that the hydraulic system is lubricated with
new fluid. (section 5.8 “Power unit out of service”)
3.2 Lifting the packed power unit
The packed power unit is labeled with center of gravity and

weight. Normally the power unit package is designed for forklift
truck handling.
Center of Gravity Label
• Center of gravity is high, see label on the power unit.
!
CAUTION
•
•
Avoid rapid acceleration, deceleration and turns while
moving the equipment.
Position the forks according to the instructions below.
Lifting with fork lift

• The absolute minimum required fork length is 51.2 in. (1300 mm).
• The minimum distance between the forks is 31.5 in. (800 mm) for a 1 pump PBC and 43.3 in.
(1100 mm) for a 2 pump power unit.
• Position forks with regards to the center of gravity.
Parts that are delivered separately
• The package is always labeled with the weight.
• Packages on shipping skids are designed for forklift truck handling only.
• Some other packages may be lifted with a lifting crane, always check the label on the package.
• Do not stand underneath hanging load.

!
DANGER
• Use only lifting equipment adapted to the weight on the
label of the package.
10
Installation and Maintenance Manual, Power Unit PBC Installation
4. INSTALLATION
4.1 Installation directions
If the PBC is to work properly, it must be installed in accordance with these instructions. The conditions
the unit will operate in must be taken into consideration.
Improper installation, not following the instructions in this manual and in the attached technical docu-
mentation, may affect the function and/or the service life of the power unit. It is important that the
safety precautions mentioned in this manual are always followed.
In order to achieve air circulation requirements, you should never

place the power unit directly against a wall or similar obstruction. If
this is the case then contact your Hägglunds Drives representative.
PAC 100/200/300/400 PAC 200D/400D/600/800
H1
H1
B2 A2 B2
H2
H2
B1 M A1 B1 M
A3 A3
Cabinet Size 1 2 3 4 5
Type PBC 100 PBC 300 PBC 400D
PBC 200D PBC 800
Dimension PBC 200 PBC 400 PBC 600
H1 84 7/8 in. (2156mm) 84 7/8 in. (2156mm) 123 1/2 in. (3138mm) 123 1/2 in. (3138mm) 126 in. (3200mm)
H2 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 3 in. (76mm)
B1 55 1/8 in. (1400mm) 82 5/8 in. (2099mm) 66 in. (1676mm) 105 in. (2667mm) 121 3/4 in. (3092mm)
A1 39 3/8 in. (1000mm) 39 3/8 in. (1000mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm) 53 in. (1346mm)
A3 82 in. (2083mm) 111 in. (2820mm) 96 in. (2439mm) 138 in. (3505mm) 154 3/4 in. (3931mm)
M 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC
11
Installation Installation and Maintenance Manual, Power Unit PBC
Placing the power unit

Take into consideration the following when placing the PBC unit:
• Place on a firm level foundation to avoid vibrations.
• Ease of maintenance and service (section 4.3 “Positioning the power unit”).
• Protect from weather, airborne sprays, heavy contamination and radiated heat.
• Ensure proper ventilation for cooling purposes and for the electric motor and air-oil cooler.
• Minimize pipe runs.
Clamp each pipe in the pipe run separately and attach it to a firm foundation to avoid vibration. The
main connections from the PBC must always be fitted to the piping with hoses.
4.2 Lifting methods and weights

Lifting with ropes and/or chains
Lift the PBC with the electric motors removed and the ropes and/or chains at a maximum lifting angle
90°.
• The minimum distance between the forks is 31.5 in. (800 mm) for a 1 pump power unit and 43.3
in. (1100 mm) for a 2 pump power unit.
The total weight of the power

unit is stamped on the rating
plate located on the Junction
box door.
Always use all four lifting points
when lifting the power unit.
MAX
90˚ O
• Do not stand underneath a hanging load.

• Use only lifting equipment adapted to the weight of the power unit
! •
(check rating plate).
Do not lift the power unit with hydraulic fluid in the tank, or with the
DANGER front bar disassembled.
12
Electric Motor Denison Pumps Air-Oil Cooler

Power HP (kW) Weight* lb (kg) Model Weight lb (kg) Size Weight lb (kg)
30 (22) 365 (165) P6S 335 (152) AOVH-30 190 (86)
40 (30) 490 (222) P7S 335 (152) AOVH-40 350 (159)
50 (37) 560 (254) P11S 484 (220) AOL-950 221 (100)
60 (45) 800 (363) P14S 484 (220) AOL-1200 296 (134)
75 (56) 840 (380) P24S 753 (342) AOL-1600 355 (161)
100 (75) 1160 (526) P30S 786 (357)
125 (93) 1540 (698)
150 (112) 1730 (785)
200 (149) 1750 (794)
250 (186) 1925 (873)
*This is the weight for a standard electrical
300 (224) 2500 (1134)
motor, more accurate weight for a specific
350 (261) 2650 (1202)
motor can be found on the rating plate.
400 (298) 3500 (1587)
450 (336) 4300 (1950)
4.3 Positioning the power unit

The following minimum space must be left around the PBC, to ensure proper ventilation and provide
sufficient working space for easier maintenance. Heavier maintenance such as changing the pump/
motor assembly will demand larger working space.
It is important that all pipes for both water and hydraulics are mounted properly to allow for sufficient
working space for maintenance.
PBC 100/200/300/400 PBC 200D/400D/600/800

FLOOR OUTLINE WITHOUT AIR COOLER
FLOOR OUTLINE WITH AIR COOLER

AIR AIR
32 [813mm] FLOW 32 [813mm] FLOW
32 [813mm] 32 [813mm]
12 [305mm] 32 [818mm] 12 [305mm]

32 [820mm]
32 [813mm] 32 [813mm]
FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM
• If air-oil cooler is mounted at a location other than on the power unit,
DANGER
! •
•
beware that the cooler will start without notice and has sharp edges
Beware of airborne particles in the outgoing air flow
If the air-oil cooler becomes loose it can cause severe personal injury.
13
4.4 Mounting of the cabinet feet

The cabinet feet (optional) minimizes the vibrations and makes it easier to level the PBC. They are
delivered separately within the cabinet and have to be mounted according to the following instructions:
1. Mount the cabinet feet before filling hydraulic fluid in the tank.
2. Mount the cabinet feet before installing the electric motor(s), if they are delivered separately or
supplied by the customer.
3. Lift the power unit according to instructions in this manual (section 3.2 “Lifting the packed power
unit”). Be sure to follow the safety precautions.
4. Mount the cabinet feet according to the drawing below.
5. Level the PBC by the adjusting screws.
[25mm-38mm]
1 [13mm]
ADJUSTABLE
Be careful while mounting the
2
2
1
! cabinet feet. Follow the safety
1-1
precautions in section “Lifting
WARNING methods and weights”
4.5 Mounting of electric motor

In certain cases the electric motor(s) are delivered separately. The following instructions are appli-
cable for these cases only.
3. Unpack the electric motor(s)
Unpack the electric motor and check it for external damage. Also, check that all rating plate data is the
same as in the attached technical documentation.
4. Check the shaft coupling(s)
Check that the axial shaft coupling clearance is in conformance with the coupling manufacturer speci-
fications.
5. Lift the electric motor
First, use the top mounted lifting ear and lift to position the electric motor vertically. Then lift with all
lifting ears. Never let the electric motor stand on the shaft coupling.
Two different types of lifting equipment may be needed in order to lift the electric motor.
6. Mount the electric motor in the power unit
Lift the electric motor into the PBC. It is important that it is hanging perpendicular. Fit the shaft
coupling through inspection hole into the nylon star coupling without causing any damage to it. The
connection box on the electric motor must be positioned as shown in the picture on page 6 (section 1.2
“Operating principle”). Lower motor to a position approximately 0.2 in. (5 mm) above bell housing.
Place greased bolts in the holes and tighten by hand.
7. Tighten bolts to the bell housing
Inspect that there is an axial clearance on the shaft coupling through the inspection hole in the bell
housing, and then tighten the attached bolts to the bell housing.
8. Electric motor connections
For connection of electric motor refer to page 18 (section 4.9 “Electric connections”).
14
!
DANGER
•
•
•
Use all lifting ears when the electric motor is hanging free.
Use only lifting equipment adapted to the weight on the rating plate.
No hands/fingers between electric motor and bell housing during assembly.
4.6 Mounting of air-oil cooler and cabinet ventilation

Normally the air-oil cooler is delivered separately and is to be mounted on the power unit. The follow-
ing instructions are applicable for coolers that are shipped loose. (Changes may occur from the draw-
ing and/or technical documentation.)
• Mount brackets with attached screws (in the drilled holes) on the PBC according to the installa-
tion drawing in attached technical documentation.
• Lift up air-oil cooler. Never lift using the electric motor.
• Mount the air-oil cooler on the brackets with the attached screws.
• Check that all screws are properly tightened.
• Connect the attached hydraulic hoses. Note that ‘Oil In’ at the power unit shall be connected to
‘Oil Out’ at the air-oil cooler and vice versa. The coupling protections must be kept on until final
assembly to avoid the entrance of dirt.
• For electric connections, couplings and hoses, see respective section.
• Air-oil cooler must always be connected with flexible hoses.
4.7 Hydraulic connections

During mounting of the hydraulic connections the following points must be kept in mind:
• The coupling protections must be kept on until final assembly.
• It is important that all pipes are properly mounted to allow for sufficient working space for mainte-
nance of the PBC.
• Always use hoses to connect pump with piping.
Professional service personnel aware of risks involved must perform all measurements in the hydrau-
lic system. Be especially cautious when connecting the A and B connections (high pressure).
*SAE-flange J 518, code 62, 414 bar

Denison Pump Main A & B Threaded holes **
(6000 psi) 90° connections have to
Size Connections * Thread Depth be used.
P6/P7
1 1/2" 5/8-11 UNC ** 4 screws needed/connection,
P11/P14 1.06 in. (27 mm) preferably with Grade 8 hex/socket
P24/P30 2" 3/4-10 UNC head cap screws.
Cabinet Dimension connection

size Power Unit
Drain line Flushing
Do not make any measurements 1 PBC 100/200
!
DANGER
or perform maintenance if the
hydraulic system is pressurized.
2
3
4
PBC 200D
PBC 300/400
PBC 400D/600
1 1/4" SAE
code 61 flange
1" SAE female
5 PBC 800
15
4.8 Electric connections

Safety precautions
• All electric equipment is intended to be installed and used by qualified personnel who are familiar
with relevant safety requirements.
• Safety equipment necessary for the prevention of accidents at the mounting and operating site
must be provided in accordance with the regulations prevailing in the local country.
• Grounding shall be carried out according to local regulations before the electric equipment is
connected to the main voltage.
• All electrical supply levels must be within the limits that the equipment is constructed for, see
technical documentation and maximum rating plate.
Junction box
Connect the cables on the screw terminals inside the junction box. Make the connections according to
the electrical drawing in the attached technical documentation.
Air-oil cooler
The voltage and connection are stamped on the rating plate. Connect the electric motor to the electri-
cal supply. Check direction of rotation, see air stream arrow in section 1.2.
Electric motor
Major voltage connection according to designation on the rating plate.
Installation of electrical equipment must in most
4.9 Pipe work DANGER

! countries be installed by licensed electricians
(reference local laws and regulations).
When sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of at
least 4 times the maximum system pressure should be used for the tensile strength. Keep in mind that
the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system
should generally be kept to a minimum but there are exceptions in certain applications. Contact a
Hägglunds Drives service representative for more information.
Hydraulic pipes
The hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.
Pressure test
A pressure test to 1 1/2 times the maximum working pressure should be performed on the main lines to
check for possible leakage.
Pressure tests on the main lines are best carried out using a hydraulic hand pump.
Hoses
To avoid damage caused by vibrations it is important that the PBC and the motor be connected to
pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order to obtain a small compres-
sion volume. Nevertheless, allowance must be made for the minimum permissible bending radius
according to the data provided by the supplier of the hose. Allowance must also be made for the flow
velocities listed under “Pipe sizes.”
Pipe flushing
The piping system must be flushed with an adequately sized flushing pump prior to starting up the PBC
unit to remove contamination introduced during assembly and/or welding. Please contact a Hägglunds
Drives service representative for proper cleaning and flushing procedure.
16
Pipe sizes
It is important that lines between the main connections of the motor and PBC are as short as possible.
This gives the following advantages:
1. Small compression volume in the hydraulic system.
This is particularly important in hydraulic systems with large and rapid load variations, and in
drives, where high speed accuracy is essential.
2. Small power losses in the hydraulic system.
3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.
For a normal hydraulic system, the total pressure drop in the pressure and return line must
not be more than 5 percent of the normal working pressure.
The following flow rates are recommended values and should not be exceeded:
Main lines 15 ft/s (4.5 m/s) Drain lines 5 ft/s (1.0 m/s)
4. Lower noise level.
In certain systems, where very small compression volumes are required, higher flow rates
are acceptable with possible increase in noise. Contact a Hägglunds Drives representative
in these specific cases.
When dimensioning hose and pipe lengths between the drain connections of the motor and the PBC,
keep in mind that the total pressure drop to the drain connections of the motor must not exceed 14.5
PSI (1 bar). The pressure drop through the PBC is 7.25 PSI (0.5 bar).
Pipe couplings
It is essential that a tight and pressure rated coupling is chosen.
The following types of coupling are recommended:
Non-welded couplings are preferred
Non welded couplings provide the most clean piping installation as compared to a welded pipe system.
Welded couplings (socket or butt type)
When using welded couplings, the pipes should be machined, normalized, and pickled. The pipes
must then be brushed, rinsed internally and blown clean before flushing.
Pipe coupling
Type collar coupling as per SAE J 514.
Pipe clamps
Pipes should be clamped with uniformly spaced clamps.
The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between
1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) for
pipes with outside diameters greater than 1 1/2 in. (38 mm).
In addition, the pipes must be clamped immediately before and after a bend. The pipes must be
clamped immediately before transition to a hose as well.
The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.
The pipe clamps must be of a type permitting a certain amount of axial and radial motion in the clamped
joint and have good vibration-absorbing properties.
17
Storage of included components

The included components must be stored in the same way as the power unit (section 3.1 “Storage of
the packed power unit”). Notice that the packing must not be removed during storage.
Do not work on the pipe system if the hydraulic system is pressurized.
DANGER
! Use necessary safety equipment during installation of the pipe system.
Usual safety requirements for each step must be followed.
Handling of fittings
Inspect the sealing surfaces on the couplings visually before mounting. It must be free of any dam-
ages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it has
nicks on it inspect it visually. Check that the seal (if any) is in its right position, free from cracks and that
it is saturated with oil.
The protection and packing on the fittings must be kept on until final assembly.
Flange fittings Clamps

The screws must be tightened crosswise. The normal distance between clamps:
JIC-fittings (SAE J514, ISO 8434) • Pipe diameter less than 1 in. (25.4 mm)
Tighten fittings by hand, then tighten 1/4 to 1/2 turn space clamps 60-80 in. (1524-2032 mm)
more using an appropriate wrench. Do not over apart.
tighten the fittings. • Pipe diameter greater than 1 in. (25.4 mm)
space clamps 80-100 in. (2032-2540 mm)
Use correct size tools, fittings can be damaged apart.
and difficult to remove. The pipes must be clamped immediately before
Be aware that all fittings may expand because of as well as after a bend and immediately before
heat and vibrations. All fittings must be checked transition to a hose.
and retightened. Welded fittings
Contact your Hägglunds Drives representative.
Mounting of hoses
Ensure that hoses are not stressed or twisted on
installation, to prevent premature failure. Bend
radius should conform to manufacturer recommen-
dations.
Pressure tests
Pressure tests should always take place before
flushing in order to release contamination by
stresses introduced by the pressure. The main
lines must be pressure and leakage tested to a
static pressure of 1 1/2 times the maximum ex-
pected system pressure (not above bursting pres-
sure). The hydraulic motor and power unit must
be disconnected or protected by closed valves
Cleaning during the pressure tests.
The pipes and hoses should be pre-cleaned, in-
spected and sealed by the supplier. If the pipes
are field bent and installed the overall system must
be flushed to reach the required cleanliness level.
18
Example of a pipe installation which

is convenient and could easily be
sound insulated
O
4.10 Extra filtration prior to start up
HYDRAULIC MOTOR
A pressure filter and check valve has to be con-
nected to the main line at the power unit. This
filter is connected on the return side of the drive Hoses
pump. connected
together
Recommended filtration degree ß10 = 75 or bet-
ter. Flow Direction
The size of the filter should be matched to that of

the pump concerned, so that the pressure drop
across the filter is not excessive and that the maxi-
Filter
mum pressure/flow ratings for the filter is not ex-
ceeded. Check valve
The main lines should be connected together at

the motor enabling the entire system to be filtered,
see the figure to the right.
The maximum flow from the power unit should be
filtered through the main circuit for at least two
hours on small installations and considerably POWER UNIT
longer on larger ones.
Use extreme caution to ensure pump is stroked in Use a check valve sized for the oil flow.
synchronization with free flow direction of check When using the main pump the maximum
valve. pressure should be reduced.
19
4.11 Commissioning
4.11.1 Prior to commissioning
• Read and understand this complete manual and the other attached technical documentation.
• Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,
and that the degree of filtration of the filters are according to the data in the technical documen-
tation.
• Check that the coupling between the electric motor and pump is properly mounted.
• Check that the pre charge pressure in the accumulator (optional) is in accordance with the
technical documentation.
Cleanliness
• The hydraulic system must be flushed and thoroughly cleaned on the inside.
• If you are uncertain about the cleanliness of the system, it must be checked prior to filling with
oil.
Pipe work
• Are the couplings properly tightened?
• Is the pipe work properly cleaned?
• Is the pipe work mounted free of stress?
• Are the lines in accordance with installation drawing/piping plan?
Electrical System
• Check that electric motor(s) and control system and other electrical components are connected
to the correct voltages.
• Check the function of electrical components and monitoring system manually. Instruments that
cannot be actuated can be checked for correct wiring and possibly operated manually. Level
switch and indication should be checked when filling the tank.
4.11.2 Filling up the system with hydraulic fluid

Before filling
• Check that the correct type and quality of
hydraulic fluid is used. Do not mix different
types of hydraulic fluid without first checking
with manufacturers.
• Check that the barrel with hydraulic fluid and
tank/hoses are not contaminated with water
or other substances.
• Follow instructions for handling of couplings
and hoses (section 4.9 “Pipework”).
• Plug the drain connection D (motor) to pre-
vent non filtered fluid being filled into the
hydraulic motor case, when filling the system
the first time. 'D1' DRAIN
• Fill the pump case with filtered hydraulic oil PORT
through the ‘D1’ port on the pump. When
finished filling the pump case, replace the
plug/hose connected to the ‘D1’ port.
20
Filling
Use a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.
New fluid is normally not filtered and will introduce dirt into the system, the
fluid must therefore always be filled through a filter. Never pour hydraulic
fluid into the tank through the air breather filter.
Always pump the fluid in through the quick connection that is marked appropriately. The quick connec-
tion is a completely rustproof quick release coupling, see figure below. The fluid filled into the system
will be filtered through the drain filter for better results.
The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gauge
on tank before starting for the first time.
Check the function of the level switch and indication during filling up of the tank.
ON FILL HOSE ON POWER UNIT
System is full when

hydraulic fluid is at 5/8 up
into the sight glass
RETURN FILTER
OIL FILL
CONNECTION
PUMP/MOTOR CASE
DRAIN FILTER
OIL HEATER
After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.
• Check caution sign on container and the warnings (section 2.4 “Choice
of hydraulic fluid”).
!
WARNING
•
•
Avoid prolonged contact of hydraulic fluid with your skin.
Clean hydraulic fluid spills from floors immediately to prevent personal
injury.
21
4.11.3 Initial start up procedure

Important Note!
• Make sure the driven system and driven machine is ready to run, warn all personnel in the area
that start up is in progress.
• Follow safety precautions in this manual (section 1.1 “Safety precautions”).
• Never operate the power unit with defective instruments or control elements.
• Keep flammable materials away from the power unit.
• During start-up period, the hydraulic system will be filtered to remove dirt particles, therefore
keep an eye on the filter indicator during the entire start up procedure.
On cold start up, the filters may indicate bypass. After a few minutes of operating, press down the
visual indicator to reset. If the indicators will not reset after system has reached operating tempera-
ture, filter element must be inspected and changed.
STEP 1 Immediately before starting
• Check fluid level in the tank and refill to about 0.79 in. (20 mm) below maximum level at visual
level gauge on tank (section 4.11.2 “Filling up the system with hydraulic fluid”).
• Check if any components need filling with clean hydraulic fluid, such as the pump case and
motor case.
• Check safety equipment.
• Check that all the prescribed steps (section 4.11.1 “Prior to commissioning”) have been carried
out.
• Make sure that all valves on the suction, pressure and inlet side of the pump, as well as any
valves on drain lines, are open.
• Check that cooling water is connected and turned on if a water-oil cooler is used.
For adjustments and settings on the control system (if any) see separate instruction in attached tech-
nical documentation.
STEP 2 Start with unloaded pump at short intervals
Starting of the PBC shall be carried out with a completely unloaded pump in short intervals.
• When the hydraulic fluid is cold, some restarts may be needed in order to raise the charge
pressure.
• Check that the charge pressure corresponds with data and settings on attached technical docu-
mentation.
• If OK, the pump may be allowed to come on stroke and introduce flow into the unloaded hydrau-
lic system.
• Flow and pressure should be limited until lines are purged of air.
Check that the charge pressure is still OK.
Immediately make sure that the ROTATION
pump has the correct direction

of rotation. Otherwise, the
pump will be damaged. The
correct direction of rotation is
evident from a sticker placed
under the electric motor, see
figure to the right.
22
STEP 3 Unloaded pump at longer intervals

Run for a period at no load condition until system is stable and control is established. Checking of the
oil level may be needed due to parts of the system having been filled with fluid.
• Check all interlocks. Check fluid level in the tank
• Check for unusual noises or vibrations.
• Check that the specified pressure level for charge pressure at the PBC is maintained in accor-
dance with the values stated on the hydraulic diagram in the attached technical documentation.
These pressure levels are preset at the factory and there is normally no need to readjust.
• Check for leakage points.
• Stop the electric motor.
• Correct any faults discovered in the points above.
• Check all connections, screws etc. and tighten if necessary.
• Restart when finished.
STEP 4 Loaded hydraulic system
The hydraulic system can be loaded when the hydraulic system function is satisfactory in unloaded
running condition.
• Gradually increase load pressure until proper operation is obtained.
• It may be necessary, at this point, to make adjustments to flow, ramp rates, etc.
• Cycle the system until normal operating temperature is reached.
STEP 5 Checking
• Check the function of the safety equipment.
• Check temperature in tank and closed loop. Check also that the cooler control is stable. If not,
investigate water supply, controls, air cooler, etc.
• Check that the pump compensator pressure control and pressure switches (optional) are set at
levels appropriate to the specific drive. Upon delivery, these pressure levels are set at the levels
specified by the customer and normally no readjustment will be necessary. The values are
stated in the technical documentation. System compensator can easily be checked by closing a
ball valve on the high pressure leg and stroking the pump until the pressure is showing on the
gauge.
• The working pressure must be checked to ensure that they correspond to the specified values.
STEP 6 Stop the electric motor
• Correct any faults discovered while performing the points of Step 5.
• Check the filter indicator. It is not unusual to change elements on commissioning as the system
is cleaning the dirt particles out. When changing filter elements carefully follow the instructions
(section 5.3 “Filter change”) to prevent introduction of dirt into the system. If there is still dirt in
the system, additional flushing is necessary in order to prevent premature failure of system
components.
• Remove waste fluid, scrap cabling, etc. to keep the area in and around the unit clean.
23
4.12 Pump settings and adjustments

Denison Gold Cup pump Working in high pressure areas
DANGER
! could be dangerous in case of
unforeseen failures.
P6S, P7S, P11S & P14S P24S & P30S
CHARGE PRESSURE
ADJUSTMENT
COMPENSATOR
CHARGE PRESSURE VALVE
ADJUSTMENT
View from the back View from the back Front view
Charge pressure and Pump compensator pressure level are set before the PBC leaves the factory and
consequently there is normally no need for readjustment. Always check the pressure levels in techni-
cal documentation. Professional service personnel familiar with the functions and risks involved
with the pump must perform setting of pressures on the pump(s). The pressures shall be set
during operation and with the system at operating temperature. Note that pressures can change with
different viscosity.
1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a
5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (on
the charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &
P11S/P14S & P24S and 261 psi (18 bar) for P30S.
If other charge pressures are to be set, contact a Hägglunds Drives representative for consultation.
2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook or
other technical documentation.
3. If the main pressure levels are to be increased: Make sure that the piping and machine
structure can take higher pressure/higher torque delivered from the hydraulic motor.
4. Compensator pressure adjustment: Dead head the pump, then activate or move the input
signal to the control so that pressure increases in the high pressure closed circuit to the pressure
limiter setting. The pressure limiter setting is reached when the pressure stops increasing and
remains steady at a given pressure level. (As shown on the gauges)
The pressure limiter setting for both A- and B-side is set on the compensator valve.
Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desired
pressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.
5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure
level in logbook or technical documentation.
24
Installation and Maintenance Manual, Power Unit PBC Maintenance
5. PREVENTIVE MAINTENANCE
5.1 Maintenance log
We recommend that a maintenance log be kept to record service/maintenance/repair, addition and
alteration of the equipment. Each note, observation or comment should be dated.
5.2 Maintenance chart

The maintenance of hydraulic systems is designed to prevent failure of the system and to keep the
system running efficiently according to specification. The specific procedures will depend on the na-
ture of the equipment, the environment it is working in and the duty cycle, keeping in mind the conse-
quences of a breakdown. To optimize the maintenance intervals a Life Cycle Cost (LCC) analysis is
recommended. Follow the safety precautions during the checkups (section 1.1 “Safety Precautions”).
Daily checks, first week after Frequent checks

commissioning • Unusual vibrations.
• Fluid leaks. • Unusual noises.
• Fluid level in the tank. • Fluid leaks.
• Operating temperature. • Fluid level in the tank.
• System pressure. • Is the unit relatively clean? Air flow paths
• System performance and general condition. unrestricted?
• Unusual noises. • Pressure levels normal - stable?
• Contamination indicators on the filters. • Actuator speeds normal - stable?
Pre-start checks (also daily) • Operating temperature.
• Fluid leaks. • Is the drive running smoothly?
• Fluid level in the tank. • Contamination indicators on the filters.
• Is the suction valve open?
• Contamination indicator on the filters.
25
Maintenance Installation and Maintenance Manual, Power Unit PBC
Scheduled maintenance
Planned maintenance at specific time intervals, including the following checks and actions:
• All points listed under frequent checks.
• Check all pressure levels.
• Check for stable temperature levels around the system.
• Drain water and sludge from the tank at the drain tap.
• Check the electric motor.
• Check the function of monitoring equipment/switches, etc.
• Clean areas where dirt is building up.
Note: never use a high pressure washing system to clean the power unit.
• Check the cables.
• Check accumulators (optional) for correct pre-charge.
• Check drain line flows and drain line oil condition.
• Check the hoses, couplings and pump(s), with regards to cracks, leaks and condition.
• Check the shaft coupling through the inspection hole. Warning, rotating parts inside the
inspection hole.
• Check the flow of cooling water.
Absolute maximum intervals for major inspection and replacement
Air Oil Air breather Accumulator(s)

Hydraulic fluid
inlet Filters on tank (optional)
After the first 100 working hours ý *
After 3 months or 500 working hours ý *
Once every 6 months þ ý * þ þ
Once every 24 months ý
*If the contamination indicator is tripped out, the filters þ=Inspection
must be changed immediately, and the oil examined. ý=Replacement
5.3 Filter change

Single filter
1. Stop the operation and electric motor.
2. Remove the filter bowl and change filter cartridge.
It is very important during the mounting not to expose the new cartridge to any dirt, therefore
keep it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage, change parts if necessary.
3. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.
Note! When removing a filter element take some time to inspect and look for unusual contamination
within the pleats. Contact your Hägglunds Drives office for advice.
26
Duplex filter
1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see
figure below.
2. Engage the switching lever and move to the other side.
3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 2-3
turns.
It is very important during the mounting not to expose the cartridge to any dirt, therefore keep
it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage. Change parts if necessary.
6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is
bubble free.
7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.
Vent screws
Pressure
• There are dangers associated equalizer
with hydraulic fluid. lever
• Store used hydraulic fluid
! and contaminated filter ele-
ments for proper disposal.
In this
position
you can Switching
lever
CAUTION • The fluid may be hot if the change
cooling is insufficient. this
element
Different hydraulic fluids are affected differently

- consult the manufacturer.
5.4 Inspection of hydraulic fluid

We recommend that the hydraulic fluid be analyzed once every 6 months. The analysis should cover
viscosity, oxidation, water content, additives and fouling. In the vast majority of cases, your oil supplier
will perform an analysis that will reveal the condition of the hydraulic fluid and can recommend suitable
actions. If the analysis reveals that the properties of the hydraulic fluid are not fulfilling the require-
ments (section 2.3 “Requirements for hydraulic fluid cleanliness”) it should no longer be used, but be
changed or cleaned immediately. Refill fluid according to instructions (section 4.11.2 “Filling up the
system with hydraulic fluid”).
27
5.5 Lubrication of electric motor

Lubricate electric motors larger than 30 HP
1. Clean the grease nipples.
2. Grease the electric motor with a grease gun.
Grease
When re-greasing, use only special ball bearing grease with the following properties:
• Good quality lithium base or lithium complex grease.
• Base oil viscosity 476-667 SSU at 104° F (100-140 cSt at 40° C).
• Consistency NLGI grades 2 or 3.
• Temperature range -22° F - +248° F (-30° C - +120° C), continuously.
Grease with the right properties is available from all the major lubricant manufacturers. If the type of
grease is changed and compatibility is uncertain, lubricate several times at short intervals in order to
displace the old grease.
Air inlet for electrical motor
Check that the air inlets on the cabinet hood and on the electric motor are not clogged by dirt and that
air can easily pass.
!
CAUTION
Check the warning label
on the grease cartridge. Frame
size
Lubrication schedule for electric motor (60 Hz)
Electric motor
HP (kW)
Lubrication
intervals
Volume of
grease
286 30 (22) 1.0 cu. in.

40 (30)
50 (37) 6 to 12 months
324-365 1.5 cu. in.
60 (45)
75 (56)
100 (75)
125 (93)
150 (112)
404-449 200 (149) 6 months 2.5 cu. in.
GREASE 509 250 (186)

NIPPLES
300 (224)
350 (261)
400 (298)
3 months check data
5011 450 (336)
5.6 Air breather change

Refer to maintenance chart (section 5.2 “Maintenance chart”) for recommended replacement inter-
vals.
1. Clean around the area where the air breather is located.
2. Unscrew the breather and make sure no foreign material has entered the tank.
3. Thread on a new air breather.
28
5.7 Cleaning of Air-Oil cooler

Cleaning of air fins
• The easiest way to clean the air fins is by using compressed air or rinsing with water.
• Fouling can be dealt with using a degreasing agent and a high-pressure washing system. When
using a high pressure washing system point the jet carefully parallel to the air fins.
Follow the safety precautions on the container of the cleaning agent used.
! Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.
Make sure that electric power is cut off before cleaning! Cleaning agent
WARNING and waste water from rinsing should be disposed of in accordance to pre-
vailing local regulations.
5.8 Power unit out of service

Periods out of commissioning
Clean and empty the cooling system (water side) before periods of rest (especially if the cooling water
is not totally clean). If the PBC is to be out of service for more than three months, the hydraulic system
must be protected internally against rust.
This can be done in the following manner:
• Use hydraulic fluid that is consistent with fluid types used at your location, which has rust pre-
venting additives.
• Use additives which give protection against rust for up to about a year. After this, the equipment
should be run at intervals to maintain a protective film on the internal surfaces of components
and oil lines, thus providing protection against corrosion.
• If any parts of the system are disconnected, note that open fittings must be protected by plugs or
covers to prevent entrance of any dirt particles.
Re commissioning
Before the drive is restarted after a long idle period, a check should be made as to whether the instruc-
tions supplied for the original commissioning still apply. Moreover, the following measures should be
observed.
• Remove preservative solution and any signs of contamination.
• Follow the procedure for initial start-up (section 4.11.3 “Initial start-up procedure”).
6. CORRECTIVE MAINTENANCE
6.1 Common
Before removing any hydraulic/electric components, disconnect the power unit. Ensure that no energy
is accumulated in the system and the power is disconnected from the electric motor. Follow recom-
mended safety procedures.
Before disassembly
• Troubleshoot the PBC and perform appropriate tests.
• Clean all assemblies and components, take all precautions necessary to prevent dirt entering
the system.
• Disassembly may only be done by professional service personnel.
29
Corrective Maintenance Installation and Maintenance Manual, Power Unit PBC
Disassembly
• Label all parts, and protect precision or machined surfaces.
• Inspect all parts during disassembly for wear or damage.
• If hydraulic fluid is to be drained and reused, make sure that drain containers are clean and
covered when not in use.
• Clean all metal parts using a suitable solvent prior to reassembly, set aside on a clean and lint
free cloth to drain.
Reassembly
• Lubricate with system hydraulic fluid.
• Replace all seals, gaskets and o-rings with new items of the correct size.
• Ensure complete sealing at pipe connections.
• Refill hydraulic fluid according to recommendations (section 4.11.2 “Filling up the system with
hydraulic fluid”).
6.2 Change of hydraulic pump/electric motor assembly

The most common method to change the pump is to lift the complete electric motor/pump unit and then
remove the pump.
The electric motor and pump are assembled into a unit and mounted on the motor support plate
attached to the frame via shock mounts.
1. Release the motor support plate: Release the motor support plate from the frame.
2. Secure lifting equipment: Adapt lifting equipment in the four holes in the corners of the motor
support plate.
3. Lift the electric motor/pump unit: Be careful and take the weight and center of gravity into
consideration. Never let the electric motor/pump stand on the charge pump.
4. Assemble: Assemble in reverse order according to point 1 to 3.
• Always use all four lifting points when lifting the electric
motor/pump unit.
• Never use the lifting ears on the electric motor to lift the
!
DANGER
•
complete electric motor/pump unit.
Use only lifting equipment adapted to the weight (section 4.2
“Lifting methods and weights”).
• Do not stand underneath hanging load
• Take center of gravity into consideration during lifting.
30
Installation and Maintenance Manual, Power Unit PBC Troubleshooting
6.3 Troubleshooting
Problem Probable cause Action

Main voltage to electric Look for the cause in the electric power
motor lacking supply network
Open suction line valve, verify switch
Suction valve closed function
Verify reservoir oil level and switch
Not enough oil in reservoir function
Power Unit does not start Reservoir temperature
above set limit Verify reservoir temp switch function
Look for the cause in the electric power
supply network
Control voltage lacking Examine the control system in the power
unit. If the control system has tripped,
determine the reason
No control current to electro hydraulic
No servo pressure stroker control. Examine the control
function or electronic control card
Coupling pump/electric Check through the inspection hole in the
Power unit fails to deliver oil motor defect bellhousing
flow Wrong direction of rotation
of hydraulic pump Check direction of rotation
Check that load pressure is not too high
Load is too large so that pressure override reduces pump
delivery
Suction line not open Open suction line valve
Charge pressure too low or
non-existent Check that charge pressure is correct
Pump/Motor baseplate
shipping bolts still installed Remove shipping bolts
Examine the suction line to charge pump

Unwanted noise Air leaks and pump for air leaks. Test by pouring oil over pipe
joints while listening for changes in noise
cavitating in the pump
Air filter in tank clogged Change filter

Worn elastomer element in
the shaft coupling Change elastomer element
Wrong direction of rotation Reverse direction of rotation
High oil temperature in No oil exchange from Check charge pressure and shuttle valve
closed circuit closed loop setting
31
Troubleshooting Installation and Maintenance Manual, Power Unit PBC
Power unit fails to deliver oil Perform previously described actions

Verify input signal to amplifier card and
No command signal to output signal to electrohydraulic pump
pump control
No pressure in system
Verify that pump and electric motor
Pump/Motor coupling not coupling and insert are installed and
installed properly tightened properly
Pump compensator valve is
not closed Replace pump compensator valve
Compare with our oil recommendations
Viscosity too low Check the oil temperature, and the
cooling circuit
Abrasive material Check filters and change if necessary.
circulating through pump Check that changing is performed at
Excessive wear with the hydraulic fluid prescribed intervals
Air in the hydraulic system Locate and remedy the air system leak
and Pump cavitating and purge air from the system
Content of water in
hydraulic fluid too high Inspect hydraulic fluid, change oil
Check flow of cooling water, water
temperature, cooler, water valve and
Poor cooling capacity water filter or air cooler (optional)
If air cooler is clean, inspect cooler fins
and remove any obstructions
High oil temperature Internal leakage in pump Change or repair pump
Too small an amount of
replacement oil in hydraulic Check that charge pump delivers
system sufficient flushing oil
Charge pressure is out of Adjust according to values on hydraulic
adjustment circuit diagram
7. DISPOSING OF POWER UNIT

When the complete PBC or a single component is worn out, it should be disposed of as soon as
possible. Used hydraulic fluid, material exposed to hydraulic fluid and grease may cause damage on
the environment and should be disposed of according to prevailing local regulations.
• Check that the power unit is completely disconnected.
!
DANGER
•
•
•
The components may contain accumulated energy.
Take fire hazards into consideration during dismantling.
The accumulator (optional) must be empty and discharged.
32
AM326-1A Printer : Precision Printing 1999
HÄGGLUNDS DRIVES INC. HÄGGLUNDS DRIVES (CANADA) INC.

2275 INTERNATIONAL STREET 853 Arvin Avenue
COLUMBUS, OHIO 43228 USA Stoney Creek Ontario L8E 5N8
Phone: (614) 527-7400 Fax: (614) 527-7401 Phone: (905) 643-6300 Fax: (905) 643-9933
www.hagglunds.com
GATE VALVE
AMERICAN VALVE OVERSEAS
BRONZE GATE VALVES

P.O. Box 35229
Greensboro, NC 27425
1-800-645-0101
or (336) 668-0554
fax: 1-800-876-0109
or (336) 668-4070
Figure: M300
Threaded Ends Meets ANSI/NSF 61 Section 8
Non-rising Stem (1998)
Solid Wedge Disc and
California Proposition 65
Rating:
125 psi WSP
200 psi WOG
Figure: M300S
Sweat Ends
Non-rising Stem
Solid Wedge Disc Meets ANSI/NSF 61 Section 8
(1998)
Available with Waste and
(specify Fig. M300SW) California Proposition 65
Dimensions:
1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4
A Center of Port to Top 3 3 1/16 3 3 1/2 4 1/16 4 3/4 5 3/16 6 3/16 7 l/2 9 10 1/4
B End to End 1 5/8 1 5/8 1 11/16 1 7/8 2 3/16 2 3/8 2 7/16 2 13/16 3 1/2 4 4 9/16
B1 End to End 1 5/8 1 3/4 2 3/8 2 3/16 3 1/16 3 1/16 4 1/8 4 3/4 4 3/4
C Overall Height 3 1/2 3 1/2 3 9/16 4 1/4 5 5 3/4 6 3/8 7 5/8 9 1/2 11 1/8 13 1/8
D Wheel Diameter 2 1/8 2 1/8 2 1/8 2 1/8 2 3/8 2 7/8 2 7/8 6 3/4 5 4 l/4 3 1/4
Weight lbs. Thd. .55 .53 .56 .81 1.10 1.80 2.l0 3.20 7.00 9.60 17.0
Weight lbs. Swt. .48 .51 .75 1.10 1.70 2.00 3.10 6.80 9.40
CABINET FEET
TF
Features
The TF mounting is installed in minutes by following the
instructions provided. There is no need to fix the machines
to the floor since the rubber base of the mounting keeps
the machine in place. Whenever necessary, the machine
can easily be re-positioned. The level is adjusted with load
applied.
The rubber element of the TF mounting is oil and chemi-

cal resistant. All metal parts are zincplated and chromated
for protection against corrosion.
Models TF 250, TF 600 and TF 1200, also available in

S/S (ISO 2604/11, BS 3605:1).
Novibra® type TF
Novibra® type TF with level adjuster is suitable for a wide
range of free standing workshop machines, e.g.
• Lathes
• Milling machines
• Grinding machines G
• Multiple operation machinery
• Presses
• Plate shears
• Nibbling machines
• Punches and cutters
• Woodworking machines
• Plastic moulding machinery H
Dimensions in mm Overall Thread Weight Max load

Type Art.No. D H min H max bolt length G (kg) (kg)
1)
TF 250 1860740 69 23 100 M 12 0.40 250
TF 250 s/s 2256520 69 23 1)
100 M 12 0.40 250
1)
TF 600 1860780 81 25 100 M 12 0.49 600
TF 600 s/s 2256530 81 25 1)
100 M 12 0.49 600
1)
TF 1200 1860790 108 29 100 M 16 1.0 1200
TF 1200 s/s 2256540 108 29 1)
100 M 16 1.0 1200
1)
TF 3000 1860800 151 35 120 M 20 2.2 3000
1)
TF 4000 1860810 170 39 120 M 20 2.9 4000
1)
TF 6000 1860820 205 44 150 M 24 4.8 6000
1) Levelling of the bolt up to its total length.
68 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
TF
Loading range per mounting (kg)
Type of General work- Presses and punches

machinery
shop machines Numbers of strokes per minute
Mounting Max load (kg) 1– 125 126– 175 176– 225 226– 275
TF 250 250 25– 125 20– 100 15– 85 10– 60
TF 600 251– 600 126– 300 101– 240 86– 200 61– 150
TF 1200 601– 1200 301– 600 241– 480 201– 400 151– 300
TF 3000 1201– 3000 601– 2400 481– 1600 401– 1000 301– 750
TF 4000 3001– 4000 2401– 3200 1601– 2100 1001– 1300 751– 1000
TF 6000 4001– 6000 3201– 4800 2101– 3200 1301– 2000 1001– 1500
Mounting instructions
1 2 3
TFE
Mounting TFE is a simpler version of type TF without Both models also available in S/S
level adjuster. It is used for machines which do not require (ISO 2604/11,BS 3605:1 )
height adjustment or where such a feature is already pro-
vided, e.g. by an adjusting screw in the machine.
Dimensions in mm Weight Max load

Type Art.No. D H (kg) (kg)
TFE 601 1861050 80 25 0.375 800
TFE 1201 1861060 109 29 0.925 1600
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 69
ISOLATION MOUNTS
Bobbins
Trelleborg Industrial AVS - Bobbins
A supplementary range of cylindrical mountings for a wide Manufactured in natural rubber hardness 40° IRH or
range of applications. They can be loaded either in com- 60° IRH.
pression or shear taking into consideration individual de-
mands for actual applications.
Type A Type B Type C
Type D Type KD Type E
Compression load Shear load
Bobbins
G ØD
L H
Cylindrical mountings type A
40° IRH 60° IRH

Type D/H GxL Art.No. Art.No. Compression Shear load Compression Shear load
40° IRH 60° IRH load load
kcomp Fmax kshear Fmax kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N) (N/mm) (N) (N/mm) (N)
A 10/10 M4x10 1255720 53 77 10 31
A 10/15 M4x10 318600 31 56 6 23
A 15/10 M4x10 318610 135 151 22 52

A 15/15 M4x10 318620 73 133 13 52
A 20/10 M6x15 318630 318640 162 170 19 42 309 324 41 92

A 20/15 M6x15 2255780 1255770 70 123 11 42 145 255 25 92
A 20/20 M6x15 2230950 1255300 45 110 8 42 96 235 18 92
A 20/25 M6x15 318650 1255780 33 105 6 42 72 227 14 92
A 20/30 M6x15 318660 318670 27 102 5 42 58 223 11 92
A 25/10 M6x15 318680 318690 314 330 29 66 574 603 64 144

A 25/15 M6x15 318700 318710 123 215 18 66 247 432 38 144
A 25/20 M6x15 318720 318730 75 184 13 66 157 385 27 144
A 25/25 M6x15 318740 318750 54 171 10 66 116 366 21 144
A 25/30 M6x15 318760 318770 43 164 8 66 93 356 17 144
A 30/15 M8x20 318780 1255830 237 378 28 95 453 723 61 208

A 30/20 M8x20 318790 1255320 129 295 19 95 261 600 42 208
A 30/25 M8x20 318800 318810 88 263 15 95 184 552 32 208
A 30/30 M8x20 1660730 1255840 67 248 12 95 143 529 26 208
A 30/35 117 516 22 208
A 30/40 M8x20 318820 318830 46 233 9 95 100 508 19 208
A 40/20 M8x20 318840 318850 275 632 34 170 534 1226 75 369
A 40/25 359 1076 58 369
A 40/30 M8x20 318860 318870 130 481 21 170 271 1002 47 369
A 40/40 M8x20 318880 318890 86 437 16 170 184 935 34 369
A 50/20 M10x25 318900 318910 564 1248 56 265 1042 2306 122 577
A 50/25 M10x25 318920 318930 335 976 42 265 652 1900 93 577
A 50/30 M10x25 1861540 1255870 234 846 34 265 472 1706 75 577
A 50/35 M10x25 318940 318950 180 774 29 265 371 1598 62 577
A 50/40 M10x25 318960 1255340 146 730 25 265 306 1533 54 577
A 50/45 M10x25 318970 1255880 123 701 22 265 261 1490 47 577
A 50/50 M10x25 318980 1255350 106 681 19 265 228 1460 42 577
A 75/40 M12x35 319000 319010 417 2032 57 596 827 4030 124 1299
A 75/50 M12x35 319020 319030 282 1766 44 596 579 3632 97 1299
A 75/55 M12x35 319040 319050 242 1689 40 596 504 3517 87 1299
A 100/40 M16x45 319060 319070 932 4541 102 1060 1755 8549 221 2309
A 100/55 M16x45 319080 319090 496 3455 71 1060 994 6929 155 2309
Bobbins
S
G ØD
L H
Cylindrical mountings type B

60° IRH
Type D/H GxL (S) Art.No. Compression load Shear load
60° IRH kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N)
B 10/10 M4x10(4) 1255930 58 56 10 23
B 10/15 M4x10(4) 319100 34 52 6 23
B 15/15 M4x10(4) 319110 79 124 13 52
B 20/15 M6x15(6) 1255960 159 238 25 92

B 20/20 M6x15(6) 1255970 105 220 18 92
B 20/25 M6x15(6) 319120 79 213 14 92
B 25/15 M6x15(6) 1255990 269 404 38 144

B 25/20 M6x15(6) 319130 172 360 27 144
B 25/25 M6x15 (6) 319140 127 342 21 144
B 25/30 M6x15(6) 319150 101 333 17 144
B 30/15 M8x20(8) 319160 494 676 61 208

B 30/20 M8x20 (8) 1256040 285 561 42 208
B 30/25 M8x20(8) 319170 201 516 32 208
B 30/30 M8x20 (8) 1256060 156 495 26 208
B 30/40 M8x20(8) 319180 109 475 19 208
B 40/30 M8x20(8) 319190 296 937 47 369

B 40/40 M8x20(8) 319200 200 875 34 369
B 50/30 M10x25(10) 319210 515 1595 75 577
B 50/40 M10x25 (10) 319220 334 1433 54 577
B 50/50 M10x25 (10) 1256120 248 1365 42 577
B 75/50 M12x35(12) 319240 632 3396 97 1299

B 75/55 M12x35 (12) 319250 550 3288 87 1299
B 100/40 M16x45 (16) 319260 1914 7994 221 2309
B 100/55 M16x45(16) 319270 1084 6479 155 2309
S = internal thread length
Bobbins
S
G ØD
Cylindrical mountings type C
60° IRH
Type D/H G(S) Art.No. Compression load Shear load
60° IRH
kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N)
C 15/15 M4(4) 1256210 86 112 13 52
C 20/20 M6(4) 66522 114 199 18 92

C 20/25 M6(6) 1256220 85 192 14 92
C 20/30 M6(6) 66548 69 189 11 92
C 25/20 M6(6) 1256230 186 325 27 144

C 25/25 M6(6) 319280 137 309 21 144
C 30/25 M8(8) 319300 218 466 32 208

C 30/30 M8(8) 1255410 169 447 26 208
C 30/35 M8(8) 319310 139 436 22 208
C 30/40 M8(8) 319320 118 429 19 208
C 40/30 M 8(8) 1255420 320 846 47 369

C 40/40 M 8(8) 1256260 217 790 34 369
C 50/30 M10(10) 1256270 558 1440 75 577

C 50/35 M10(10) 2255730 438 1349 62 577
C 50/40 M10(10) 1256280 361 1294 54 577
C 50/45 M10(10) 1256290 308 1257 47 577
C 50/50 M10(10) 1256300 269 1232 42 577
C 75/36 M12(12) 66746 1180 3635 141 1299

C 75/40 M12(12) 319330 977 3402 124 1299
C 75/45 M12(12) 319340 805 3202 109 1299
C 75/50 M12(12) 2256670 684 3066 97 1299
C 75/55 M12(12) 1255430 596 2969 87 1299
C 100/40 M16(16) 319350 2074 7217 221 2309

C 100/45 M16(16) 319360 1655 6587 193 2309
C 100/50 M16(16) 319370 1374 6156 172 2309
C 100/55 M16(16) 319380 1174 5849 155 2309
Bobbins
G
Type D Type E
L G
H H
ØD ØD
Cylindrical mountings type D/E/KD
Compression load
Type D/H GxL Art.No. Art.No. 40° IRH 60° IRH
40° IRH 60° IRH Fmax Fmax
(N) (N)
D 10/10 M4x10 319390 59
D 15/15 M4x10 319400 131
D 20/10 M6x15 319410 295

D 20/15 M6x15 319420 248
D 20/20 M6x15 319430 233
D 20/25 M6x15 319440 226
D 25/10 M6x15 319450 532

D 25/15 M6x15 319460 416
D 25/20 M615 319470 379
D 30/15 M8x20 319480 663

D 30/20 M8x20 319490 578
D 30/25 M8x20 1534870 542
D 30/30 M8x20 319500 523
D 40/25 M8x20 319510 1044

D 40/30 M8x20 319520 985
D 40/40 M8x20 319530 928
D 50/20 M10x25 319540 2094
D 50/30 M10x25 319550 1653
D 50/40 M10x25 319560 1512

D 50/45 M10x25 319570 1476
D 75/25 M12x35 319580 5446
D 75/40 M12x35 319590 3895
G(S)
E 30/17 M8(8) 1256930 1661280 225 500
E 50/20 M10(10) 319600 1700
E 50/36 M10(10) 1659990 319610 550 1100
E 50/45 M10(10) 1659870 1000
KD 25/12 M6x16 1534150 300

KD 25/12 M6x18 1533450 250
KD 50/17 M10x28 1256940 1400
P6S, P7S & P8S PUMP MANUAL
DENISON HYDRAULICS
goldcup series
closed circuit piston pumps
P6, P7, P8S
service information
Publ. S1-AM025-A
E-Mail: denison@denisonhydraulics.com Internet: http://www.denisonhydraulics.com

CONTENTS
PAGE
installation 3
typical characteristics 3
fluid connections 4
general 5
description 5
mounting 5
shaft information 5
piping 5
service information 5
recommended fluids 5
viscosity 6
viscosity index 6
temperature 6
alternate fluids 6
maintenance 6
fluid cleanliness for new installation 6
start-up procedure 6
comparison of solid contamination classification system 7
troubleshooting 7
assembly tool drawings, T1, T2, T3, T4, T5 9
disassembly 11
rework of wear parts 12
assembly 13
drive shaft and bearing 13
barrel and auxiliary drive shaft 13
rocker cam 15
pistons and shoes 16
mounting flange, cam & cradle 16
housing 17
housing, end cap, cam and barrel 17
port block 18
mounting port block to housing 18
gerotor and barrel holddown 19
valve block (before 7-93) 20
valve block (after 7-93) 22
valve block for special mounting of servo valve (before 7-93) 26
valve block for special mounting of servo valve (after 7-93) 29
output controls 32
input controls 32
shaft and seal installation 33
mechanical shaft seal assembly procedure 33
counter-balance servo stem 34
rear drive adapter 34
pilot valve 36
shuttle valve 36
shuttle valve mounting 37
important instructions 38
instructions for replenishing circuit isolation plug 38
hydraulic circuit 40
test procedure 41
general requirements 41
basic pump test 41
(refer to manual S1-AM030 for controls service information)
ordering code 43
seal kits
complete S23-15092
valve block S23-00135
HI-IQ valve block S13-04226
shaft seal replacement S23-44302
shaft seal 623-00006
shuttle valve S23-15089
Note: New revisions are shown underlined.

Pages are marked Revised where changes have been made.
2
INSTALLATION
TYPICAL CHARACTERISTICS Specification Term P6 P7 P8
• displacement at max. angle in.3/rev. 6.00 7.25 8.00

cm3/rev (98) (119) (131)
• pressure ports A & B max. psi 5000 5000 3600

continuous bar (345) (345) (248)
max. intermittent psi 6000 6000 4350
bar (414) (414) (300)
• speed, max. continuous rpm 3000 3000 1800
• flow, ports A or B @ 1500 RPM gpm 38.9 47.1 51.9

(theoretical ) L/min. (147) (178) (196)

• flow, internal replenishing pump gpm 6.9 6.9 6.9

@ 1800 RPM (theoretical ) L/min. (26.1) (26.1) (26.1)
• flow, auxiliary pump, external gpm 9.3 9.3 9.3

at 1800 RPM (theoretical) L/min. (35.2) (35.2) (35.2)
(see note)
• replenishing pressure psi 200 200 200

bar (14) (14) (14)
• servo pressure psi 335-535 335-535 335-535

bar (23-37) (23-37) (23-37)
• mounting-2 bolt flange SAE C C C
• shaft-spline SAE C C C
keyed
• fluid connection ports A & B in 1-1/2 1-1/2 1-1/2

SAE-4 bolt pad for 6000 mm (38.1) (38.1) (38.1)
split flange
• weight w/rotary servo lbs. 335 335 335

kg. (152) (152) (152)
Note: Any SAE-A or B mount pump may be used with the appropriate external drive
3
INSTALLATION
port size function

A 1 1/2" 4 bolt SAE 6000 psi inlet/outlet
AG, BG SAE - 6 straight thread system pressure gage, ea. side
B 1 1/2" 4 bolt SAE 6000 psi outlet/inlet
C SAE - 16 straight thread internal auxiliary pump inlet
D1, D2 SAE - 12 straight thread case drain
D3 SAE - 16 straight thread replenishing relief drain
DG SAE - 6 straight thread case pressure gage
DS SAE - 4 straight thread shuttle repl. pilot drain (ext.drain)
FA, FB 1/4 - 18 dryseal NPTF control pressure gage, ea. side
G SAE - 8 straight thread int. aux. pump outlet to filter
H SAE - 8 straight thread filter return
I SAE -16 straight thread inlet to optional pump (gear pump)
SAE - 1 1/4 3000 psi, 4-bolt pad optional - vane pump
K SAE -16 straight thread aux. replenishing port
KA SAE - 12 straight thread aux. repl. inlet to shuttle
KG SAE - 6 straight thread replenishing pressure gage
M SAE - 8 straight thread auxiliary servovalve drain
S SAE - 8 straight thread servovalve inlet
VA/VB SAE - 4 straight thread individual compensator vent
Conversion Adapter Kit “A” mount S23-12438-0

“B” mount S23-12669-0
4 Revised
INSTALLATION
GENERAL The DENISON HYDRAULICS Goldcup 6, 7, and 8 axial piston pumps feature advance
design concepts which are time proven and provide for advance pumping and control
concepts. The instructions contained in this manual cover complete disassembly and
reassembly of the unit. Before proceeding with the disassembly or reassembly of any
unit, this manual should be studied in order to become familiar with proper order and
parts nomenclature.
DESCRIPTION The use of a rocker cam to control the pump displacement provides a small package
size, reduces wear, and speeds control response. The control vane actuator eliminates
linkage and backlash inherent in typical stroking cylinder designs.
Standard controls for the Goldcup units are Rotary Servo and Compensator Override.
Additional optional controls are also available.
MOUNTING This pump is designed to operate in any position. The mounting hub and four bolt mount-
ing flange are in full conformance with SAE standard. The pump shaft must be in align-
ment with the shaft of the driven load and should be checked with a dial indicator. The
mounting pad or adaptor into which the fluid pump pilots must be concentric with the pump
shaft to prevent bearing failure. This concentricity is particularly important if the shaft is
rigidly connected to the driven load without a flexible coupling.
SHAFT INFORMATION Splined: The shafts will accept a maximum misalignment of 0.006" TIR (.15 mm).
Angular misalignment at the male and female spline axes must be less than ±.002” per
inch radius (.002 mm per mm radius). The coupling interface must be lubricated. DENI-
SON HYDRAULICS recommends lithium molybdenum disulfide or similar grease. The
female coupling should be hardened to 27-45 Rc and must conform to SAE-J498B
(1971) Class 1 flat root side fit.
Keyed: High strength heat treated keys must be used. Replacement keys must be hard-
ened to 27-34 Rc. The key corners must be chamfered .030"-.040" (.75-1 mm) at 45° to
clear radii that exist in the keyway.
Splined or Keyed: Both types of shafts will accept a side load of 170 lbs. (77 kg) at the
center of the spline or key, with a B10 life of 10,000 hours at 1800 RPM.
PIPING Connect inlet and outlet lines to the port block of the pump.
The maximum case pressure is 75 PSI (5.17 bar) continuous, 125 PSI (8.6 bar) inter-
mittent. Case pressures must never exceed inlet pressure by more than 25 PSI (1.7 bar).
When connecting case drain line make certain that drain plumbing passes above high-
est point of the pump before passing to the reservoir. If not, install a 5 PSI (.3 bar) case
pressure check valve to be certain the case is filled with oil at all times.
The case leakage line must be of sufficient size to prevent back pressure in excess of 75
PSI (5.7 bar) and returned to the reservoir below the surface of the oil as far from the
supply suction as possible. All fluid lines, whether pipe, tubing, or hose must be adequate
size and strength to assure free flow through the pump. An undersized inlet line will pre-
vent the pump from reaching full speed and torque. An undersized outlet line will create
back pressure and cause improper operation. Flexible hose lines are recommended. If
rigid piping is used, the workmanship must be accurate to eliminate strain on the pump
port block or to the fluid connections. Sharp bends in the lines must be eliminated wher-
ever possible. All system piping must be cleaned with solvent or equivalent before
installing pump. Make sure the entire hydraulic system is free of dirt, lint, scale, or other
foreign material.
Caution: Do not use galvanized pipe. Galvanized coating can flake off with
continued use.
SERVICE INFORMATION These hydraulic products are designed to give long dependable service when properly
applied and their systems properly maintained. These general instructions apply to typi-
cal systems. Specific instructions for particular equipment can be developed from them.
RECOMMENDED FLUIDS See DENISON HYDRAULICS bulletin SPO-AM305 for more details.
5 Revised
INSTALLATION
FILLING CASE It is essential to make certain that the case (pump housing) is as full of fluid as possible
and remains full during operation and at rest.
Always fill to the highest available point. Remove a plug or screw and allow the oil to
escape through this point.
Recommended fill points:
Mounting orientation vertical, shaft up. D1 or D2 (drain) port in housing

Vent DG2 port in mounting flange (new units)
or one of the upper screws which attach the
control. See installation drawing.
Vertical, shaft down 1) or horizontal D1 or D2 (drain port in housing.

drain ports to the side 1) Vent DG (case gage) port in port block.
MAINTENANCE This pump is self-lubricating and preventative maintenance is limited to keeping system
fluid clean by changing filters frequently. Keep all fittings and screws tight. Do not oper-
ate at pressures and speeds in excess of the recommended limit. If the pump does not
operate properly, check the Trouble Shooting Chart before attempting to overhaul the
unit. Overhauling is relatively simple and may be accomplished by referring to the
Disassembly, Rework Limits of Wear Parts and Assembly Procedures.
FLUID CLEANLINESS Fluid must be cleaned before and continuously during operation by filters that maintain a
cleanliness level of NAS 1638 Class 8.
START UP PROCEDURE • Read and understand the instruction manual. Identify components and their function.
• Visually inspect components and lines for possible damage.
• Check reservoir for cleanliness and drain and clean as required.
• Check fluid level and fill as required with filtered fluid at least as clean as that recom-
mended. Fill pump case with clean oil prior to starting.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature.
• Reduce pressure settings of relief valve. Make sure accurate pressure readings can be
made at appropriate places.
• If solenoids in system, check for actuation.
• Start pump drive. Make sure pump and motor fill properly.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines especially in
pump and motor inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds, sys-
tem shocks and air in fluid.
• Equipment is operational.
6 Revised
TROUBLESHOOTING
TROUBLESHOOTING Component problems and circuit problems are often inter-related. An improper circuit
may operate with apparent success but will cause failure of a particular component with-
in it. The component failure is the effect, not the cause of the problem.
This general guide is offered to help in locating and eliminating the cause of problems by
studying their effects:
effect of trouble possible cause fault which needs remedy

noisy pump air in fluid leak in suction line
leak at shaft seal
low fluid level
turbulent fluid
return lines above fluid level
gas leak from accumulator
excessive pressure drop in the inlet line from a
pressurized reservoir
suction line strainer acting as air trap
cavitation in fluid too cold
pump or motor fluid too viscous
rotating group fluid too heavy
shaft speed too high
suction line too small
suction line collapsed
suction strainer too small
suction strainer too dirty
operating altitude too high
boost or replenishment pressure too low
replenishment flow too small for dynamic conditions
misaligned shaft faulty installation
distortion in mounting
axial interference
faulty coupling
excessive overhung loads
mechanical fault piston and shoe looseness or failure
in pump bearing failure
incorrect port plate selection or index
eroded or worn parts in the displacement control
erosion on barrel air in fluid see above
ports and port cavitation see above
plate
high wear in excessive loads reduce pressure settings
pump and motor reduce speeds
contaminant improper filter maintenance
particles in fluid filters too coarse
introduction of dirty fluid to system
reservoir openings
improper reservoir breather
improper line replacement
7
TROUBLESHOOTING
TROUBLESHOOTING effect of trouble possible cause fault which needs remedy

(continued) high wear in Improper fluid fluid too thin or thick for operating temperature range
pump and motor breakdown of fluid with time/temperature/shearing
(continued) effects
incorrect additives in new fluid
destruction of additive effectiveness with chemical
aging
improper repair incorrect parts
incorrect procedures, dimensions, finishes
unwanted water condensation
in fluid faulty breather/strainer
heat exchanger leakage
faulty clean-up practice
water in makeup fluid
pressure shocks cogging load mechanical considerations
worn relief valve needed repairs
worn needed repairs
compensator
slow response in replace or relocate
check valves
servo pressure increase pressure and check pressure drop
too low to through servo filter
maintain firm
control
excessive improve decompression control
decompression
energy rates
excessive line reduce line size or lengths
capacitance eliminate hose
(line volume,
line stretch,
accumulator
effects)
barrel blow-off re-check pump hold-down, rotating group, drain
pressure
heating of fluid excessive pump recheck case drain flow and repair as required
or motor fluid too thin
leakage improper assembly, port timing
relief valve set too low (compared to load or to compensator)
instability caused by back pressure, worn parts
compensator set too high (compared to relief)
worn parts
pump too large select smaller pump displacement
for fluid needs
heat exchanger water turned off or too little flow
water too hot
fan clogged or restricted
efficiency reduced by mud or scale deposits
intermittent hydraulic fluid flow
reservoir too little fluid
entrained air in fluid
improper baffles
insulating air blanket that prevents heat rejection
heat pickup from adjacent equipment
8
ASSEMBLY TOOL DRAWINGS
T-1
MATERIAL
CRS 1" DIA. X 2 5/8"
(25.4mm) (66.68 mm)
T-2
Note: Dimensions in ( ) are mm.
9
T-3
T-4
T-5
Material:
OHTS 5 5/8 x 1 1/4 DIA
(130.17) x (31.75)
Hardened Tip RC 58-62
10
UNIT DISASSEMBLY
INTRODUCTION The instructions contained in this section cover a complete teardown of the subject
pump. Disassemble only as far as necessary to replace or repair any worn parts.
DISASSEMBLY Position pump unit so that valve block assembly is on top. A bench or similar suitable sur-
face capable of supporting unit should be used. Disassembly area should be clean.
VALVE BLOCK See figure 14. Remove the eight hex. head cap screws (17) and lift the entire block
assembly from the port block.
See figure 12/13. Remove the four hex. head cap screws (58) and four soc. hd. screws
(53) and lift the entire block assembly from the port block.
(before 7-93) See figure 10. Remove the four screws (39) to separate the cover (21) from the block
(11). Do not remove the check valves (19).
Remove plugs (43), (36) and pin (40). Remove the 8-32 nut from the bottom of cover (21)
to remove filter assembly (34).
Remove housing (29) and O-ring (28). Remove items (30), (31), (32) and (33) as a unit.
Insert a small brass rod thru the hole in the housing and tap out piston (27) and O-ring
(26).
Remove spring (25) and cone (24). Remove seat (23) and O-ring (22).
Note: Seat is made for hex. wrenching. Use 1/2" six point socket with 1/4" drive.
Remove O-ring (37) and replenishing relief valve (41). Inspect orifices (12) visually to
insure they are open. Do not remove unless damage or clogging is apparent.
Remove springs (16), (17) and (18). Remove retainer (15) and poppets (13) and (14).
Remove the four screws (4) from the plate (6) and (11). Remove gasket (7).
Remove seats (8) and (9). Do not remove roll pins (5) and (10) unless replacements are
needed.
(after 7-93) See figure 11. Remove plugs (20), (23) and pin (21). Remove the 8-32 nut from the bot-
tom of block (1) to remove filter assembly (14). Do not remove the check valves (2).
Remove housing (8), O-ring (9), piston seal (10), O-ring (11), screw (6), nut (7), and
acorn nut (45) as a unit.
Remove plug (25) and replenishing relief valve (36).
Remove O-rings (37), (48) and (47). Remove four screws (43) and remove the retainer
plate (42). Do not remove roll pins (46) unless replacements are needed.
Remove gasket (29) and seats (27) and (28). Remove poppets (30), (31) and springs
(32), (33), (35) and retainer (34).
Inspect orifices (3) visually to insure they are open. Do not remove unless damage or
clogging is apparent.
CONTROLS See figure 14. Remove the four screws (14) from the side cover (16) and remove the
input shear seal valve assembly
Note: The myltite washers (13) should be replaced at assembly.
Remove the four screws (14) from the side cover (15) and remove the counter balance
shear seal assembly.
Remove the two screws (12) and remove the balance stem (9) and balance plate (10)
EXTERNAL PUMP, SHUTTLE See figure 14. Remove two screws (20) and remove external pump (21).
VALVE AND REAR ADAPTER
Remove four screws (23) and remove shuttle valve (24).
Remove four screws (9) fig. 15 and remove adapter (22).
BARREL HOLDDOWN AND See figure 9. Remove retainer ring (16), pin (14), holddown nut (13), insert (15), thrust
GEROTOR ASSEMBLY washers (10), bearing (11) and seal ring (12).
Remove pressure plate (9), Gerotor side plate (5) “O” rings (7) and (8).
Remove Gerotor assembly (3), dowel pin (4), key (2), and side plate (1).
11
UNIT DISASSEMBLY
PORT BLOCK See figure 8. Remove four screws (1) that secure the port block (2) to the housing (6). Use
caution when removing screws on valve block side to prevent marring valve block face.
Remove port block (2) and gasket (5). Remove port plate (4) and port plate pins (3).
Note: port plate will in some instances adhere to port block upon disassembly.
See figure 7. Remove the check valve assemblies (7) from the port block.
Remove needle bearing (2) from the port block.
Remove two screws (5), lockwashers (6), check rings (3), and clamps (4). Only one
check ring assembly in open circuit pumps.
BARREL AND AUXILIARY SHAFT Remove face plate (2, fig. 6) from face of barrel assembly.
BARREL AND AUXILIARY SHAFT
Remove the barrel assembly (1, fig. 4) by grasping the auxiliary shaft and lifting the com-
plete assembly out of the housing.
DRIVE SHAFT See figure 14. Remove the four screws (8) and gaskets (7). Remove seal retainer (6),
and the stationary part of the shaft seal (4). Refer to view of item 4.
Carefully remove the carbon ring and the remainder of the shaft seal from the shaft.
Caution: Do not scratch seal surface of shaft when removing seal.
Remove snap ring (3) and the shaft and bearing assembly (1). Remove shim (2).
HOUSING After shaft assembly has been removed, position the unit on end with the mounting
flange turned down.
Push the ends of the small tube lines away from the housing.
Lift the housing from the mounting flange, remove the gasket, and dowel pins from the
mounting flange.
Do not remove the roll pins and the bearing from the housing unless the bearing is dam-
aged and must be replaced.
ROCKER CAM AND CONTROL See figure 4. Remove the complete assembly (5) from the mounting cap (7) and posi-
STROKING ASSEMBLY tion on a clean flat surface with the two tubes (2) in a horizontal position and located at
the top. Mark the cam (24) and cradle (20) as indicated in Figure 3. These marks will
determine positioning of parts during reassembly.
Carefully remove the small tube lines (3) and (4) from the cradle.
Caution: Do not bend these lines
See figure 3. Position the assembly in an upright position on the flat surface of the cra-
dle (20). Remove the retaining ring (1) and thrust washer (2). Remove the piston and
shoe assembly (4) and the creep plate (5) from the cam (24). Carefully remove the two
set screws (6a) and two screws (6) that secure the servo plate to the cam (24) and
remove the servo input parts (7, 8 and 9).
Remove the four 7/16" screws (10) and eight 1/4" screws (11) and (12) from the control
covers (15R) and (15L). Remove the four dowel pins (16) and remove the two chambers
(17). Remove the two special seals (18) and the four steel balls (19). Remove the two
vane seal cartridge assemblies (23) and the four holddown vanes (22) from the rocker
cam (24).
Note: Some units may have thin shims under the holddown vanes.
Remove the rocker cam (24) from the cradle (20).
Caution: Do not remove the plugs from the rocker cam.
12
UNIT DISASSEMBLY
REWORK LIMITS OF WEAR max. rework

PARTS 6, 7.25 and 8.0 in3 from original min. dimension after rework
port plate face .010” (0,254 mm) .295” (7,49 mm)
shoe retainer face .005” (0,127 mm) .307” (7,8 mm)
piston shoe face .006” (0,152 mm) .008” (0,2 mm)
(pocket)
creep plate face .005” (0,127 mm) .286” (7.13 mm)
face plate none replace
IMPORTANT:
The port plate both faces finish must be 25 microinches (635 mm), flat within .00006
(0015 mm) and parallel within .001(0254 mm) T.I.R.
The creep plate wear face finish must be 10 microinches (254 mm), flat within .0002
(0381 mm) and parallel to the backside within .0005 (0127 mm)T.I.R.
The shoe retainer wear face finish must be 32 microinches (813 mm), and flat within
.0015 (0381 mm) (must not be convex).
The piston shoes wear face finish must be 5 microinches (127 mm), and must be lapped
in a set with the retainer plate, all shoe sole thicknesses to be within .001 (0254 mm) after
lapping. The maximum permissible shoe and piston axial looseness is .010 (254 mm).
The special retaining ring service kit (S23-12461) may be required to control shoe
holddown clearance.
13
ASSEMBLY PROCEDURES
CLEANING AND INSPECTION All parts must be inspected and be free of material defects, dirt, scratches or any foreign
material.
All parts must be cleaned with a suitable cleaning solvent and all holes and passages
blown out with dry, clean, compressed air.
After cleaning and inspection, all parts must be covered with a light film of oil and pro-
tected from dirt and moisture. Excessive handling of internal parts should be avoided
prior to assembly.
During assembly, lapped and ground surfaces must be lubricated with clean oil and pro-
tected from nicks or surface damage.
DRIVE SHAFT AND BEARING See figure 1. Pass one retaining ring (3) over the internal end of drive shaft (1) and install
in the groove near the shaft seal surface.
Caution: Do not pass the ring over the seal surface.
Press the bearing (2) over the same end of the shaft and seat against the ring.
Support only the inner race of the bearing and press on the coupling end of the shaft.
Caution: Do not use excessive force and distort or damage the retaining ring.
Install the other retaining ring (3) in the other retaining ring groove. Be sure that both
rings are fully seated.
PARTS LIST FOR FIGURE 1

S13-41805 DRIVE SHAFT ASSEMBLY (SPLINED)
S13-41806 DRIVE SHAFT ASSEMBLY (W/KEYWAY)
quantity
item description part no. #3 #2
1 #3 (splined shaft) 033-70567 1 -
#2 (keyed shaft) 033-70579 - 1
Figure 1 2 shaft bearing 230-82140 1 1
3 retaining ring 033-70817 2 2
4 square key 5/16 x 1-1/4 033-71348 - 1
BARREL AND AUXILIARY See figure 2. Position the barrel (1) in a press with the large end turned down and insert
DRIVE SHAFT tool figure T-1 in the splined shaft hole in the barrel.
Place stop (3) and spring (4) over shaft (2) in the same sequence as shown.
Insert shaft (2) in barrel (1) and rest on tool figure T-1. Position the spring retainer (5) over
the shaft (2) and against spring (4).
Carefully place tool figure T-2, with the large end of the tapered hole up, over the shaft
(2) and against the barrel face (1). Insert ring (6) around the shaft (2) and in the tool.
Position the ring with the gap within 5/8" (16 mm) of the notch in the barrel for easy
removal.
Place tool figure T-3 over the shaft (2) with the small end against ring (6). Press on the
end of the assembly tool and seat the ring (6) in the groove of the barrel (1).
Remove the assembly tools. Check to be sure that the ring is properly seated. Check bar-
rel face to be certain it is not marred.

S23-12363 P6 COMPLETE BARREL AND SHAFT ASSEMBLY
quantity
item description part no. P6 P7 P8
1 barrel & sleeve ass’y (P6) S13-43657 1 - -
Figure 2 barrel & sleeve ass’y.(P7) S13-47511 - 1 -
barrel & sleeve ass’y (P8) S23-12718 - - 1
2 auxiliary drive shaft 033-91050 1 1 1
3 stop 033-53944 1 1 1
4 barrel holddown spring 033-70493 1 1 1
5 spring retainer 033-53945 1 1 1
6 retaining ring 033-70494 1 1 1
Consult DENISON HYDRAULICS Service for parts prior to 1983 units.
14
ASSEMBLY PROCEDURES

rocker cam, pistons and retainer
item description part no qty.

1 retaining ring (yellow) .083" (2.11 mm) 033-70484 1
retaining ring (green) .081" (2.06 mm) 033-70488
retaining ring (red) .079" (2.01 mm) 033-70490
retaining ring (white) .087" (2.21 mm) 033-72175
retaining ring (blue) .085" (2.16 mm) 033-72176
retaining ring (black) .077" (1.96 mm) 033-54826
retaining ring service kit S23-12461
2 thrust washer 033-72249 1
3 not used
4 piston & shoe assy. w/retainer See below
5 creep plate 033-71261 1
6 button hd. screw 353-25041 2
6a setscrew, 2 ea. 312-09032 2
7 servo stem 033-71312 2
8 orifice screw 033-70819 2
9 servo plate 033-53874 1
*10 hex. hd. screws 7/16-14 x 2-1/2 306-40183 4
*11 hex. hd. screws 1/4-20 x 1-1/4 306-40188 4
*12 hex. hd. screws 1/4-20 x 2-1/4 306-40187 4
*13 hex socket plug SAE-4 488-35001 2
*14 O-ring 90-6290-4 691-00904 2
*15R right side chamber cover CW rot. 033-70572 1
right side chamber cover CCW rot. 033-70612
*15L left side chamber cover CW rot. 033-70571 1
left side chamber cover CCW rot. 033-70574
*16 dowel pin 1/4 x 1-1/2 324-21624 4
*17 chamber 033-72266 2
*18 seal 606-25036 2
*19 steel ball 3/16 201-06001 4
*20 rocker cradle 033-53951 1
*22 hold down vane 033-70816 4
*23a -seal backup plate 033-70802 4
*23b -vane seal 033-70501 2
*23c -O-ring 90-914-20 691-00120 2
*23d -spacer 033-70519 2
*23e -check valve 033-70803 2
*24 rocker cam S23-12105 1
25 pressure tube 033-70524 2
*Note: Item 10 through 24 can be ordered as a complete rocker cam & control stroking
assembly.
S23-12196 is for RH pumps
S23-12197 is for LH pumps
item description P6S P7S P8S qty.

4 piston & shoe assy. S13-43655 S13-42308 S21-11650 1
w/retainer
4a shoe retainer 033-54290 033-54290 033-57376 1
4b piston & shoe assy. S13-45680 S13-46040 S21-11649 7
15
ASSEMBLY PROCEDURES
ROCKER CAM/PISTONS
AND RETAINER
Marks Designate
Top of Assembly
Figure 3
Note: Install items 6, 7, 8, and 9 on side shown of rocker
cam if pump model number has “B” suffix. Install on
opposite side if “A” suffix.
ROCKER CAM See figure 3. Position the cradle (20) on a clean flat surface with the large flat area down.
Position the rocker cam (24) on the cradle (20). Note marks made earlier to indicate top
of rocker cam & cradle.
Place O-ring (23c) around spacer (23d) and insert in the vane seal (23b).
Insert check valve (23e) inside of spacer (23d) and assemble between the two backup
plates (23a) with the notched V’s exposed.
Install assembled cartridge in slot in cam as indicated in Figure 3. Repeat steps 1, 2 and
3 on other side of cam.
Insert the four holddown vanes (22) in the slots on each side of the control vanes (23).
Position both control chambers (17) on a clean flat surface with seal grooves turned up.
Drop the four steel balls (19) in the four counterbored holes at each end of the seal
grooves.
Lubricate seals (18) and insert in seal grooves in control chamber (17).
The tapered side of the seals must be pushed into the grooves and the ends must cover
the steel balls.
Install the control chamber (17) with seal (18) and steel balls (19) assembled over the
control vane (23). The seal must be against the cam. Rotate the chamber until it passes
over the control vane assembly, then rotate in the opposite direction until the 1/4" dowel
pins (16) can be pushed through the chamber (17) and into the cradle (20). Install cham-
ber in the same manner on the other side of the cam.
Two sets of chamber covers are available. The set marked CW must be installed in the
right hand rotation pump and the set marked CCW must be used in the left hand rota-
tion pump. (Rotation is determined facing the shaft end of pump.) The covers must be
installed with the tubing holes and the tapped holes at the top of the unit. Install cham-
ber covers (15r) and (15l) on the control chambers (17) over the dowel pins (16). The
tapped holes must be at the top. Refer to the “T” marked on the rocker cam (24) and cra-
dle (20).
Install four 1/4-20 screws, two (11) and two (12), in each side and torque to 10 ft.-lbs.
(13.56 Nm)
Install two 7/16-14 screws (10) in each side and torque to 45 ft.-lbs. (61.0 Nm)
Install O-ring (14) and plug (13) in each cover.
16
ASSEMBLY PROCEDURES
ROCKER CAM Install tubes (25) in reamed holes in each cover. These tubes must be a tight fit. If tubes
(continued) are loose, the ends can be expanded with a tapered punch.
Tap the tubes in place with a plastic mallet.
Install two orifice screws (8) in the servo stem (7).
Install servo plate with the end of the screws (6) through the servo stem. The orifice
screw end of the servo stem must be against the servo plate.
Position the stem and plate on the rocker cam input side at 9 o’clock position on “B” suf-
fix or 3 o’clock on “A” suffix models with the screws positioned over the 10-24 tapped
holes. Torque the screws (6) to 40 in. lbs. (4.5 Nm). Install setscrews (6a) and torque to
5 ft.-lbs. (6.8 Nm). Caution: The set screws must not protrude from the servo plate.
Install creep plate (5) over center post on rocker cam with small O.D. of plate turned
toward cam.
PISTONS AND SHOES See figure 3. Insert the seven piston and shoes (4b) in the shoe retainer (4a). Position
the assembly (4) over the center post and against the creep plate.
Install thrust washer (2), over center post.
MOUNTING, FLANGE, CAM & Five different retaining rings (1) are available for the holddown assembly. Each ring is
CRADLE, BARREL marked; white dot .087 (2.21 mm) thick, blue dot .085 (2.16 mm) thick, yellow dot .083
(2.11 mm) thick, green dot .081 (2.06 mm) thick, and red dot .079 (2.01 mm) thick. Install
the thickest ring (1) with the dot up, that will fit in the groove on the center post and allows
a maximum clearance of .002-.004 (.051-.102 mm) between the shoe and creep plate
while grasping one piston and lifting tightly against shoe retainer.
The piston and shoe assembly (4) must be free to rotate easily by hand. The assembly
must be rotated through 360° to confirm there is no binding and that each shoe is always
free in the retainer plate. Oil the assembly thoroughly.
Position the cradle and cam assembly with the piston and shoe assembly attached with
T marked on the cradle turned up.
See figure 4. Insert tube line assemblies (3 and 4) in the holes provided in cradle.
Note: Tube assemblies (3 & 4, fig. 4) must be a snug fit into holes in cradle. Expand end
of tubes with a pointed tool to assure fit.
Position the mounting flange (7) with the large open end up, and install two dowel pins
(6) in the cradle mounting surface of the flange and two dowel pins (6) in the outer edge
of the flange.
See
Fig. 3 Install rocker cam and cradle assembly over the two dowel pins (6) in the mounting
flange. Be certain that cradle is seated over the pins and against the flange with the tube
lines (3) and (4) in the grooves in the flange.
Position the mounting flange with the rocker cam assembly installed on the top or bottom
side and install two or more 1/4-20 x 1-1/4" screws through the seal retainer area into the
cradle. Be certain the cradle is fully seated in flange. These screws are required to hold
the rocker cam assembly in place and will be removed later.
Return the assembly to an upright position with the mounting flange down.
Tilt the rocker cam to either extreme position in the cradle.
Position the Barrel Assembly with Auxiliary Shaft (1) directly over the pistons. Start with
the uppermost piston and guide them one at a time into the barrel. Return the rocker cam
to a level position in the cradle.
item description part no. qty.

1 barrel and auxiliary shaft assy. See fig. 2 1
3 tubing assy. (right side) S13-42402 1
4 tubing assy. (left side) S13-42403 1
5 rocker cam and stroking assy. See fig. 3 1
6 dowel pin 3/8" X 3/4" 324-22412 4
7 mounting flange 033-70604 1
Figure 4
17
ASSEMBLY PROCEDURES
HOUSING See figure 5. Position housing (1) on a clean flat surface with the large open end up.
S13-42335
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clear oil and protected from nicks or surface damage.
2
Clean housing, item #1, and barrel bearing, item #2. Apply loctite primer grade "T" & loc-
tite retaining compound #609 to bearing O.D. & bearing bore of housing. Rest housing
on mounting flange end.
Position notch on bearing (2) with hole in housing bore. Insert Pressing Plug tool (figure
Drive 1
T-4) in the bearing. With smooth and steady force, press the bearing into the housing
Shaft Right bore until seated. DO NOT HAMMER OR BEAT INTO PLACE.
End Side
Install bearing retainer (7) with O-ring (8). Torque to 50 lb.-ft. (68 Nm).
Bottom
3
Turn housing (1) on side and install roll pin (4) in the 1/4" through hole in the control cover
4 pad. The pin must be 3/8" below the pad surface. THE PIN END MUST NOT INTER-
FERE WITH THE INTERNAL BEARING CAGE. Install two dowel pins (3) in the blind
Left
holes in the same pad.
Repeat the above step on the opposite side of the housing.

Port Block End
Place O-ring (5) on plug (6) and install in bottom of housing (1). (Roll pins (4) are in bot-
Figure 5 tom of housing.)

1 housing 033-91108 1
2 bearing 033-91107 1
3 dowel pin 324-21608 4
4 roll pin 325-16280 2
5 O-ring 90-6290-12 691-00912 1
6 hollow hex plug SAE-12 488-35014 1
7 retainer-bearing 033-91106 1
8 O-ring, 90 S-1 ARP 908 691-00908 1
HOUSING, END CAP, CAM See figure 6. Insert the three face plate pins (1) in the holes provided in the barrel face.
AND BARREL
Apply heavy grease to the face of the barrel and install the face plate (2) over the pins
(1) in the barrel.
Make certain the face plate is properly seated on the barrel and pins with the steel
side towards the barrel face. The face plates have only one side bronzed and this
should be toward the port plate. If necessary, remove coating from edge of face plate
to determine bronze side.
Install gasket (3) over the two dowel pins (item 6 on Fig. 4) in the mounting flange.
Position the Housing Assembly (4) over the Barrel and Auxiliary Shaft Assembly and
carefully guide the pressure tubes and tube lines (items 2, 3 and 4 on Fig. 4) through the
Housing Assembly (4).

1 face plate pins 033-49825 3
*2 barrel face plate 6 in3 only 033-71530 1
barrel face plate 7.25 and 8.0 in3 033-72532 1
3 housing gasket 033-91067 1
4 housing assembly See fig. 4 1
*Note: item 2: (Ref. only) Arcuate port width: 6 in3 is 13/32" (10,3 mm), 8.0 & 7.25 in3 is
1/2" (12.7 mm)
See
Fig. 4
Figure 6
18
ASSEMBLY PROCEDURES
PORT BLOCK See figure 7. Position the port block (1) on a clean flat surface with the two open ports up.
THE OPPOSITE FACE MUST NOT BE SCRATCHED OR DAMAGED. Position needle
bearing (2) on tool (Figure T-5) with the marked end of the bearing against the shoulder on
the tool and press the bearing (2) into the port block. The bearing must be .010-.025" (.254-
.635 mm) below the surface.
Slip check ring (3) into the two 1.50" (38 mm) ports and align holes in the ring with the
side holes in the port wall.
Place lock washers (6) on special screws (5). Insert (5) through port wall and drilled holes
in checks (3) and thread into clamps (4). Torque to 10 ft. lbs. (13.56 Nm).
Thread socket pipe plugs (8) into port block.
Thread two check valve assemblies (7) into valve face of port block.
Figure 7 Place O-ring (10) on hollow hex plug (9) and thread into tapped hole in top of the port
block.

1 port block 033-71296 1
2 needle bearing 230-82146 1
3 check ring 033-70502 2
4 clamp 033-70489 2
5 special screw 033-70908 2
6 no. 10 lock washer 348-10016 2
7 check valve assy. S13-40266 2
8 1/4 soc. pipe plugs 431-90404 2
10 O-ring 90-6290-6 691-00906 1
MOUNTING PORT See figure 8 on next page. Position the pump with the unplugged hole (top drainport) in
BLOCK TO HOUSING the housing assembly at 12 o'clock position.
Install gasket (5) on the housing assembly (6).
Install the two special pins (3) in the face of the port block assembly. Apply petroleum jelly
or heavy grease to the plate (4) and position port plate over the pins (3) on the port block.
Port plate must be fully seated and indexed towards direction of rotation. (See port plate
view in figure 8.)
Slide the port block assembly and port plate over the end of the auxiliary shaft. Be cer-
tain that tubes 2, 3 and 4 shown on Fig. 4 are engaged and that the port plate (4) is still
on the pins (3).
When the pump is properly assembled, the valve mounting surface will be at the top of
the unit.
Install the four bolts (1), and torque to 225 ft.-lbs. (305 Nm). Caution: Use care to prevent
damage to the valve mounting surface while installing and torquing the two top bolts.

1 hex head cap screw 5/8-11 x 9 306-40182 4
2 port block assy. See Fig. 7 1
3 port plate pins 033-49825 2
4 RH port plate 6 in3 033-71526 1
LH port plate 6 in3 033-71525 1
RH port plate 7.25 in3 033-72811 1
LH port plate 7.25 in3 033-53776 1
RH port plate 8.0 in3 033-91252 1
LH port plate 8.0 in3 033-91553 1
6 housing Assy. S13-42335 1
7 mounting flange See Fig. 4 1
19
ASSEMBLY PROCEDURES
MOUNTING PORT
BLOCK TO HOUSING
(continued)
Rear View –
Width of Arcuate Ports
6 in.3 is 13/32" (10,3 mm)
7.25 and 8.0 in.3 is 1/2 (12,7 mm)
Figure 8
15
16 13
14
GEROTOR IN POSITION FOR RH ROTATION
Figure 9
GEROTOR AND BARREL See figure 9. Position the unit with the shaft in a horizontal position and the valve block
HOLDDOWN mounting surface turned up. Rotate the shaft until the small keyway in the auxiliary shaft
is at 12 o’clock.
If pump is being assembled for right hand rotation install dowel pin (4) in hole in port
block at the 9 o’clock position; if left hand pump, install at 3 o’clock position when view-
ing from port block end of unit.
Install side plate (1), steel side first, over dowel pin. Insert key (2) in shaft keyway. Install
the inner gear of the gerotor assembly (3b) on the shaft and over the key (2). Install the
eccentric ring (3a) on the dowel pin (4). Install the large outer gear of the gerotor assem-
bly (3b) inside the eccentric ring (3a) and over the inner gear.
Note: When changing pump rotation consult parts list for proper side plate.
Place O-rings (7) and (8) on side plate assembly. Lubricate the O-rings and slip the pres-
sure plate (9) over the O-rings on the side plate assembly. Slip the two plates over the
auxiliary shaft and position the gerotor side plate over the dowel pin (4).
Place seal ring (12) on auxiliary shaft. Position bearing (11) between the two thrust wash-
ers (10) and install around the seal ring (12). Install insert (15) over spline on shaft.
Thread holddown nut (13) on the shaft and tighten no more than 10 ft. lbs. (13.56 Nm)
max. Back off the nut (13) until second slot is aligned with pin hole in the shaft. Insert pin
(14) through nut and shaft and secure with ring (16).
Check the main shaft for smooth rotation. If not smooth, check the gerotor parts for posi-
tion and hold down nut for proper adjustment.
20
ASSEMBLY PROCEDURES

1 side plate 033-71492 1
2 square key 1/8 x 9/16 211-22034 1
3 gerotor and eccentric ring assy. S13-43334 1
3a eccentric ring 033-72256 1
3b inner and outer gerotor 033-71500 1
4 dowel pin 3/16 x 1-9/16 324-21225 1
*5 gerotor sideplate and bearing assy See below 1.
7 O-ring 70-914-44 671-00144 1
8 O-ring 70-914-29 671-00129 1
9 pressure plate 033-70531 1
11 bearing 230-82164 1
12 seal ring 033-72101 1
13 holddown nut 033-91052 1
14 pin 033-53921 1
15 insert 033-91051 1
16 retaining ring 033-53923 1
* for RH pumps use S13-46762

* for LH pumps use S13-46763
VALVE BLOCK See figure 10.

(before 7-93)
Note: Prior to assembly of reconditioned parts, check finish of gasket surface on
valve block and retainer. Must have 60 rms finish with no grinding marks which might
carry oil to outside surface. If lapping is necessary, check depth of pockets for valve
seats after lapping. Must be .085" (2.16 mm) minimum after lapping, to provide clear-
ance for valve seats.
Lubricate the four orifice plugs (12) and insert in the top of valve block (11).
Check the pilot valve assembly (41) to be certain that approximately 1-1/2 threads are
exposed from this small nut on the bottom of the valve assembly. This setting will allow
the valve to function at about 200 PSI (14 bar). Each complete right hand turn of this
screw will increase the pressure about 50 PSI (3.4 bar). Torque hex lock nut to 20-25 in.
lbs. (2.26 to 2.82 Nm). Thread the check valve (41) into the 3/8-24 tapped hole into the
valve block (11) as shown.
Press the two dowel pins (10) into the holes provided in the bottom of the valve block
(11). The pins (10) must be .12" (.3 mm) below the surface.
Place the two sequence seats (8) in the sequence ports (SB, SA). Place the four valve
seats (9) in the ports marked RB, RA, RV and servo. Position the gasket (7) and retain-
er plate (6) over the seats and insert the four screws (4) in the block (11). Torque to 10
in.-lbs. (1.1 Nm).
Position the valve block and the attached parts with four orifices (12) turned up. Insert the
two 1-7/16 long springs (17) in the two sequence poppets (13) and install (13) and(17)
in the block and over the sequence seats (18) in ports SB and SA. Install the four valve
poppets (14) in the ports marked RB, RA,RV and servo. Servo and RV seats to seated
with grooved side down. Insert spring retainer (15), large end first, in the servo poppet.
Insert the light weight spring (18) 1-9/16" (39.7 mm) long in the RV poppet. Insert the
three 1" (25.4 mm) long springs (16) in poppets RB, RA and servo.
Lubricate the two check valves (19) and install in sides of cover (21).
Lubricate O-ring (22) and place on seat (23) and install in valve cover (21). Use a 1/2" 6
point 1/4" drive socket and torque to 15 ft-lbs. ((20.4 Nm). Do not use impact wrench.
Lubricate O-rings (26) and (28) and place on parts (27) and (29). Assemble parts 30, and
33 on (31) and start (31) into housing (29). Push seal piston (27) and O-ring (26) into
housing (29) with the small end of the piston exposed. Place spring (25) on cone (24) and
insert all these parts in the valve cover (21). Be certain that cone (24) enters seat (23).
Disassemble the strainer assembly (34) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in. (1.47 Nm).
21 Revised
ASSEMBLY PROCEDURES
VALVE BLOCK Lubricate O-rings 37. Install (37) in the block (11).
before 7-93 (continued)
Position the cover (21) over the springs and poppets and install the four screws (39). BE
CERTAIN THAT THE SPRINGS ARE IN THE RIGHT POSITION BEFORE TIGHTENING
THE SCREWS.
Install dowel pin or roller pin (40) in the hole over the servo poppet. Lubricate the four
O-rings (42) and place on the four plugs (43). Install the four plugs. Lubricate O-ring (35)
and place on plug (36) and install.
Caution: Use of other than SAE plugs will result in malfunction and possible pump
damage
Invert the complete assembly and install roll pins (5) thru plate (6) and into the valve
block. Install O-rings (2) and (3) in the plate (6).

1 not used
2 O-ring 70-914-2 671-00014 2
3 O-ring 70-914-1 671-00013 2
4 10-24 x 1/2 button hd screw 353-25023 4
5 1/8 x 3/4 roll pin 325-08120 2
6 retainer plate 033-91422 1
7 lower gasket 033-91193 1
8 sequence seat 033-70507 2
9 valve seat 033-70500 4
10 3/16 x 3/4 roll pin 325-12120 2
11 valve block 033-72377 1
12 .047 orifice plug 033-25528 4
13 sequence poppet 033-72378 2
14 valve poppet 033-72379 4
15 spring retainer 033-70482 1
16 spring (1 OAL) 033-71086 3
17 spring (1-7/16 OAL) 033-70512 2
18 spring (light weight) 033-22141 1
20 not used
21 valve cover 033-72376 1
22 O-ring 6290-3 691-00903 1
23 seat 033-70508 1
24 cone 033-12288 1
25 spring 033-12289 1
26 O-ring 70-6227-7 671-00012 1
27 seal piston 033-21767 1
28 O-ring 90-6290-10 691-00910 1
29 housing 033-70545 1
30 5/16-24 hex nut 335-13100 1
31 5/16-24 x 1-1/2 soc set screw 312-13160 1
32 not used
33 acorn nut 327-25006 1
34 servo strainer assy. S13-43240 1
35 O-ring 90-6290-6 691-00906 1
36 hex plug SAE-6 488-35003 1
37 O-ring 671-00050 2
38 not used
39 hex hd cap screw 10-24 x 1-3/4 306-40167 4
40 dowel pin 1/8 x 5/8 324-20810 1
41 pilot relief assy S23-12813 1
42 O-ring 90-6290-4 691-00904 5
22
ASSEMBLY PROCEDURES
Valve Block
(Before 7-93)
S23-00904
Figure 10

(after 7-93)
Note: Do not use impact tools or over tighten threaded parts.
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (1) with the six poppet valve bores up in order to press two roll pins
(46) in position. (Roll pins to be .12" (3.04 mm) below surface of valve block).
Install four orifice plugs (3) into valve block (1) and tighten in place.
a. Install the orifice screw of the strainer assembly into valve block. Thread elastic stop
cap screw, 6-32 x 1/4" long. Torque #6-32 screw to 13 lb-in (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve block.
23
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
after 7-93 (continued) Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
groove side facing up, over poppets.
Place spring (32) 1.56" long (39.6 mm) into bore next to compensator valve side of block.
Install replenish poppet over spring. Position seat (28) with the groove side facing down,
over poppet.
Insert spring (35) 1.09" long (27.7 mm) into the remaining bore. Place spring retainer (34)
in spring. Place servo poppet (31) over the retainer and spring. Position seat (28) with
the groove side facing down, over poppet.
Carefully position the retainer plate over seats and poppets. Pressing with one hand on
the valve block, compress seats, poppets and springs far enough to alternately thread
two button head cap screws (43) in far enough to hold the retainer plate. Install the other
two screws and alternately tighten screws. Torque to 30 lb-in. (3.39 Nm).
Lubricate O-ring (4) and install on to seat (5), thread seat in valve block. (Be careful not
to damage bore in the seat.) Torque to 15 lb-ft (20.34 Nm).
Apply vaseline to shank of cone (13) and install spring (12) on cone. Carefully insert cone
and spring into valve block positioning point of cone into bore of seat.
Lubricate O-ring (11) install in groove of piston (10) and insert end into spring (12).
Lubricate O-ring (9) and install on housing guide (8) and thread into valve block. Tighten
in place.
Thread nut (7) on socket set screw (6) and thread screw into housing guide (8) until it
starts to compress spring.
Using a small bladed screw driver, thread the pilot replenishing relief valve assembly (36)
into valve block and lightly tighten in place. (Do not over tighten. Over tightening can
cause sides of slot to break now or at next removal.)
Lubricate O-ring (4) and install on plug (25) and tighten plug in place.
Thread check valve (2) into valve block and lightly tighten in place. (Do not over tighten.)
Lubricate O-ring (22) and install on plug (23) and tighten in place.
Repeat step 18, on other end of valve block.
Install pin (21). Lubricate O-ring (22) and install over plug (23) and tighten plug in place.
Lubricate two O-rings (22) and install over two plugs (25) and tighten in place.
Using a small hammer carefully tap roll pins (46) into and thru the retainer plate (42), the
pins should bottom out in hole leaving enough length sticking out for piloting into the port
block.
Lubricate O-ring (47), (48) and (37) and install in the bottom of retainer plate (42).
Valve is ready to install on pump.
24
ASSEMBLY PROCEDURES
Valve Block
(After 7-93)
S23-12770
Seal Kit
S23-00135
Figure 11
25
ASSEMBLY PROCEDURES

1 valve block 033-91221 1
2 check valve S13-40266 2
3 orifice plug (.0465 dia.)
(1.18 mm) 033-91249 4
4 gasket, O-ring 691-00903 3
5 seat 033-70508 1
6 screw, socket head 5/16-24 x 1 312-13160 1
7 nut, hex jam 5/16-24 335-13100 1
8 housing guide 033-70545 1
9 gasket, O-ring 691-00910 1
10 piston 033-21767 1
11 gasket, O-ring 671-00012 1
12 spring 036-12289 1
13 cone 036-12288 1
14 assy servo strainer S13-43240 1
19 gasket, O-ring 691-00906 1
20 plug 488-35003 1
21 pin, 1/8 x 5/8 324-20810 1
22 gasket, O-ring 691-00904 5
23 plug 488-35001 5
25 plug 488-35049 2
26 pin, roll 3/16 x 3/4 325-12120 2
27 seat, sequence 033-70507 2
28 replenish & servo seat 033-70500 4
29 gasket, valve block 033-91193 1
30 poppet, sequence 033-72378 2
31 poppet, dual & replenish 033-72379 4
32 spring, replenish 033-22141 1
33 spring, sequence & servo 033-70512 2
35 spring, dual relief 033-71086 3
36 pilot valve, replenish relief S23-12813 1
37 gasket, O-ring 671-00050 1
43 screw, button head
#10-24 x 3/4 LG 353-25078 4
45 nut, acorn 5/16-24 327-25006 1
46 pin, roll 1/8 x 3/4 325-08120 2
47 gasket, O-ring 671-00013 2
48 gasket, O-ring 671-00014 2
26
ASSEMBLY PROCEDURES
VALVE BLOCK
for special mounting of servo valve
(before 7-93)
S23-11433
Figure 12
See figure 12.
Note: Prior to assembly of reconditioned parts, check finish of gasket surface on valve
block and retainer. Must have 60 rms finish with no grinding marks which might carry oil
to outside surface. If lapping is necessary, check depth of pockets for valve seats after
lapping. Must be .085" (2.16 mm) minimum after lapping, to provide clearance for valve
seats.
Place valve block (25) with O-ring groove down and horizontal in order to press two roll
pins (26) in position. (Roll pins need to be .12" (3.05 mm) below surface of valve block).
Apply a liberal amount of vaseline or grease to the six counterbores in the face of the valve
block (25). Install two valve seats (27) tapered bore side first, into counterbores and
against roll pin (26), one required each end, (outer-most counterbores in block). Insert the
valve seats (28) and valve seat (44) in remaining counterbores as shown.
Press two roll pins (46) into retainer plate (42). Each roll pin should stick out approximately
.25" (6.35 mm) from each face of the retainer plate.
27
ASSEMBLY PROCEDURES
VALVE BLOCK Position valve block gasket (29) on valve block. Take care that none of the gasket is cov-
for special mounting of servo valve ering the valve seats.
before 7-93 (continued) a. Position retainer plate (42) with O-ring grooves facing up, over valve block gasket.
Install four button-head cap screws (43), torque to 30 in.-lbs. (3.39 Nm).
b.Turn the assembly over so that it is resting with the retainer plate O-ring side down-
ward.
Place spring (33) (1.43" long) (36.3 mm) into poppet (30) and insert small hole end first
into outer-most bores at each end of the valve block (25).
Insert three poppets (31) and one poppet (34) in remaining bores as shown, small diam-
eter end first.
Slip springs (33) into poppets (34) and (30) as shown.
Insert two springs (35) (1.09" long) (27.7 mm) into remaining outer poppets (31).
Install spring (32) 1.56" long (39.6 mm) into remaining poppet located in center of valve
block.
Install four orifice plugs (3) in valve block (25) and tighten in place.
Thread pilot replenishing relief valve (36) into block (25). Valve must not extend below
lower surface of retainer plate.
Place O-ring (4) onto seat (5) and install in valve block cover (1). (Be careful not to dam-
age bore in seat.) Torque (5) to 15 ft.-lbs. (20.4 Nm). (Do not use impact wrench).
Lubricate O-ring (11) and insert into groove of seal piston (10) and slip spring (12) onto
end of seal piston and press into bore of housing guide (8).
a. Lubricate O-ring (9) and install on housing guide (8).
b. Place shank of cone (13) into spring (12).
c. Align cone with seat in valve cover and thread housing guide into bore and tighten
in place.
Thread nut (7) on soc. setscrew (6) and thread into housing guide (8) until it starts to
compress spring. Thread acorn nut (45) on soc. setscrew (6).
Coat check valve (2) threads with loctite removable thread locker #242 and thread into
end of valve cover (1). (Be sure check valve is properly installed and does not block pas-
sages from orifice plug (3). Lubricate O-ring (22) and install on plug (23) and tighten.
Repeat above step at the opposite end of the valve cover (1).
Disassemble the strainer assembly (14) in valve block and reassemble per the following:
a. Install the orifice screw of strainer assembly (14) into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 in.-lbs. (2.6 Nm).
b. Install the strainer support, filter screen and #6-32 x 1/4 lg. screw. Torque #6-32
screw to 13 in.-lbs. (1.47 Nm).
Place O-ring (37) and two (2) O-rings (47) into the grooves on the upper surface of the
valve block and secure with vaseline or grease.
Place valve cover (1) over valve block (25) positioning over springs (33), (32) and (35)
and secure in place with four (4) socket hd. cap screws (41).
Lubricate O-ring (19) and install over plug (20) and tighten plug in place.
Lubricate O-rings (47) and install in underside of manifold block (15). Carefully, place
manifold block (15) on top of the valve cover (1) making sure the O-rings are correctly
seated. Secure with four (4) soc. hd. cap screws (41) by threading into valve block (25).
Insert spring (16) and spool (38) into manifold (15) with the spring guide and spring
towards the left side of the manifold (15) when viewing from the top rear.
Install temporary plugs (49) and (50) in 1/2" tube and 1/4" tube ports, front and back and
side. Insert O-ring (19) and plug (20) in alternate drain port.
28
ASSEMBLY PROCEDURES

(before 7-93)

1 valve cover 033-54391 1
2 valve check S13-40266 2
3 orifice #56 (.0465) 1/16 pt 033-25528 5
4 O-ring, 90 S-1 ARP 903 691-00903 1
5 seat 033-70508 1
6 set screw, 5/16-24 x 1 cup pt 312-13160 1
7 hex jam nut 335-13100 1
8 guide-housing 033-70545 1
9 O-ring, 90 S-1 ARP 910 691-00910 1
10 piston 033-21767 1
11 O-ring, 70 S-1 ARP 012 671-00012 1
12 spring 036-12289 1
13 cone 036-12288 1
14 servo strainer S13-43240 1
15 manifold 033-54389 1
16 spring (Lee #LC-038C-19) 225-92083 1
19 O-ring, 90 S-1 ARP 906 691-00906 3
20 plug 6HP5N- PL 488-35041 3
21 gasket 035-47851 1
22 O-ring, 90 S-1 ARP 904 691-00904 10
23 plug, 4HP5N-S w/o PL 488-35001 9
25 valve block 033-54390 1
26 roll pin 3/16 x 3/4 325-12120 2
27 seat sys relief 033-70507 2
28 servo seat 033-70500 3
29 gasket 033-91193 1
30 poppet 033-72378 2
31 poppet 033-72379 3
32 spring 033-22141 1
33 spring 033-70512 3
34 poppet, servo relief 033-54398 1
35 spring 033-71086 2
36 valve, repl S23-12699 1
37 O-ring, 70 S-1 ARP 050 671-00050 1
38 spool 033-54392 1
39 O-ring, 90 S-1 ARP 008 691-00008 1
41 screw, soc hd 10-24 x 2-3/4 358-10300 4
43 screw 353-25023 4
44 seat, servo relief 033-54399 1
45 acorn nut 327-25006 1
46 rollpin 1/8 x 3/4 325-08120 2
47 O-ring, 70 S-1 ARP 013 671-00013 6
48 O-ring, 70 S-1 ARP 014 671-00014 2
49 plug 3/4-16 449-00016 2
50 plug 7/16-20 449-00013 1
51 cover, gasket 035-47852 1
52 screw, soc hd 10-32 x 1/2 359-09080 4
53 screw, soc hd 3/8-16 x 4 358-16360 4
54 plug 035-54400 1
55 screw, hex hd 306-40132 4
seal kit S23-04226
29
ASSEMBLY PROCEDURES
VALVE BLOCK
(after 7-93)
S23-12776
Figure 13
See figure 13.
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in (1.47 Nm).
Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
30
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
for special mounting of servo valve step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
after 7-93 (continued)
Place spring (32) 1.56" (39.6 mm) into bore next to com-pensator valve side of block.
over poppet.
Insert spring (33) 1.43" (36.3 mm) into the remaining bore. Place servo poppet (37) over
the retainer and spring. Position seat (44) with the tapered bore facing down, over poppet.
Lubricate O-ring (11) install in groove of piston (10) and insert end of piston into spring
(12).Lubricate O-ring (9) and install on housing guide (8) and thread into valve block.
Tighten in place.
Lubricate O-ring (4) install on plug (25) and tighten plug in place.
Lubricate O-ring (22) install on plug (23) and tighten in place.
Repeat above step on other end of valve block.
Lubricate O-rings (22) install over plugs (23) and tighten plugs in place.
Lubricate O-rings (4) install on plugs (25) and tighten in place.
Lubricate O-ring (19) install over plug (20) and tighten in place.
towards the left side of the manifold (15) when viewing from the top rear. Install orifice
plug (61) in manifold (15).
Install temporary plug, (50) in 1/4" tube port. Insert O-ring (19) and plug (20) in alternate
drain port.
block.
31
ASSEMBLY PROCEDURES

(after 7-93)

3 orifice #56 (.0465) 033-91249 4
4 O-ring, 90 S-1 ARP 903 691-00903 3
5 seat 033-70508 1
6 set screw, 5/16-24 x 1 cup pt. 312-13160 1
7 hex jam nut 335-13100 1
9 O-ring, 90 S-1 ARP 910 691-00910 1
10 piston 033-21767 1
11 O-ring, 70 S-1 ARP 012 671-00012 1
12 spring 036-12289 1
13 cone 036-12288 1
15 manifold 033-54389 1
16 spring (Lee #LC-038C-19) 225-92083 1
19 O-ring, 90 S-1 ARP 906 691-00906 3
20 plug 6HP5N-PL 488-35041 3
22 O-ring, 90 S-1 ARP 904 691-00904 10
23 plug, 4HP5N-S w/o PL 488-35001 9
25 plug (3HP5N-S) 488-35049 2
26 pin, roll 3/16 x 3/4 325-12120 2
27 seat, sys relief 033-70507 2
28 servo seat 033-70500 3
29 gasket 033-91193 1
30 poppet 033-72378 2
31 poppet 033-72379 3
32 spring, (light weight) 033-22141 1
33 spring (1.47 (36.5 mm) O.A.L.) 033-70512 3
35 spring (1" (25.4 mm) O.A.L.) 033-71086 2
36 valve, repl. S23-12699 1
37 O-ring, 70 S-1 ARP 050 671-00050 1
38 spool 033-54392 1
39 O-ring, 90 S-1 ARP 008 691-00008 1
41 screw, soc hd 10-24 x 1 1/4 358-10180 4
43 screw 353-25078 4
45 acorn nut 327-25006 1
46 roll pin 1/8 x 3/4 325-08120 2
47 O-ring, 70 S-1 ARP 013 671-00013 6
48 O-ring, 70 S-1 ARP 014 671-00014 2
50 plug 7/16-20 449-00013 1
53 screw, soc hd 3/8-16 x 4 358-16360 4
54 plug 035-54400 1
58 screw, hex hd 306-40132 4
61 orifice #56 (.0465) 033-25528 1
seal kit S23-04226
32
ASSEMBLY PROCEDURES

1 no. 3 splined shaft assy. (see fig. 1) S13-41805 1
no. 2 keyed shaft assy. (see fig. 1) S15-41806
2 shim .008 (.203 mm) (use only 1) 033-53948 1
shim .007 (.178 mm) 033-53949
3 ret. ring .066/.068 (1.68/1.73 mm) (use only 1) 033-53901 1
ret. ring .070/.072 (1.78/1.83 mm) 033-53902
ret. ring .074/.076 (1.88/1.93 mm) 033-53903
4 shaft seal 623-00006 1
5 O-ring 671-00043 1
6 seal retainer 033-57892 1
7 nyltite gasket 631-45003 4
8 screw 306-40144 4
9 servo stem 033-71312 1
10 balance plate 033-70546 1
11 spacer 033-71247 2
12 soc. hd. cap screw 10-24 x 2-3/4 358-10300 2
13 nyltite washer 631-45007 8
14 hex washer hd. screw 3/8-16 x 1-1/4 353-25018 8
15 output control assy. see below 1
16 input control assy. see below 1
17 hex. hd. cap screw 3/8-16 x 3-1/4 306-40184 8
*18 O-ring 671-00017 1
*19 O-ring 671-00048 1
20 hex hd screw 306-40025 2
21 optional - gear pump C.W.(see note) 512-42023 1
- gear pump C.C.W. 512-42024
- vane pump TB006 (CW) 024-51095-0/01
- vane pump TB006 (CCW) 024-51096-0/01
22 rear adapter, SAE-A for shuttle valve (Std.) S23-12362
rear adapter, SAE-B for shuttle valve (Std.) S23-12670
23 hex screw 306-40224 4
24 shuttle valve-external drain (see fig. 16) S23-11966 1
shuttle valve-internal drain (Std.) S23-12007
*Some controls use gasket 033-91058 in lieu of O-rings (cast iron covers).
Powder metal covers have groove for O-rings 671-00048, 671-00017.
Note: Any pump with SAE-A or SAE-B mounting may be used, with the corresponding
adapter assembly (22).
OUTPUT CONTROLS output controls part no.

standard, with volume indicator S13-42064
torque limiter S23-12299
INPUT CONTROLS input controls part no.

10 “B” mtg. CW, “A” mtg. CCW S23-12327
10 “B” mtg. CCW, “A” mtg. CW S23-12328
2H S23-12328
40 S23-12344
4A S23-12325
4B S23-12343
4C S23-12324
5A '0' deadband S23-12413
5C S23-12414
60 S13-48944
6B S23-12424
8A S23-12268
9A S23-12667
33 Revised
ASSEMBLY PROCEDURES
Valve Block
See Fig.
10, 11,
12, 13
21
20
22
24
23 Figure 14
SHAFT AND SEAL INSTALLATION See figure 14. Stand the pump in an upright position with the port block inlet and outlet
pads turned down.
Install the shaft and bearing (1) assembly in the mounting flange and cradle. Be certain
that there are no burrs or sharp edges on shaft seal area of the shaft.
For a rigid shaft application use the shim (2) that results in least clearance around the
shaft bearing. Do not use a shim with a floating shaft.
Install the snap ring (3) in the mounting flange to retain the Shaft Assembly. Be certain
that the ring is fully seated in the groove. Use the ring that results in the tightest fit.
MECHANICAL SHAFT SEAL

ASSEMBLY PROCEDURE
Warning: When installing a new mechanical shaft seal, exercise care to insure that
all of the parts fit together properly. This is particularly important if the seal was once
assembled and disassembled for some reason. If the rubber boot, item 4, grips the
shaft and doesn't slide on the shaft, as it is disassembled, then the spring, item 7, can
disengage the shell, item 5, from the band, item 6, so that they do not re-engage
properly when reassembled. Be sure the shell and the band are properly engaged
before reassembling the seal, and stays engaged during assembly.
Note: Lubricate seal and shaft with clean hydraulic fluid of the same type that will be
used in the system.
34
ASSEMBLY PROCEDURES
See figure 14. The seal assembly (4) is available as a complete unit only.
Caution: Before installing the seal assembly examine all the parts. The lapped seal
seat and the carbon ring have a precision finish that must be handled with care. Be
certain that both parts are free of scratches, marks and cracks.
Place the spring retainer (e) over the shaft and against the retaining ring on the shaft
assembly. Place the spring (d) against the retainer (e). Apply grease to the inner surface
of the rubber friction ring (f) and position the shell containing the rubber friction ring (f)
and carbon ring (c) over the shaft with the carbon ring exposed. Apply grease to the
square section rubber seal (a) and install on the ceramic seat (b). Insert the seat and seal
in the seal retainer (6) with the lapped side of the seat in position to contact the carbon
ring. Place the seal retainer assembly and O-ring (5) over the shaft with the lapped sur-
face against the carbon face. Place the four gaskets (7) on the four screws (8) and insert
the seal retainer (6). Depress the seal retainer only far enough to start the four screws
and tighten evenly. Torque to 10 ft.-lbs. (13.56 Nm).
Note: Seal installation must be completed quickly to avoid the rubber friction ring from
seizing on the shaft.
COUNTER-BALANCE SERVO Place the two spacers (11) on the two screws (12) and insert through the balance plate
STEM (10) and servo stem (9).
Insert these parts through the opening in the side of the housing assembly and position
the screws over the two #10-24 tapped holes in the rocker cam.
Hold these parts against the cam and alternately tighten the screws (12) to hold the
assembly firmly in place. Torque screws to 5 ft.-lbs. (6.78 Nm)
REAR DRIVE ADAPTER See figure 15. Place wave spring, (8) over isolation tube (4). Lube O-ring (7) and assem-
ble to isolation tube. Place isolation tube against pressure plate, item (9) Fig. 9.
Lube O-ring (5) and assemble to adapter (1).
Lube tetraseals (10). Insert into adapter block and carefully assemble adapter block to
port block. Using screws (9) and washers (12) to hold adapter block in place, torque to
150 ft-lbs. (203 Nm).
Insert retaining ring (6) into groove of coupling insert (3).
Coupling (2) with coupling insert (3) and retaining ring (6) may be installed to end of aux-
iliary shaft when external pump is mounted.
Adapter
Figure 15
35
ASSEMBLY PROCEDURES

1 adapter — SAE-A with shuttle pad 033-91015 1
adapter — SAE-B with shuttle pad 033-57967
adapter — SAE-A no shuttle 033-57958
adapter — SAE B no shuttle 033-57957
2 coupling 033-57963 1
3 insert — SAE-A 033-57965 1
insert — SAE-B 033-57964
4 tube — Isolation 033-57966 1
5 gasket — O-ring 671-00147 1
7 gasket — O-ring 671-00033 1
8 spring — wave 225-92093 1
9 screw — HHC 306-40088 4
10 gasket — Square 691-10131 2
11 gasket — O-ring (with SAE-A) 671-00152 1
gasket — O-ring (with SAE-B) 671-00155
12 washer 350-10136 4
PARTS LIST FOR FIGURE 16 SHUTTLE VALVE ext. int.

drain drain
item description part no. qty. qty.
1 blk-shuttle 033-57752 1 1
2 pilot valve ext. drain S23-22865 1 —
pilot valve int. drain S26-22867 — 1
3 spool 033-57180 1 1
4 spring stop washer 033-57182 2 2
5 sleeve 036-27549 1 1
6 piston 036-32902 1 1
7 spring 036-27547 1 1
8 spring 033-57181 2 2
9 O-ring 691-00125 2 2
10 O-ring 691-00026 1 1
11 tetraseal 691-10221 2 2
12 plug 488-35024 2 2
13 screw, HHC 1/2-13 x 3 1/2 306-40224 4 4
14 screw, SHC 3/8-24 x 1 3/4 359-15220 3 3
15 O-ring 691-00916 2 2
16 plug 488-35014 1 1
17 O-ring 691-00912 1 1
shuttle valve w/external drain S23-11966
shuttle valve w/internal drain S23-12007
PARTS LIST FOR FIGURE 16 PILOT VALVE ext. int.

drain drain
2-1 orifice 036-25528 1 1
2-2 O-ring 695-00013 2 2
2-3 cap 036-38910 1 1
2-4 set screw 312-35051 1 1
2-5 spacer 036-27548 1 1
2-6 piston 036-11694 1 1
2-7 block 036-11710 1 1
2-8 seat 036-11692 1 1
2-9 cone 036-12288 1 1
2-10 spring 036-32465 1 1
2-11 spring 036-85514 1 1
2-12 screw SHC 3/8-24 x 1-3/4 (w/hole) 036-36749 1 1
2-13 piston 036-21767 1 1
2-14 O-ring 675-00012 1 1
2-15 plug 036-21765 1 1
2-16 nut hex 5/16-24 333-13001 1 1
2-17 screw S.S. 5/16-24 x 1-5/8 312-13200 1 1
2-18 nut acorn 036-33474 1 1
2-19 plug hex soc. (external drain) 431-90104 1 —
2-20 plug-SAE-4 488-35001 — 1
2-21 O-ring 691-00904 — 1
seal kit, shuttle valve 523-15089
36 Revised
ASSEMBLY PROCEDURES
Exploded View of Shuttle

Valve Exploded View of
Pilot Valve
Figure 16
PILOT VALVE See figure 16. Insert seat (2-8) into cap (2-3) and seat in bottom of bore.
Install small end first of block (2-7) into bore and against seat.
Install small end first of piston (2-6) into block (2-7).
Install spacer (2-5) and secure in place with set screw (2-4).
Install spring (2-11) onto cone (2-9) . Install spring (2-10) over spring (2-11), and insert into
cap (2-3) and seat (2-8).
Install O-ring (2-14) in piston (2-13) and insert small end into springs.
Install plug (2-15), screw (2-17) & nut (2-16). Set per requirement and cover with acorn
nut. (2-18).
Insert orifice plug (2-1) in center hole of cap.
Grease and install O-rings (2-2).
If externally drained, insert plug (2-19) into hole on spring end of cap.
If internally drained, insert plug (2-20) and O-ring (2-19) in cap drain port.
SHUTTLE VALVE See figure 16. Lube spool (3) and insert it into valve body (1). When the spool is fully
engaged, move the spool back and forth a few times to check for smooth operation. Spool
must move freely in body bore.
Install spring stop (4) into one end of valve body (1). Make sure it is seated properly.
Insert spring (8) into valve body (1) over the spool (3). Install plug (12) & O-ring (15) into
the valve body (1).
Repeat step #2 on other end of valve body.
Lube O-ring (9) and install into valve body (1). Make sure it fits exactly.
Lube O-ring (9) and place over the sleeve (5) and install into bore of valve body (1). Be
careful not to jam sleeve in bore.
37
ASSEMBLY PROCEDURES
SHUTTLE VALVE Insert piston (6) into sleeve (5) and place spring (7) into piston (6).
(continued)
Lube O-ring (10) and place onto the sleeve (5).
Lube O-rings which come on pilot valve sub-assembly (2).
Mount pilot valve cap sub-assembly (2) onto shuttle block (1). Use three S.H.C. screws
(14) and the one screw which comes with the pilot valve sub-assembly. Make sure that
the screw that comes with the valve cap sub-assembly is positioned on end closest to
acorn nut. Torque to 50 ft-lbs. (68 Nm) Run lead wire which comes with valve cap sub-
assembly through holes in special screw and acorn nut. Twist ends together.
SHUTTLE VALVE MOUNTING Lubricate tetraseals (11) figure 16 and place in C' bores of shuttle valve mounting surface.
Carefully attach shuttle valve to adapter (22) fig. 14, using hex hd. screws (13) figure 16.
Torque to 75 lb-ft. (102 Nm).
38
IMPORTANT INSTRUCTIONS
Without Filter No Plug
External Filter With Plug
INSTRUCTIONS FOR CAUTION: The isolation plug enclosed is to be used ONLY if an external filter circuit
REPLENISHING CIRCUIT is provided. DO NOT operate this unit with the isolation plug installed unless an exter-
ISOLATION PLUG nal line has been provided.
When the external filter circuit IS NOT used discard the isolation plug.
When the external filter circuit IS used install the isolation plug between port G and H
(refer to appropriate installation drawing): use a 3/16 Hex. wrench by 4" minimum length
INSERTING THE ISOLATION PLUG INTO PORT H and tighten to 80 - 120 in.-lb. torque.
(9.04-13.56 Nm)
Isolation plug: Part No. 311-45032 (3/8-16 x 1/2 UNC Flat point set screw).
39
HYDRAULIC CIRCUIT
40 Revised
HYDRAULIC CIRCUIT
41 Revised
TEST PROCEDURES
GENERAL REQUIREMENTS 1. Maximum runout between pump shaft and electric motor shaft .003 (.076 mm) T.I.R.
A floating shaft must have a support in mounting bracket. A fixed shaft should not have
a support bearing in mounting bracket.
2. Electric motor speed - 1800 RPM.
3. Inlet temperature - 130° ± 10°F. (54°C ± 4°C)
4. Inlet condition Main Pump 100 to 150 PSI. (6.9 to 10.3 bar)
Gerotor 10" HG to 5 PSI. (25.4 mm HG to .34 bar)
5. Case pressure 65 PSI ± 10 PSI. (4.5 ± .69 bar).
6. Fluid - 200SSU @ 100°F. (37.8°C)
BASIC PUMP TEST 1. Mount pump on test stand. Connect system lines and gerotor inlet line to pump.
Connect case drain line to flowmeter. Connect shuttle return line to reservoir. If shuttle
pilot valve is externally drained, connect drain to max. 5 PSI (.34 bar) return line. If an
auxiliary pump is mounted, connect auxiliary pump inlet to reservoir. If auxiliary pump is
not mounted, remove coupling and seal auxiliary unit mounting surface.
2. Start electric motor.
3. Rotate pump input control shaft. The servo control should control pump displacement
through its full range. Set pump displacement for full volume, and adjust system pressure
for 1000 PSI (69 bar). Check and record system flow and case drain flow above and below
center.
6.0 in3 7.25 in3 8.0 in3

Maximum 47 GPM 57 GPM 63 GPM
System Flow (177.9 l/m) (215.7 l/m) (238 l/m)
Maximum 1.5 GPM 1.8 GPM 1.5 GPM
Case Drain Flow (5.71 l/m) (6.8 l/m) (5.7 l/m)
4. Back out compensator adjusting screw until unit is fully compensated (count number
of turns). Observe volume indicator and stroke rotary servo input shaft from full to full
position on each side of center. Indicator should remain on or very near zero position
("O"). If compensator functions normally, return compensator adjusting screw to its orig-
inal position and proceed with Step 5.
Caution: Do not over-tighten adjusting screw.
5. Cycle pump at 10 sec. intervals-full volume above center to full volume below
center*—as follows:
5 minutes at 1000 PSI (69 bar)
6. Adjust system pressure to 5000 PSI (345 bar) and set pump displacement for full vol-
ume. Check and record system flow and case drain flow above and below center.
*Pumps with screw adjustment controls do not need to be cycled.
6.0 in3 7.25 in3 8.0 in3

Minimum 41 GPM 50.0 GPM 55 GPM
System Flow (155.9 l/m) (189 l/m) (208 l/m)
7. Set pump to compensate at 5000 PSI (345 bar). Servo pressure should be at least
650 PSI (45.5 bar). Check and record replenishing flow. (Case leakage flow).
Maximum flow-14.6 GPM (55.3 l/m) with Barnes auxiliary pump. 6.5 GPM (24.6 l/m)
without auxiliary pump.
8. Set pump to compensate at minimum PSI. Check and record replenishing and servo
pressure.
Servo pressure-Minus Case Pressure 455 to 570 PSI (31.3 to 39.3 bar).
Repl. pressure-Minus Case Pressure 350 PSI ± 20 PSI (24.1 ± 1.4 bar).
42
TEST PROCEDURES
BASIC PUMP TEST If pressures are incorrect, remove replenishing relief valve pilot and increase or decrease
pressure as required. (One full turn on adj. screw will cause pressure to change approx-
(continued)
imately 50 PSI) (3.4 bar). Re-torque locknut to 20-25 in-lbs. (2.3-2.8 Nm).
Note: There is no servo relief valve adjustment. Increasing or decreasing repl. pres-
sure will cause both servo and repl. pressure to change by the same amount.
9. Set pump to full displacement and set the test stand relief valve at approx. 2000 PSI
(138 bar). Set the pump compensator at 1000 PSI (69 bar). Set the shuttle relief valve
pilot cap to 220 ± 20 PSI (15.2 ± 1.4 bar) above case pressure and secure with locknut
and acorn nut.
10. Stroke pump to center position and observe repl. pressure. It should rise to the value
in step 8 above.
11. Slowly cycle the pump across center several times while observing repl. pressure
drops to 220 ± 20 PSI (15.2 ±1.4 bar) while on stroke, and rises to 350 ± 20 PSI (24.1 ±
1.4 bar) at zero stroke, to verify shuttle operation.
12. Set pump to compensate at 5000 PSI (345 bar). Record repl. and servo pressure.
Servo Pressure-Minus Case Pressure-660 to 770 PSI (45.5 to 53.1 bar).

Repl. Pressure-Minus Case Pressure-350 ± 20 PSI (24.1 ± 1.4 bar).
13. Set pump to compensate at minumum PSI. Servo pressure should return to 455 to
570 PSI (3.3 to 39.3 bar).
Note: After completing step 13, proceed with pump control test and adjustment. Refer
to the goldcup control manual #S1-AM030 for your control type. Continue with step
14 after testing controls.
14. Adjust pump displacement for full volume and adjust system pressure to 6000 PSI
(413.8 bar).**Adjust compensator from 6000 PSI to 3000 PSI (413.8 to 206.9 bar) to min-
imum pressure. At each pressure, stroke rotary servo input shaft to the full position on
each side of center. Cam indicator should remain on or very near the zero position with
no oscillation. System pressure should not vary from Port "A" to Port "B" more than 150
PSI (10.3 bar) and not oscillate.
Minimum compensator pressure should be under 500 PSI (34.5 bar)
**Caution: DO NOT hold pump at 6000 PSI (413.8 bar) for longer than one minute at
any time. This is only an intermittent pressure rating.
15. Set compensator for 1000 PSI (69 bar) when fully compensated, UNLESS OTHER-
WISE SPECIFIED. Increase and decrease system pressure above and below compensa-
tor setting. When system pressure is above compensator setting, the pump should de-
stroke and not oscillate. When the system pressure is below the compensator setting, the
pump should stroke to full volume.
16. Check pump for external leaks. No external leaks permitted.
Note: Refer to Manual S1-AM030 for Control Service information.
43
ORDERING CODE
Model Number P 6 S -2 R 1 * -4 A 2 - A - 00 -0 -B 0- M2-XXXXX
Pump series
Displacements, Max.
6 = 6.0 in3/rev., 98 cc/rev.
7 = 7.25 in3/rev., 119 cc/rev.
8 = 8.0 in3/rev., 131 cc/rev.
Pump type
S = closed circuit, with shuttle valve
Shaft
SAE = C
2 = keyed
3 = spline
Rotation, shaft
viewed from shaft end
R = clockwise
L = counter-clockwise
Fluid class
1 = compatible w/Buna N
4 = compatible w/EPR
5 = compatible w/Viton
Design letter - P6 Design C, P7 & 8 Design A

Primary controls
1 = screw adjustment
2 = cylinder control
4 = rotary servo-spring centered w/trimmer
5 = electrohydraulic stroker
6 = hydraulic stroker
7 = servovalve & feedback device
9 = electric stroker
(All include rotary servo, pressure compensator override & displ. indicator)
Primary controls, options
0 = none
A = adjustable maximum volume stops
B = automatic brake control
C = A & B combined
D = 10 gpm servovalve w/feedback potentiometer
E = 10 gpm servovalve w/feedback RVDT
F = 10 gpm servovalve w/pot. & man. override -w/4A2 control
G = 10 gpm servovalve w/2/RVDT & man.override -w/4A2 control
H = 3 position 2A control
Secondary controls
2 = auxiliary replenishment port on centerline - STD
4 = torque limiter and auxiliary replenishing port
Control location
A = command on port A side, displ. ind. on opp. side
B = command on port B side, displ. ind. on opp. side
500 control 600 control 700 control 8A control
00 = w/deadband 00 = 75-350 psi, 00 = w/o man. override shut-off 00 = 75-350 psi, (5-24 bar)
(5-24 bar)
01 = w/o deadband 01 = 75-435 psi, 01 = w/man. override shut-off 01 = 75-435 psi, (5-30 bar)
(5-30 bar)
02 = N/A 02 = 100-380 psi, 02 = N/A 02 = 110-375 psi, (7.6 bar)
(7-26 bar)
03 = 150-400 psi, (10-28 bar)
04 = 75-250 psi, (5-17.2 bar)
For all other controls use 00
Internal pump
0 = 1.07 in3/rev., 17.7 cc/rev.
x = none
External drive A = SAE-A B = SAE-B P Pumps only

External mounting 0 = pump not mounted 1 = pump mounted, - must be separately specified
Designates special
Allowable Controls: 102, 104, 2A2, 2A4, 2H2, 2H4,402, 4A2,4A4,

4B2, 4B4, 4C2, 4C4, 5A2, 5A4, 5C2, 5C4,
602, 604, 6B2, 6B4, 7D2, 7E2, 7F2, 7G2,
8A2, 8A4, 9A2, 9A4
44 Revised
NOTES
45
NOTES
46
NOTES
47
SALES AND SERVICE WORLDWIDE
International Distributors Australia France Mexico, Central America, South

In Europe: DENISON HYDRAULICS Pty. Ltd. DENISON HYDRAULICS America and Caribbean
Cyprus 41-43 St. Hillers Road FRANCE SA Countries Contact
Eastern Europe P.O. Box 192 14, route du Bois Blanc DENISON HYDRAULICS Inc.
The Faroe Islands Auburn, N.S.W. 2144 BP 539 6167 NW 181 Terrace Circle North
Finland Tel. (612) 9646 5200 18105 Vierzon Miami, FL 33015, USA
Greece Fax (612) 9643 1305 Tel. (33) 2 48 53 01 20 Tel. (305) 362 2246
Iceland Other sales offices: Fax (33) 2 48 75 02 91 Fax (305) 362 6220
Norway Queensland Other sales offices:
Portugal South Wantirna Victoria Bordeaux Other European, Middle East
Switzerland Western Australia Lyon and African Countries Contact
Turkey Paris DENISON HYDRAULICS
Austria FRANCE SA
In Africa: DENISON HYDRAULIK GmbH Germany 14, route du Bois Blanc
Algeria Zweigniederlassung Linz DENISON HYDRAULIK GmbH BP 539
Egypt Haidbachstraße 69 Herderstrasse 26 18105 Vierzon Cedex
Ivory Coast A-4061 Pasching D-40721 Hilden France
Morocco Tel. (43) 7229 4887 Tel. (49) 2103 940-6 Tel. (33) 2 48 53 01 45
Nigeria Fax (43) 7229 63092 Fax (49) 2103 940-880 Fax (33) 2 48 53 01 46
South Africa Other sales offices:
Togo Benelux Dresden Singapore
Tunisia DENISON HYDRAULICS Hanover DENISON HYDRAULICS S.E.A.
BENELUX B. V. Stuttgart Pte. Ltd.
In Middle East: Pascalstraat 100 No. 11 Lorong Tukang Dua
Iran 3316 Dordrecht Great Britain 2261 Singapore
Israel Holland DENISON HYDRAULICS U.K. Tel. (65) 2687840
Lebanon Tel. (31) 786179 900 Ltd. Fax (65) 2687847
Pakistan Fax (31) 786175 755 Kenmore Road
Qatar Wakefield 41, Industrial Estate Spain
Saudi Arabia Canada Wakefield, WF20XE DENISON HYDRAULICS, S.A.
Syria DENISON HYDRAULICS West Yorkshire Gomis, 1
United Arab Emirates CANADA Inc. England 08023 Barcelona
2320 Bristol Circle, Unit 1 Tel. (44) 19 24 826 021 Tel. (34) 3418 46 87
In Far East: Oakville, ON L6H 5S2 Fax (44) 19 24 826 146 Fax (34) 3211 65 07
Indonesia Tel. (905) 829 5800 Other sales offices: Other sales offices:
Korea Fax (905) 829 5805 Burgess Hill San Sebastian
Malaysia Other sales offices:
New Zealand Montreal, QC Hong Kong, N. T. Sweden
Philippines Calgary, AB DENISON HYDRAULICS Ltd. DENISON HYDRAULICS
Thailand Unit 3, 25/F Wharf Cable Tower SVENSKA AB
China, P.R. 9 Hoi Shing Road Sporregatan 13
DENISON HYDRAULICS Ltd. Tsuen Wan 213 77 - Malmö
3F, No. 1, Mao Jia Zhai, Bai Lian Jing Tel. (852) 24988381 Tel. (46) 40 21 04 40
Pudong New Area Fax (852) 24991522 Fax (46) 40 21 47 26
Shanghai 200126, Other sales offices:
Tel. (86) 21 5886 8991 Italy Spånga
Fax (86) 21 5886 1978 DENISON HYDRAULICS S.r.l.
Viale Europa 68 Taiwan, R.O.C.
Denmark 20090 Cusago DENISON HYDRAULICS Ltd.
DENISON HYDRAULIK Tel. (39) 2 90 33 01 6F-10, No. 79, Sec. 2, Roosevelt Road
DENMARK A/S Fax (39) 2 90 39 06 94 Taipei,
Industrikrogen 2 Tel. (886) 2 3645101 / 3645102
DK-2635 Ishöj Japan Fax (886) 2 3639025
Tel. (45) 4371 15 00 DENISON JAPAN Inc.
Fax (45) 4371 15 16 4-2-1 Tsujido-Shinmachi USA
Fujisawa 251, DENISON HYDRAULICS Inc.
Finland Tel. (81) 466 35 3257 14249 Industrial Parkway
DENISON HYDRAULICS Fax (81) 466 35 2029 Marysville, OH 43040
P.O. Box 36 Other sales office: Tel. 937 644 3915
FIN-08101 Lohja Osaka Fax 937 642 3738
Tel. (358) 208 33 045 For nearest Distributor:
Fax (358) 207 33 045 Call toll free 1 800 551 5956
Other sales offices:
Fulton, CA
Mulberry, FL
Moline, IL
Rock Island, IL
Kentwood, MI
Portland, OR
Collierville, TN
Arlington, TX
Houston, TX
Your local DENISON representative

Printed in U.S.A. 6-98
Internet: http://www.denisonhydraulics.com
E-mail: denison@denisonhydraulics.com
900 PUMP CONTROL
DENISON HYDRAULICS
controls for
goldcup pumps & motors series 6. . .30
service information
valve block
"B" side
control
mounting
"A" side
control
mounting
rotation
Publ. S1-AM030-A replaces S1-AM030 11-96

GOLDCUP CONTROLS ORDERING CODE
P 6 P -2 R 1 C -4 A 2 -A -00 -B 1 -M-XXXXX
Pump series Control Feature
500 Control
Primary Controls 00-with deadband
1-Screw Adjustment 01-without deadband
2-Cylinder Control
4-Rotary Servo (spring centered w/trimmer) 600 Control
5-Electrohydraulic Stroker 00-75-350 PSI (5-24 bar)
6-Hydraulic Stroker 01-75-435 PSI (5-30 bar)
7-Servovalve & Feedback Device 02-100-380 PSI (7-26 bar)
8-Proportional Hydraulic Stroker 03-150-400 PSI (10.3-27.6 bar)
9-Electrohydraulic Stroker
(All include rotary servo, pressure compensator 700 Control
override & displ. indicator) 00-w/o manual override shut-off
01-w/manual override shut-off
Primary Control Options
0-None 800 Control
A-Adjustable maximum volume stops 00-75-350 PSI (5-24 bar)
B-Automatic brake control 01-75-435 PSI (5-30 bar)
C-A & B above, together 02-100-380 PSI (7-26 bar)
D-10 GPM Servovalve w/feedback potentiometer 03-150-400 PSI (10.3-27.6 bar)
E-10 GPM Servovalve w/feedback RVDT 04-75-250 PSI (5-17 bar)
F-10 GPM Servovalve w/pot. & manual override
w/4A2 Control 900 Control
G-10 GPM Servovalve w/RVDT & manual override 00-24 VDC
w/4A2 Control 01-12 VDC
H-3 pos (Spring centered w/trimmer) ALL OTHER CONTROLS USE 00
Secondary Controls Control Location

2-Auxiliary Replenishment Port on Centerline A-Command on Port A side
4-Torque Limiter and Auxiliary Replenishment Port B-Command on Port B side
(Displ. indicator on opposite side)
Allowable Controls, P_P: Allowable Controls, P_V:*

102,104,2A2,2A4,2H2,2H4,402,404,4A2,4A4,4B2,4B4, 102,104,2A2,2A4,4A2,4A4,4C2,4C4,5A2,5A4,
4C2,4C4,5A2,5A4,5C2,5C4,602,604,6B2,6B4,7D2, 5C2,5C4,6A2,6A4,6C2,6C4,7D2,7E2,7F2,7G2,
7E2,7F2,7G2,8A2,8A4,8C2,8C4,9A2,9A4,9C2,9C4, 8A2,8A4,8C2,8C4,9A2,9A4,9C2,9C4
*P_V not available on 24 & 30 Series
M 6 H -2 N 1 C -2 A 0 -A -00 -M-XXXXX
Motor series Control Feature
500 Control
Primary Controls 1-without deadband
2-Cylinder with adjustable maximum & minimum stops
5-Electrohydraulic Stroker 600 Control
6-Hydraulic Stroker 0-170-350 PSI (11.7-24.1 bar)
8-Proportional Hydraulic Stroker 1-200-450 PSI (17.2-31 bar)
9-Electrohydraulic Stroker (without deadband) 2-150-380 PSI (10.3-26.2 bar)
(All include rotary servo stem and displacement indicator) 3-75-250 PSI (5-17 bar)
Primary Control Options 800 Control

0-None 0-75-250 PSI (5-17 bar)
Secondary Control options 900 Control

0-None 0-24 VDC
5-Reverse compensator (not available on 24 & 30 series) 0-12 VDC
Control Location
A-Command on Port A side
B-Command on Port B side
Allowable Controls: M*V,M*H: 2A0,2A5,5A0,5A5,6A0,6A5,8A0,8A5,9A0,9A5
4
GOLDCUP CONTROLS CHARACTERISTICS
TABLE 1 TYPICAL CHARACTERISTICS
Specifications Typ. Value

Control stop adjustment, 0 to full volume
1A, 2A, 4A, 4C 6.72 Turns
5A, 5C 8.48 Turns
6A, 6C 6.06 Turns
8A, 8C, 9A, 9C 5.04 Turns
Servo response time, 0 to full volume
P6, P7, P8 .9 Seconds
P11, P14 1.5 Seconds
Compensator off stroke response, full to 0 volume.
P11, P14 .070 Seconds
Servo shaft rotation, 0 to full volume 19 degrees
Fluid connections:
Signal ports, 2A 1/8 Dryseal NPTF
Signal ports, 2H, 60, 6A, 6B, 6C, 8A, 8C SAE -4 St. Thd. O-ring seal
Brake port, 4B, 4C, 5C, 6B, 6C, 8C, 9C SAE -6 St. Thd. O-ring seal
Bypass port to system pressure, 4B, 4C, 5C, 6B, 6C SAE -4 St. Thd. O-ring seal
Bypass port to system pressure, 8C, 9C SAE -6 St. Thd. O-ring seal
Bypass port to replenishing, 4B, 4C, 5C, 6B, 6C, 8C, 9C SAE -6 St. Thd. O-ring seal
*5A, 5C CONTROLS

Hysteresis Less than 5%
Linearity Within 5%
Response 0.5 seconds, zero to full. (control response)
Temperature null shift Less than 2% per 100° F (38°C)
Deadband 0% or 10%
Input pressure 400 psi (28 bar) nominal, range 200-1000 psi (14-70 bar)
Coil resistance 24 to 30 Ohms
Electrical input Full stroke .275 ma. typ., 400 ma. max., Max. current 600 ma.
Torque for manual operation 20 in.-lb (2.25 Nm) with control pressure shut off.
*Note: If the driver uses Pulse Width Modulation, (PWM) the frequency must be 2000 Hz. or higher to avoid erratic operation.
Water Glycol, Phosphate Ester (including Skydrol), and Invert emulsions cannot be used with 5A and 5C controls.
60, 6A, 6B, 6C PUMP CONTROLS

Feature Control press. Control press. Max. hysteresis @ Max. hysteresis @
min. displacement max. displacement min. displacement max. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
00 60-90 (4.1-6.2) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
01 60-90 (4.1-6.2) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
02 100-120 (6.9-8.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
03 135-165 (9.3-11.4) 375-425 (25.9-29.3) 30 (2.1) 50 (3.4)
5
6A MOTOR CONTROLS
max. displacement min. displacement max. displacement min. displacement
0- 155-185 (10.7-12.7) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
1- 185-215 (12.8-14.8) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
2- 135-165 (9.3-11.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
3- 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
700 FEEDBACK CONTROLS

Input voltage +/- 15 Volts
Input Amperes
Potentiometer 3 ma
D.C. RVDT 30 ma
* Output Volts @ max displacement, 19° CW rotation facing control
Potentiometer +3.1 Volts
D.C. RVDT -2.3 Volts
Output impedance
Potentiometer 2.5 K Ohms
D.C. RVDT <1 Ohm
*With connector terminal B at +15 Volts, terminal D at - 15 Volts. This polarity must be maintained for D.C. RVDT, Polarity is optional
for potentiometer.
8A, 8C PUMP CONTROL
Code Control press. Control press Max. hysteresis @ Max. hysteresis @
00 60-90 (4.1-6.2) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
01 60-90 (4.1-6.2) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
02 100-120 (6.9-8.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
03 135-165 (9.3-11.4) 375-425 (25.9-29.3) 30 (2.1) 50 (3.4)
04 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
Torque for manual operation (no control pressure) begin stroke 7.5-20 in. lb. (0.8-2.2 N·m)
Torque for manual operation (no control pressure) end stroke 28-58 in. lb. (3.2-6.5 N·m)
8A MOTOR CONTROL
0* 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
1* 235-265 (16.2-18.3) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
Signal ports SAE - 4
9A, 9C PUMP CONTROL 9A MOTOR CONTROL

Code mA @min. mA @max. Code mA @max. mA @min. Coil Nom.
displacement displacement displacement displacement voltage resist.
00 360 +/- 60 650 +/- 110 0* 360 +/- 60 580 +/- 100 12 Volt 10 Ohm
01 180 +/- 30 325 +/- 55 1* 180 +/- 30 290 +/- 50 24 Volt 41 Ohm
* Hysteresis- percent of full displacement 5% typ. 8% max.
* Linearity - percent of full displacement within 8%
Manual override 3/16"(4.8 mm) internal hex
Torque to override (no signal current) 30 in.-lb (3.4 N•m) typ.
Mating connector (supplied) DIN 43650 type AF
*Specifications above are based on using a Jupiter 900 Driver with a 24 VDC supply and set at 120 Hz pulse width modulation.
Performance will vary when other controls are used. 100 to 200 Hz pulse width modulation is recommended.
6
GOLDCUP CONTROLS SERIES 900
9A ELECTRIC STROKER
S23-12667 Feature 00 cross ctr. Pump
S23-12940 Feature 00 cross ctr.

P6R,P7R,P8R
S23-12734 Feature 00 CW-A,CCW-B-

Pump)
S23-12733 Feature 00 CCW-A,CW-B-

Pump)
S23-15050 Feature 0* A Mtg. Motor)
S23-15051 Feature 0* B Mtg. Motor)
DESCRIPTION The 9A consists of one or two electric proportional pressure control valves mounted on
the 8A cover to provide the pilot pressure signal. It is a simple electrohydraulic control
with comparable performance to the 5A in most applications. Refer to 8A for stroker
description.
The Jupiter 900 Driver Card has been developed to accompany the 9A control with
24V coil.
DISASSEMBLY 1. Disconnect connector (46) from coil (52).

See Figure 9A 2. Remove proportional valve or valves from block (39). Do not attempt disassembly
of the valve, other than replacement of the coil, (52) and external O-rings, (38-a), (38-
b) and (38-c).
3. Remove screws (2) from control. Remove proportional valve block (39) from con-
trol. Remove control from pump.
4. Examine orifices (37) for plugging or contamination. Examine servo plate for exces-
sive scratching on surface. Note if orifices in stem are open. If servo plate is
scratched or orifices appear to be plugged, remove plate and servo stem by removing
two soc. setscrews from plate, then alternately loosening the two button hd. screws
under the setscrews.
5. Remove retaining ring (4) and press the shaft assembly through the valve body
(10).
6. Examine shoes (8) and (18) for contamination in balance pads and excessive
scratching on shoe faces. Note the two shoes are not identical and must be installed
in the proper position upon reassembly.
7. Remove the plug (13) with the stop assembly intact.
8. Remove the centering adjustment screw (23) with the spool assembly and stop
assembly intact. Note: positive centering and control starting current are determined
by the spring preload. Do not disassemble or change unless setting is incorrect.
9. Clean and examine all parts for breakage or evidence of abnormal wear.
REWORK OF WEAR PARTS Description Rework

Servo plate face Fine stone to remove raised burrs & dings
Shear seal Fine stone to remove raised burrs & dings. Note:
grooves to supply balance pads must be present
and adequate.
Control cover Stone or lap inside face to remove raised burrs &
dings.
Spool Break sharp edges or dings.
ASSEMBLY All parts are to be inspected and be free of material defects, dirt, scratches, or any for-
eign material.
All parts are to be cleaned with a suitable cleaning solvent and all cores and passages
blown out with clean dry compressed air.
After cleaning and inspection, all parts are to be covered with a light film of oil and
should be protected from dirt and excessive handling until assembled onto the unit.
During assembly, lapped and ground surfaces should be kept lubricated and protected
from nicks or surface damage.
1. Apply pipe sealant to the 1/8” pipe plug (12) and install in the cover plate. Torque to
100 lbs-in. (11.3 Nm).
87
2. Thread trimmer locknut (22) all the way onto trimmer screw (23). Slip back-up
washer (21), small dia. first, onto trimmer screw and against locknut. Using a 3/4-16
hex nut with a 1.030” (26.2mm) dia. x .030/.035” (0.76/0.89mm) deep c’bore, crimp the
washer onto the stop. Washer must be free to rotate slightly. Remove crimping nut.
See Figure 8A-1 3. Compress spring (4) solid in order to remove spring set. This may be safely
accomplished using a 1/4” (6.35 mm) dia. bolt, nut and washers.
4. Assemble retaining ring (2), guide (3), spring (4) and guide (3) onto spool (1).
5. Tighten nut (7) till it just starts to load the spring, then tighten 2-5/6 additional turns.
6. Install locknut (5) onto spool and lock against nut (7) without changing adjustment.
See Figure 9A 7. Insert spool assembly (11), spring end first, into trimmer screw (23). Compress
snap ring on the spool assembly until it snaps into internal groove inside trimmer
screw. See that it is securely seated.
8. Thread spring stop locknut (24) all the way onto adjusting spring stop (25). Slip
back-up washer (26), small diameter first, onto stop and against locknut. Using a 9/16-
18 hex nut with a .810/.815” (20.6/20.7mm) dia. x .030-.035” (0.76-0.89mm) dp. c’bore,
crimp washer onto stop. Washer must be free to rotate slightly. Remove the crimping
nut.
9. Install O-ring (35) on plug (34) and insert into spring stop (25). Install O-ring (27)
onto stop (25) and against washer (26).
10. Thread adjusting spring stop (25) into trimmer screw (23) until it just touches the
spool assembly. Be sure spool assembly is against snap ring.
11. Determine the correct position of the spool assembly in the valve body. For 9A
standard pump controls, and for 9A motor controls mounted on the “B” port side, the
spool assembly is installed in the side of the control cap containing the 1/8” pipe plug
(12). For controls used on P*R pumps, and motor controls mounted on the “A” port
side, the spool assembly is installed on the side opposite the 1/8” pipe plug (12).
CONTROL SPOOL POS.

MODEL LOCATION REF. FIG. 9A
P*P, P*V, P*S “A” OR “B” OPPOSITE
P*R “A” OR “B” AS SHOWN
M*H, M*V “A” AS SHOWN
M*H, M*V “B” OPPOSITE
12. Place O-ring (14) on trimmer screw (23) and thread assembly into the cover plate,
as noted above.
13. Install adjusting screw (15) in plug (13). Install O-ring (14) on plug. Thread adjust-
ing screw in until it protrudes approximately 1/2” from top of plug (13). For motor con-
trols, install two nuts (36) on the inner end.
14. Thread cover nut (16) with O-ring (31) onto adjusting screw.
15. Install plug (28) and O-ring (29) into cover nut (16).
16. Install this assembly in body on the opposite side from the spool assembly (11).
17. Install nut (36) on adjusting screw (6). Thread adjusting screw into stop (25).
18. Install roll pins (30) into drilled holes in surface of cover, being careful not to dam-
age surface.
19. Install 0-ring (7) in groove of shear seal (8).
20. Install shear seal with o-ring in large hole on the servo link, on the servo shaft
side. Be certain that the shear seal is sitting with the flange flush against the servo
link surface.
Note: The shear seal will fit in one position only, otherwise one side will be held up
by the lip of the servo link. Shear seal (8) must be installed to face against the cover
plate (10). This shear seal (8) differs from shear seal (18) in that the face surface is
machined with two .094” (2.4mm) radius scallops.
21. Install thrust bearing (9) over servo shaft and seat against the servo link.
22. Slip washer (33) over the servo shaft and against the thrust bearing.
23. Using installation tool T-1, install O-ring (5) in the second groove from the end of
the shaft (1). Warm glyd ring (20) to make it pliable, and install over O-ring (5).
24. Install the servo shaft assembly in the cover plate (10). Pin must engage slot in
spool assembly (11).
25. Install retaining ring (4) into the groove of the servo shaft extending thru the cover
plate.
26. Apply loctite® 271 on threads of screw (43), and on threads of shaft assembly (1).
Assemble nut (44) on screw, insert screw into shaft assembly and turn in snugly. Hold
screw and arm. Torque nut to 14 lb.-ft. (19 Nm).
27. Place two spring washers (17), nested with the bent sections matching each other,
into the large hole in the servo link.
88
28. Place washer (32) against the spring washers.

29. Install O-ring (7) into groove in the remaining shear seal (18). Note: This shear
seal does not contain the two .094” (2.4mm) radius scallops in the face. Place on top
of washer, (32). Position shear seal to match the lip on the servo link.
30. Install four orifices (37) in two tapped holes in stroker block (39) closest to the
valve opening. Insert one orifice, then another on top of the first. Torque to 70 lbs-in.
(7.9 Nm).
31. Install proportional pressure valve(s) in block (39). Torque to 20 lb.-ft. (27 Nm).
Cross-center pumps use two valves. One side of center pumps and motors use one
valve. See chart for location of single valve:
CONT. LOCATION VALVE LOCATION

PUMP, CW-A, CCW-B VALVE “B”, FIG. 9A
PUMP, CW-B, CCW-A VALVE “A”, FIG. 9A
MOTOR, B MTG. VALVE “B”, FIG. 9A
MOTOR, A MTG. VALVE “A”, FIG. 9A
32. For controls with single valve, install soc. setscrew (54) in the tapped hole furthest
in from the unused opening. Torque to 70 in.-lb. (7.9 Nm). Install plug (53) and O-ring
(55) in the unused opening. Torque to 20 lb.-ft. (27 Nm).
33. Install coil(s) (52) on proportional valve (38). CAUTION! Torque to 20-25 in.-lb.
(2.2-2.8 Nm) max.
34. Install remaining parts.
35. If control is to be tested on unit, install stroker block assembly and control on
pump control pad with O-rings (3, 31, and 45), gasket (19), washers (49) and screws
(2). Torque to 30 Lb.-ft. (40.8 Nm).
9A CONTROL TEST SETUP Remove plug over input shaft. Insert T handle 3/16” Allen wrench into opening.
Connect proportional control driver to proportional valve. Connect pressure gage on
SAE-4 port adjacent to proportional valve or valves.
Rotate wrench handle to check for free play. Turn spring stop adjustment in or out till
it just contacts the spring and there is no free play. Lock in place. Note: this adjust-
ment is critical to accurate neutral adjustment!
9A PUMP TEST 1. Turn trimmer screw to place input shaft on the zero stroke position. Check for posi-
tive centering. Lock in place. For cross-center pumps, set max. volume stops so that
servo shaft link touches stop pins when handle is stroked each side of center. For one
side of center pumps, set max. stop so that servo shaft link touches the stop pin. Set
min stop to prevent crossing over center. Lock stops in place.
2. Apply signal current to one proportional valve. Adjust current from minimum to
maximum. Note the pressure and current value at which pump just starts to stroke,
and at which the pump reaches full stroke These must be within the following values:
Coil Cont. Pr. Ma. Min. Cont. Pr. Ma

Min. Disp. Disp. Max. Disp. Max. Disp.
12 Volt 75 ±15psi 360 ± 60 250±25psi 650 ± 110
(5.17±1bar) (17.2±1.7bar)
24 Volt 75±15psi 180 ± 30 250±25psi 325 ± 55
(5.17±1bar) (17.2±1.7bar)
3. If control pressure is off the same amount at start and end of stroke, the control
may be disassembled and the spring (Figure 2) readjusted. One flat (1/6 turn) of
adjustment will change the pressure by 4.6 psi (0.31 bar).
4. If the change in pressure from start to end of stroke is incorrect, the spring (Figure
2) is incorrect and must be replaced.
5. If pressures are correct but current is incorrect, then either the coil is incorrect or
the proportional valve is bad.
6. With minimum signal, pump shall return to zero stroke within 200 psi. (13.8 bar)
max.
7. For cross-center pumps, repeat test on opposite side of center.
8. Increase and decrease current between minimum and maximum several times.
Pump stroke should follow control pressure smoothly and proportionally. Full to zero or
zero to full stroke should be achieved in no more than two seconds. Adjust stroke up
to approximately 50% stroke from zero stroke, then adjust down from full stroke to the
same current value. The flow at the two settings shall not vary more than 25%.
9A MOTOR TEST 1. Turn trimmer screw to place input shaft on the full stroke position. Lock in position.
2. Rotate input handle to reduce motor displacement to minimum. CAUTION! do not
exceed motor rated speed! Adjust minimum stop screw to set minimum displacement
at 25% of full displacement. (4 times the rpm at maximum displacement.)
89
3. Lock screw in this position.

4. Apply signal current to proportional valve. Adjust current from minimum to maxi-
mum. Note the pressure and current value at which motor just starts to reduce stroke,
and at which the motor reaches minimum stroke. These must be within the following
values:
Max. Disp. Disp. Min. Disp. Min. Disp.
12 Volt 75 ±15psi 360 ± 60 205±25psi 580 ± 100
(5.17±1bar) (14.1±1.7bar)
24 Volt 75±15psi 180 ± 30 205±25psi 290 ± 50
(5.17±1bar) (14.1±1.7bar)
8. With minimum signal, motor shall return to full stroke.
Motor stroke should follow control pressure smoothly and proportionally. Full to min. or
min. to full stroke should be achieved in no more than two seconds. Adjust stroke
down to approximately 50% stroke from full stroke, then adjust up from 25% stroke to
the same signal. The speed at the two settings shall vary no more than 25%.
10. When control has satisfactorily passed test, remove stop assembly, set and lock
the two nuts on the inside to prevent adjustment below 25% stroke. Re-install stop.
90
PARTS LIST
Figure 9A Electric stroker
Feature ➔ 00 00 01 00 0*
Option ➔ P*P, P*S 6R,7R,8R P*P,P*S P*V M*H, M*V
Pump Pump Pump Pump Motor
Assembly No. ➔ S23-12667 S23-12940 S23-12957 S23-12734 S23-15050
S23-12733 S23-15051
ITEM DESCRIPTION PT. NO. QTY. QTY. QTY. QTY. QTY.
1 Servo shaft S23-12267 1 1 1 1 1
2 HHCS 3/8-16 X 3.25” 306-40184 4 4 4 4 4
3 O-ring, 70- S-5 ARP 013 675 00013 9 9 9 9 9
4 Ring, Truarc #5144-50 356-65070 1 1 1 1 1
5 O-ring, 70 S-5 ARP 012 675-00012 5 5 5 5 5
6 HHCS, 5/16-24 X 1” 307-13160 1 1 1 1 -
Setscrew, 5/16-24 X 1.25” 312-13180 - - - - 1
7 O-ring, 70 S-5 ARP 017 675-00017 2 2 2 2 2
8 Shear Seal 033-71371 1 1 1 1 1
9 Bearing 230-82141 1 1 1 1 1
10 Cover-9A 033-91220 1 1 1 1 1
11 Spool Assy (Fig. 8A-1) S23-12956 1 1 1 1 1
12 Flush plug 1/8” 431-90204 1 1 1 1 1
13 SAE plug 033-91027 1 1 1 1 1
14 O-ring, 90 S-5 ARP 908 695-00908 3 3 3 3 3
15 Soc. setscrew, 5/16-24 X 2” 312-35062 1 1 1 1 -
Setscrew, 5/16-24 X 2.50” 312-35063 - - - - 1
16 Nut 033-91033 1 1 1 1 1
17 Finger Spring 350-10067 2 2 2 2 2
18 Shear seal 033-70525 1 1 1 1 1
19 Gasket 033-91058 1 1 1 1 1
20 Glyd ring 679-00004 1 1 1 1 1
21 Washer 350-10139 1 1 1 1 1
22 Nut 033-91115 1 1 1 1 1
23 Center trimmer 033-91028 1 1 1 1 1
24 Locknut 492-15353 1 1 1 1 1
25 Stop 033-91026 1 1 1 1 1
26 Washer 350-10126 1 1 1 1 1
27 O-ring, 90 S-5 ARP 906 695-00906 1 1 1 1 1
28 Plug, Parker 2P5N-S 488-35029 1 1 1 1 1
29 O-ring, 90 S-5 ARP 902 695-00902 1 1 1 1 1
30 Rollpin 3/16 X .75” 325-12120 2 2 2 2 2
31 O-ring, 70 S-5 ARP 014 675-00014 2 2 2 2 2
32 Washer 350-10064 1 1 1 1 1
33 Washer 350-10141 1 1 1 1 1
34 Piston 033-91099 1 1 1 1 1
35 O-ring, 70 S-5 ARP 010 675-00010 1 1 1 1 1
36 Nut, 5/16-24 335-13100 1 1 1 1 3
37 Orifice, .025” 033-91225 4 4 4 4 4
38 Valve- proportional 517-00085 2 2 2 1 1
38-a O-ring, 70 S-5 ARP 015 675-00015 2 2 2 1 1
38-b O-ring, 90 S-5 ARP 016 695-00016 2 2 2 1 1
91
PARTS LIST
Feature ➔ 00 00 01 00 0*
S23-12733 S23-15051
38-c O-ring, 90 S-5 ARP 116 695-00116 2 2 2 1 1
39 Stroker Block 033-54991 1 1 1 1 1
40 Plug, SAE-4 488-35061 2 2 2 2 2
41 O-ring, 90 S-5 ARP 904 695-00904 2 2 2 2 2
42 Plug. Parker 8HP N-S 488-35018 1 1 1 1 1
43 SHCS, 1/4-20 X 2.25” 358-12100 1 1 1 1 1
44 Nut, 1/4-20 333-12001 1 1 1 1 1
45 O-ring, 70 S-5 ARP 121 675-00121 1 1 1 1 1
46 Connector 167-01008 2 2 2 1 1
47 Guard 033-54994 1 1 1 1 1
48 SHCS, 1/4-20 X 2.25” 306-12260 2 2 2 2 2
49 Washer 350-10144 4 4 4 4 4
50 Plate 030-55002 1 - - - -
Plate 030-55003 - 1 1 1 1
51 Drive screw 320-10203 2 2 2 2 2
52 Coil, 24 VDC. 517-00086 2 2 - 1 1
Coil, 12 VDC 517-00087 - - 2 - -
53 Plug, Parker 10 P50N-S 488-35016 - - - 1 1
54 SHCS, 10-32 X .19” 312-09030 - - - 1 1
55 O-ring, 90 S-5 ARP 910 695-00910 - - - 1 1
56 Washer 345-10016 2 2 2 2 2
92
ELECTRIC STROKER
FIGURE 9A
93
NOTES
115
International Distributors Australia Germany Spain

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Norway Other sales offices: Other sales offices:
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Tel. (65) 2687840
Other sales offices: Fax (65) 2687847
Bordeaux
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Paris 10-96
Printed in U.S.A.
OPI 2M 10203
TB VANE PUMP
Vane Pumps
TB Series - Single Pumps

.5 - 2.4 in3/rev. - 2755 psi
2
P S
Performance @ 1500 rpm (fluid 25 cSt)
Output Flow (gpm) Input Power (hp)

in3
SIZE / 0 1450 2538 7 1450 2538 SIZE
rev
psi psi psi psi psi psi
003 0.54 3.5 2.7 2.4 0.5 3.2 4.4 003

004 0.78 5.1 4.3 3.8 0.7 4.6 7.8 004
005 0.98 6.3 5.6 5.0 0.7 5.6 9.7 005
006 1.26 8.2 7.4 6.9 0.8 7.2 12.3 006
008 1.59 10.3 9.6 9.0 0.9 9.0 15.4 008
009 1.92 12.5 11.7 11.1 1.1 10.9 18.6 009
011 2.17 14.1 13.3 12.8 1.1 12.2 21.1 011
012 2.42 15.7 15.0 14.4 1.2 13.5 23.5 012
Key sheet (Example: TB-011-1R00-A100)
1. TB-011-1R00-A100 .....................................Series
6. TB-011-1R00-A100 ....................................Design
2. TB-011-1R00-A100 ................................ Cam size
Size.........in3/rev Size.........in3/rev Size.........in3/rev
7. TB-011-1R00-A100 ..............................Seal Class
003..........0.54 006 ......... 1.26 011 ......... 2.17 Buna N : mineral oil 1
004..........0.78 008 ......... 1.59 012 ......... 2.42
005..........0.98 009 ......... 1.92
8. TB-011-1R00-A100 ................... Port Connections
3. TB-011-1R00-A100 .....................................Shafts Pressure port P Threaded SAE, 4 bolts
Suction port S SAE-12 ¾” NPTF ¾”
4. TB-011-1R00-A100 ..................................Rotation
SAE-20 00
CW R Threaded
1” ¼ NPTF 03 0X
CCW L
SAE, 4 bolts 1” ¼ 01
5. TB-011-1R00-A100 ....................................Porting
P & S : same side / opposite side 01 / 00
 DENISON HYDRAULICS Ref. : 2-AM-VP002-BB (Feb-2000).

2-2 Specifications may be revised at any time. Refer to Technical Literature for latest data.
TB Series – Medium Duty, Single Pump
TB
E 1.22
F 3.39
G 5.72
J1 3.250
2
J2 3.248
N 4.19
O 5.13
P ∅ .44
Torque
Shafts in-lb
TB L1 L2 DIAMETER K1 x K2 H1 M1
1 Key : No SAE (∅.75) - ● 2.66 1.25 .750 - .749 .188 x.186 0.83 -
3 Spline : No SAE - ● 1.50 0.75 Class 1-J498b, 16/32 d.p. - 11 teeth

4 Spline : SAE A - ● 1.23 0.59 Class 1-J498b, 16/32 d.p. - 9 teeth
Dimensions (i n)
Ports Options Threads T1
A1 B1 C1 D1
P Threaded, SAE SAE - 12 (1” 1/16 - 12UNF) 2.75 -

00 5
S Threaded, SAE SAE - 20 (1” /8 - 12UNF) 2.75 -
3
P SAE - 1 ¼” 0.87 1.87 ∅.75 2.75 /8”-16UNC x .87
01
7
S SAE - ¾” 1.19 2.31 ∅1.25 2.75 /16”-14UNC x .87
1
P Threaded, SAE SAE - 12 (1” /16 - 12UNF) 2.75 -
03
S Threaded, NPTF NPTF - 1” ¼ 2.75 -
P Threaded, NPTF NPTF - ¾” 2.75 -
0X

CHECK VALVE
6C/3C Inline Check Valves
◆ Poppet style – soft seat

◆ Steel or stainless steel construction; other materials
available
◆ Flow rates to 175 gpm (662 l/min)
◆ SAE, NPSF, NPT, BS 2779 & ORS end fittings available
◆ Up to 6000 psi (415 bar) working pressure -
1/4”, 3/8”, 1/2”, 3/4” & 1”
1-1/4”, 1-1/2” & 2”
Features
These soft seat (virtual zero leak), with guided poppet valves offer a wide variety of end fitting configurations and elastomers
and the option of 316 stainless steel construction. These options enable a valve to be configured to meet the needs of any
system. Snap-tite’s versatile 6C/3C Inline Check Valves are designed with a 4:1 safety factor at a maximum working
pressure of 6000 psi (415 bar) making them ideal for any application.
*Dimensions and Specifications

Size 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
In. .75 1.12 1.25 1.62 1.88 2.00 2.50 3.25
Hex
mm 19.05 28.45 31.75 41.15 47.75 50.80 63.50 82.55
In. 2.82 3.38 3.73 4.91 6.07 5.76 6.51 7.28
Length
mm 71.60 85.85 94.75 124.70 154.20 146.30 165.35 184.90
Cv .45 1.80 3.40 7.40 9.50 12.30 16.15 21.80
lbs. .29 .81 1.20 2.05 3.40 3.75 7.80 13.00
Weight
kg. .13 .37 .54 .93 1.54 1.70 3.54 5.90
gpm 3.00 8.00 12.00 20.00 30.00 90.00 125.00 175.00
Flow
l/min. 11.40 30.30 45.45 75.70 113.55 340.65 473.15 662.40
FLOW, I/min FLOW, I/min

HYDRAULIC OIL AT 38° C, FULLY OPEN HYDRAULIC OIL AT 38° C, FULLY OPEN
37.85
75.70
113.55
151.40
189.25
378.50
757.00
113.55
378.50
1892.50
11.36
15.14
18.93
37.85
75.70
1.36
1.51
1.89
3.79
7.57
.38
.76
100 6.90
3.45
PRESSURE DROP, bar
PRESSURE DROP, bar

PRESSURE DROP, psi
PRESSURE DROP, psi
2.76 500 34.48

30 2.07 400 27.59
20 1.38
300 20.69
10 .69 200
/4"
13.79
"
1-1
1/4
"
3/8
5.0 .35
"
1/2
4.0 .28
/2"
"
100 6.90
3/4
3.0 .21
1-1
1"
2.0 .14
50 3.45
1.0 .07
40 2.76
.5 .034 30 2.07
.4 .028
2"
.3 .021 20 1.38
.2 .014
.1 .007 10 .69
.1
.2
.3
.4
.5
1.0
2.0
3.0
4.0
5.0
10
20
30
100
10
20
30
40
50
100
200
500
FLOW, gpm FLOW, gpm

HYDRAULIC OIL AT 100° F, FULLY OPEN HYDRAULIC OIL AT 100° F, FULLY OPEN
Note: Gallons shown are in U.S. gallons. *Dimensions shown are for NPTF ported valves; for other end fitting configurations consult factory.
Ordering Information
Inline Check Valves - 5,000 psi (345 bar) rated

CPI F F - 4 P - 15
Series Inlet Outlet Port Size Thread Type Spring Pressure Seal
CPI - F- F- NPSF or BSP SAE RP - 05 - 5 psi (.35 bar) No letter for
Inline Female Female 2 - 1/4” Female 15 - 15 psi (1 bar) Viton (std.)
Check 3 - 3/8” British Parallel 25 - 25 psi (1.75 bar) A - Buna
Valve 4 - 1/2” 8 - 1/2” BS 2779 65 - 65 psi (4.50 bar) E - Ethylene
Poppet 6 - 3/4” 12 - 3/4” P - Female NPSF Propylene
Style 8 - 1” 16 - 1” S - Female SAE
Inline Check Valves - Up to 6,000 psi (415 bar) rated•

S 6C 4 F - F 5
Material Check Size Inlet Outlet Spring Seal

No letter Valve 4 - 1/4” M - Male NPT M - Male NPT Pressure No letter for
Steel 6C - 6 - 3/8” F - Female NPTF F - Female NPTF 5 - 5 psi Viton (std.)
Zinc Clear 6,000 psi* 8 - 1/2” EF - Female SAE EF - Female SAE (.35 bar) M - Military
Dichromate (415 bar) 12 - 3/4” EM - Male 37° Flare EM - Male SAE 37° Flare 25 - 25 psi variation of
Plated operating 16 - 1” ORS - Male Face ORS - Male Face (1.75 bar) Buna N for
(standard) pressure Seal Seal 65 - 65 psi MIL-H-5606
S - 316 3C - 20 - 1-1/4” RP - Female British RP - Female British (4.5 bar) fluids
Stainless Parallel BS 2779 Parallel BS 2779 A - Buna
3,000 psi 24 - 1-1/2”
Steel (210 bar) 32 - 2” E - Ethylene
operating
pressure CAC 10 - 15 - A -1
Series Rated Flow Cracking Pressure Seal Air Pilot* Current

CAC - Poppet 10 - 10 gpm (38 l/min) 15 - 15 psi (1 bar) No letter Option Design
Cartridge Pilot 25 - 25 gpm (95 l/min) 25 - 25 psi (1.7 bar) for Viton P - O-ring on -1
Check Valve 50 - 50 gpm (189 l/min) 60 - 60 psi (4 bar) A - Buna N Pilot Piston
CPC - Poppet (60 psi spring is
Cartridge Check recommended)
Valve *CAC only
CAV 10 - 3P - 15 A
Series Rated Flow Port Size Cracking Air Pilot Seal

CAV - Single Pilot 10 - 10 gpm (38 l/min) NPT SAE Pressure P - O-ring on No letter for
Operated Check 1/4”, 3/8”, 1/2” ports 2P - 1/4” 4S - 1/4” 15 - 15 psi (1 bar) Pilot Piston Viton
Valve 25 - 25 gpm (95 l/min) 3P - 3/8” 6S - 3/8” 25 - 25 psi (1.7 bar) (60 psi spring is A - Buna N
CAD - Dual Pilot 3/8”, 1/2”, 3/4” ports 4P - 1/2” 8S - 1/2” 60 - 60 psi (4 bar) recommended)
Operated Check 50 - 50 gpm (189 l/min) 6P - 3/4” 12S - 3/4”
Valve 3/4”, 1” ports 8P - 1” 16S - 1”
*3/4” 6C SST working pressure - 5000 psi (345 bar), 1” 6C SST working pressure - 4000 psi (275 bar)
! WARNING !
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH,
PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Snap-tite, Inc., its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having
technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to
the variety of operation conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of
the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Snap-tite, Inc. and its subsidiaries
at any time without notice.
Distributed by:
Quick Disconnect & Valve Division Industrial Estate

201 Titusville Road Whitemill - Wexford
Union City, Pennsylvania 16438-8699 USA Republic of Ireland
PH: 814-438-3821 FAX: 814-438-3069 PH: 353-53-41566 FAX: 353-53-41582
e-mail: qd&v_sales@snap-tite.com e-mail: snaptite@snap-tite.iol.ie
www.snap-tite.com www.snap-tite.com ISO-9001 Certified
qd/icv.799
FLEXIBLE JAW COUPLING
KTR Kupplungstechnik ROTEX® KTR-N 40210 E
GmbH Operating- / Assembly Instructions sheet: 1
D-48407 Rheine Design 001 and 018 edition: 7
ROTEX® is a torsionally flexible jaw coupling. It is able to compensate for shaft displacement
caused by, as an example, inaccuracies in production, heat expansion, etc.
Table of Contents
1 Technical Data
2 Hints
2.1 General Hints
2.2 Safety and Advice Hints
2.3 General Hints to Danger
2.4 Proper Use
3 Storage
4 Assembly
4.1 Components of the Couplings
4.2 Hint regarding the finish bore
4.3 Taper Lock Clamping Sleeve
4.4 Assembly of the Hubs
4.5 Displacements - Alignment of the Couplings
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.1 Control intervals for couplings in hazardous areas

5.2 Approximate values of wear
5.3 Permissible coupling materials in the hazardous area
5.4 Marking of coupling for the hazardous area

5.5 Starting
5.6 Breakdowns, causes and elimination
5.7 Certificate of Conformity according to the EG Standards 94/9/EG
dated 23 March 1994
Urheberschutz Gezeichnet: 16.01.03 Sha/Tn Ersatz für: Verteiler

gemäß DIN 34 Geprüft: 17.01.03 Sha Ersetzt durch: W K V VA M
1 Technical Data
® ®
picture 1: ROTEX (material: Al-D) picture 2: ROTEX (material: GG 25 / GGG 40)
Table 1: material Al-D

1)
spider (part 2) dimension [mm]
®
ROTEX compo- nominal torque [Nm] set
finish bore general 2)
size nent screws
92 Sh A 98 Sh A 64 Sh D d (min-max) 3)
L l1; l2 E b s DH dH D;D1 N G t
14 1a 7,5 12,5 - 6 - 16 35 11 13 10 1,5 30 10 30 - M4 5
1 6 - 19 32
19 10 17 - 66 25 16 12 2 41 18 20 M5 10
1a 19 - 24 41
1 9 - 24 40
24 35 60 - 78 30 18 14 2 56 27 24 M5 10
1a 22 - 28 56
1 10 - 28 48
28 95 160 - 90 35 20 15 2,5 67 30 28 M8 15
1a 28 - 38 67
Table 2: material GG 25 / GGG 40

1)
®
size nent screws
1 12 - 38 66
114 45 37
38 1a 190 325 405 24 18 3 80 38 M8 15
38 - 45 78
1b 164 70 62
1 14 - 42 75
126 50 40
42 1a 265 450 560 26 20 3 95 46 M8 20
42 - 55 94
1b 176 75 65
1 15 - 48 85
140 56 45
48 1a 310 525 655 28 21 3,5 105 51 M8 20
48 - 60 104
1b 188 80 69
1 20 - 55 98
55 410 685 825 160 65 30 22 4 120 60 52 M10 20
1b 55 - 70 118
65 1 625 940 1175 22 - 65 185 75 35 26 4,5 135 68 115 61 M10 20
75 1 1280 1920 2400 30 - 75 210 85 40 30 5 160 80 135 69 M10 25
90 1 2400 3600 4500 40 - 90 245 100 45 34 5,5 200 100 160 81 M12 30
100 1 3300 4950 6185 50 - 115 270 110 50 38 6 225 113 180 89 M12 30
110 1 4800 7200 9000 60 - 125 295 120 55 42 6,5 255 127 200 96 M16 35
125 1 6650 10000 12500 60 - 145 340 140 60 46 7 290 147 230 112 M16 40
140 1 8550 12800 16000 60 - 160 375 155 65 50 7,5 320 165 255 124 M20 45
160 1 12800 19200 24000 80 - 185 425 175 75 57 9 370 190 290 140 M20 50
180 1 18650 28000 35000 85 - 200 475 185 85 64 10,5 420 220 325 156 M20 50
1) Maximum torque of the coupling TKmax. = nominal torque of the coupling TK Nenn. x 2.
2) Threads for set screws are opposite the keyway in case of material Al-D and on the keyway in case of material GG 25 / GGG 40.
3) From size 125 thread for set screws on request.

1 Technical Data
® ®
picture 3: ROTEX (material: steel) picture 4: ROTEX design DKM
Table 3: material steel

1)
®
size nent screws
92 Sh A 98 Sh A 64 Sh D d (min-max)
L l1; l2 E b s DH dH D N G t
1a 66 25
19 10 17 21 0 - 25 16 12 2 40 18 40 - M5 10
1b 90 37
1a 78 30
24 35 60 75 0 - 35 18 14 2 55 27 55 - M5 10
1b 118 50
1a 90 35
28 95 160 200 0 - 40 20 15 2,5 65 30 65 - M8 15
1b 140 60
1 114 45 70 27
38 190 325 405 0 - 48 24 18 3 80 38 M8 15
1b 164 70 80 -
1 126 50 85 28
42 265 450 560 0 - 55 26 20 3 95 46 M8 20
1b 176 75 95 -
1 140 56 95 32
48 310 525 655 0 - 62 28 21 3,5 105 51 M8 20
1b 188 80 105 -
1 160 65 110 37
55 410 685 825 0 - 74 30 22 4 120 60 M10 20
1b 210 90 120 -
1 185 75 115 47
65 625 940 1175 0 - 80 35 26 4,5 135 68 M10 20
1b 235 100 135 -
1 210 85 135 53
75 1280 1920 2400 0 - 95 40 30 5 160 80 M10 25
1b 260 110 160 -
1 245 100 160 62
90 2400 3600 4500 0 - 110 45 34 5,5 200 100 M12 30
1b 295 125 200 -
Table 4: design DKM

1)
®
ROTEX nominal torque [Nm] meas- set
general 2)
size ure d, screws
92 Sh A 98 Sh A 64 Sh D
D, D1LDKM l1; l2 E b s DH dH l11 l12 G t
19 10 17 - 92 25 16 12 2 40 18 10 42 M5 10
24 35 60 - 112 30 18 14 2 55 27 16 52 M5 10
28 95 160 - 128 35 20 15 2,5 65 30 18 58 M8 15
see table 1 to 3
38 190 325 - 158 45 24 18 3 80 38 20 68 M8 15

42 265 450 - 174 50 26 20 3 95 46 22 74 M8 20
48 310 525 - 192 56 28 21 3,5 105 51 24 80 M8 20
55 410 685 - 218 65 30 22 4 120 60 28 88 M10 20
65 625 940 - 252 75 35 26 4,5 135 68 32 102 M10 20
75 1280 1920 - 286 85 40 30 5 160 80 36 116 M10 25
90 2400 3600 - 330 100 45 34 5,5 200 100 40 130 M12 30
1) Maximum torque of the coupling TKmax. = nominal torque of the coupling TK Nenn. x 2

1 Technical Data
®
picture 5: ROTEX design Taper-Lock
Table 5: design Taper-Lock

1)
® Taper-
ROTEX compo- nominal torque [Nm]
finish bore general Lock-
size nent
92 Sh A 98 Sh A 64 Sh D d (min-max) sleeve
L l1; l2 E b s DH dH D1 N
24 1a 35 60 - 10 - 22 64 23 18 14 2 55 27 - - 1008
28 1a 95 160 - 10 - 25 66 23 20 15 2,5 65 30 - - 1108
38 1a 190 325 - 10 - 25 70 23 24 18 3 80 38 78 15 1108
42 1a 265 450 - 14 - 40 78 26 26 20 3 95 46 94 16 1610
48 1a 310 525 - 14 - 40 106 39 28 21 3,5 105 51 104 28 1615
55 1a 410 685 - 14 - 50 96 33 30 22 4 120 60 118 20 2012
65 1 625 940 - 14 - 50 101 33 35 26 4,5 135 68 115 5 2012
75 1 1280 1920 - 16 - 60 130 52 40 30 5 160 80 158 36 2517
90 1 2400 3600 - 25 - 75 149 52 45 34 5,5 200 100 160 14 3020
CAUTION !
For a continuous and troublefree operation of the coupling it must be designed according
! to the selection instructions (according to DIN 740 part 2) for the particular application
®
(see ROTEX catalogue).
If the operating conditions (performance, speed, changes at engine and machine) change,
the coupling selection must be checked again.
2 Hints
2.1 General Hints
Please read through these mounting instructions carefully before you set the coupling into operation. Please pay
special attention to the safety instructions!
The ROTEX® coupling is approved for the use in hazardous areas.
When using the coupling in hazardous areas please observe the special hints and instructions
regarding safety in enclosure A.
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.

2 Hints
STOP DANGER ! Danger of injury to persons.
CAUTION ! Damages on the machine possible.

!
F ATTENTION ! Pointing to important items.
PRECAUTION ! Hints concerning explosion protection.
2.3 General Hints of Danger
DANGER !
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Please make sure to disengage the power pack before you perform your work.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
• Do not touch the operation area of the coupling as long as it is in operation.
• Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
2.4 Proper Use
You may only assemble, operate and maintain the coupling if you
• carefully read through the mounting instructions and understood them
• had technical training
• are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 5 in chapter 1).
Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting
damages. To further develop the product we reserve the right for technical modifications.
The ROTEX® described in here corresponds to the technical status at the time of printing of these mounting
instructions.

3 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years in case of favourable stock
conditions.
CAUTION !
The storage rooms may not include any ozone-generating devices, like e. g. fluorescent
! light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is under
65%.
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
Components of ROTEX®, shaft coupling design No. 001
Compo-
Quantity Designation
nent
1 2 hub
2 1 spider
3 2 setscrew
®
picture 6: ROTEX
Components of ROTEX®, DKM design No. 018
Compo-
nent
1 2 hub
2 2 spider
3 1 DKM - spacer
4 2 setscrew
®
picture 7: ROTEX DKM

4 Assembly
Components of ROTEX®, Taper Lock Clamping Sleeve
Compo-
nent
hub for taper
1 2
clamping sleeve
taper lock clamping
2 2
sleeve
3 1 spider
4 4 setscrew
®
picture 8: ROTEX Taper-Lock-clamping sleeve
Features of the standard spiders
spider hardness
marking (colour)
(Shore)
92 Sh A yellow
95/98 Sh A red
natural white with green
64 Sh D-F
marking of teeth
DANGER !
STOP Valid for all materials !
The maximum permissible bore diameters d (see
table 1 to 5 in chapter 1 - Technical Data) must not be
exceeded. If these figures are disregarded, the
coupling may tear. Rotating particles may cause
serious danger.
• Hub bores machined by the customer have to observe

concentric running or axial running, respectively (see
picture 9).
• Please make absolutely sure to observe the figures for
dmax.
• Carefully align the hubs when the finish bores are
brought in.
• Please provide for a setscrew or an end plate for the picture 9: concentric running and axial running
axial fastening of the hubs.
Table 6: Setscrews
ROTEX® size 14 19 24 28 38 42 48 55 65
dimension G M4 M5 M5 M6 M8 M8 M8 M10 M10
tightening torque TA [Nm] 1,5 2 2 4,8 10 10 10 17 17
®
ROTEX size 75 90 100 110 125 140 160 180
dimension G M10 M12 M12 M16 M16 M20 M20 M20
tightening torque TA [Nm] 17 40 40 80 80 140 140 140

4 Assembly
Assembly of the taper lock-clamping sleeve:

The taper lock clamping sleeve has cylindrical and even pocket holes parallel to the axis. Only half to these
holes are in the material of the sleeve. The other half located at the hub has convolutions.
Push the coupling hub and the taper lock clamping sleeve into each other, make holes onto the cover and
tighten the grub screws slightly.
Disassembly of the taper lock clamping sleeve:

By removing the grub screws you can detach the taper lock clamping sleeve. Afterwards, one of the grub screws
is screwed into the thread of the sleeve as forcing screw and tightened.
The detached coupling hub can be manually taken off the shaft with the taper lock clamping sleeve.
Table 7:
taper lock screw dimension
clamping G L SW TA quantity spanner
sleeve [inch] [inch] [mm] [Nm]
1008 1/4 1/2 3 5,7 2 SW 3
1108 1/4 1/2 3 5,7 2 SW 3
1610 3/8 5/8 5 20 2 SW 5
1615 3/8 5/8 5 20 2 SW 5
2012 7/16 7/8 6 31 2 SW 6
2517 1/2 7/8 6 49 2 SW 6
3020 5/8 1 1/4 8 92 2 SW 8 picture 10: withworth grub screw (BSW)
F
ATTENTION !
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION !
Please pay attention to the danger of ignition in hazardous areas.
DANGER !
STOP Touching the heated hubs causes burns.
We would recommend to wear safety gloves.
CAUTION !
For the assembly please make sure that the distance dimension E (see table 1 to 5) is kept
! to ensure that the spider can be moved axially.
Disregarding this hint may cause damage on the coupling.
• Assemble the hubs onto the shaft of driving and driven side.
• Move the power packs in axial direction until the dimension E is achieved.
• If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for
adjusting the dimension E.
• Fasten the hubs by tightening the setscrews DIN 916 with cup point.

4 Assembly
F
ATTENTION !
If the shaft diameters with inserted feather key are smaller than the dimension dH (see
table 1 to 5) of the spider, one or two shaft ends may protude into the spider.
The displacement figures shown in tables 8 and 9 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion or lowering of foundation.
CAUTION !
In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
! hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 8 and 9). If the
figures are exceeded, the coupling is damaged.
In case of a use in hazardous areas for the explosion group IIC (marking II 2G c IIC T4),
only the half displacement figures (see tables 8 and 9) are permissible.
Please note:
• The displacement figures mentioned in tables 8 and 9 are maximum figures which must not arise in parallel.
If radial and angular displacement arises at the same time, the permissible displacement values may only be
used in part (see picture 12).
• Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 8 and 9
can be observed.
angular displacements radial displacements axial displacements
∆KW = L1max. - L1min. [mm] Lmax = L + ∆KA [mm]

picture 11: displacements

4 Assembly
Example for the misalignment

combinations given in picture 12:
Example 1:
∆KR = 30%
∆KW = 70%
Example 2:
∆KR = 60%
∆KW = 40%
∆Ktotal = ∆KR + ∆KW ≤ 100 % picture 12: combinations of displacement
Table 8: Displacement figures for type 001 (standard coupling)

ROTEX® size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
max. axial displacement
1,0 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0 3,4 3,8 4,2 4,6 5,0 5,7 6,4
∆Ka [mm]
max. radial displacement with
0,17 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48 0,50 0,52 0,55 0,60 0,62 0,64 0,68
n=1500 1/min ∆Kr [mm]
max. radial displacment with
0,11 0,13 0,15 0,17 0,19 0,21 0,25 0,26 0,28 0,32 0,34 0,36 0,38 - - - -
n=3000 1/min ∆Kr [mm]
∆Kw [degree]
1,2 1,2 0,9 0,9 1,0 1,0 1,1 1,1 1,2 1,2 1,2 1,2 1,3 1,3 1,2 1,2 1,2
max. angular displacement
with n=1500 1/min
0,67 0,82 0,85 1,05 1,35 1,70 2,00 2,30 2,70 3,30 4,30 4,80 5,60 6,50 6,60 7,60 9,00
∆Kw [mm]
∆Kw [degree]
1,1 1,1 0,8 0,8 0,8 0,8 0,9 1,0 1,0 1,0 1,1 1,1 1,1 - - - -
with n=3000 1/min
0,62 0,70 0,75 0,84 1,10 1,40 1,60 2,00 2,30 2,90 3,80 4,20 5,00 - - - -
∆Kw [mm]
Table 9: Displacement figures for type 018

ROTEX® size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
- 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0 3,4 - - - - - -
∆Ka [mm]
- 0,54 0,53 0,60 0,77 0,84 1,00 1,11 1,40 1,59 1,78 - - - - - -
n=1500 1/min ∆Kr [mm]
- 0,50 0,47 0,53 0,61 0,67 0,82 1,01 1,17 1,33 1,63 - - - - - -
n=3000 1/min ∆Kr [mm]
∆Kw [degree]
max. angular displacement - 1,20 0,90 0,90 1,00 1,00 1,10 1,10 1,20 1,20 1,20 - - - - - -
with n=1500 1/min
∆Kw [degree]
with n=3000 1/min

5 Enclosure A
design 001: hub / spider / hub

design 018: hub / spider / DKM spacer / spider / hub
ROTEX® DKM and ROTEX® ZS-DKM only with spacer made from steel.
explosion group control intervals

A checking of the circumferential backlash and a visual check of the flexible spider must
be effected after 3,000 operating hours for the first time, after 6 months at the latest.
If you note an unconsiderable or no wear at the spider after this first inspection, the further
inspections can be effected, in case of the same operating parameters, respectively after
6,000 operating hours or after 18 months at the latest.
II 2G c IIB T4
If you note a considerable wear during the first inspection, so that a change of the spider
would be recommended, please find out the cause according to the table „Breakdowns“, as
far as possible.
The maintenance intervals must be adjusted according to the changed operating
parameters.
II 2G c IIC T4
far as possible.
parameters.
ROTEX® Coupling
® ®
picture 13: ROTEX coupling picture 14: ROTEX spider
Here the backlash between coupling cams and the flexible spider must be checked by a feeler gauge.
When reaching the limit of wear of max. friction, the spider must be exchanged immediately, independent of the
inspection intervals.

5 Enclosure A
In case of a backlash of more than x mm, the flexible spider must be exchanged.
The reaching of the exchange values depends on the operating conditions and the existing operating
parameters.
CAUTION !
picture 15: checking of the limit of wear picture 16: wear of spider
Table 10:
ROTEX® limits of wear (friction) ROTEX® limits of wear (friction)
size Xmax. [mm] size Xmax. [mm]
9 2 65 5
14 2 75 6
19 3 90 8
24 3 100 9
28 3 110 9
38 3 125 10
42 4 140 12
48 4 160 14
55 5 180 14
In the explosion groups IIB and IIC only the following material combinations may be used:
GG 25 - GG 25
GGG 40 - GGG 40
steel - steel
stainless steel - stainless steel
Aluminium as coupling material is generally excluded for the explosion area.

5 Enclosure A
Couplings for the use in hazardous areas are marked for the respectively permissible conditions of use.
Explosion group IIC: e. g. II 2G c IIC T4
In the marking II 2G c IIC T4 the explosion group IIB is included.
5.5 Starting
Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and
the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated
tightening torques dependent on the type of coupling.
If used in hazardous areas, the setscrews must be additionally secured against self-loosening to fix
the hub, e. g. with Loctite (medium strength).
Last but not least, the coupling protection against unintended contact must be fixed.
Coupling protection in the hazardous area.

Covering of the coupling
The couplings must be provided with firm coverings (if possible, made from stainless steel)
protecting the couplings against falling objects. There can be regular openings in the coverings
which may not exceed the following dimensions:
circular openings rectangular openings

diameter in mm side length in mm
top surface of the covering 4 4
side parts of the covering 8 8
The distance between the cover and the rotating parts must be at least 5 mm.
The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings made from
aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor if the
magnesium part is below 7,5 %. The cover may only be taken off after having stopped the unit.
During operation, please pay attention to

• strange running noises
• occurring vibrations.
CAUTION !
If you note any irregularities at the coupling during operation, the drive unit must be turned
! off immediately. The cause of the breakdown must be found out with the table
„Breakdowns“ and, if possible, be eliminated according to the proposals. The possible
breakdowns mentioned can be hints only. To find out the cause all operating factors and
machine components must be considered.

5 Enclosure A
5.6 Breakdowns, Causes and Elimination
danger hints for

breakdowns causes elimination
hazardous areas
1) put the unit out of operation
2) eliminate the reason for the
misalignment (e. g. loose foundation
increased temperature
bolts, break of the engine fixing, heat
the the spider surface;
misalignment expansion of unit components, change
danger of ignition by
of the assembly dimension E of the
hot surfaces
coupling)
3) checking of wear see under point
Control
change of the 1) put the unit out of operation
running noises 2) disassemble the coupling and remove
and / or occurring wear of spider,
rests of the spider
vibrations short-term torque danger of ignition due
3) check coupling parts and exchange
transmission due to to sparking
damaged coupling parts
metal contact
4) insert spider, assemble coupling parts
5) check alignment, correct if necessary
2) check alignment of coupling
loose screws for danger of ignition due
3) tighten the screws to secure the hubs
axial securement of to hot surfaces and
and secure against self-loosening
hubs sparking
Control
wear of spider, 1) put the unit out of operation
danger of ignition due
torque transmission 2) change complete coupling
to sparking
due to metal contact 3) check alignment
break of the cams
danger of ignition due 2) change complete coupling
due to high shock
to sparking 3) check alignment
energy / overload
4) find out the reason of overload
break of cam operating
2) check the operating parameters and
parameters do not
danger of ignition due select a larger coupling (consider
correspond to the
to sparking installation space)
performance of the
3) assemble new coupling size
coupling
4) check alignment
mistake in service of danger of ignition due 2) change complete coupling
the unit to sparking 3) check alignment
4) instruct and train the service staff
premature wear of the the spider surface;
spider danger of ignition by
hot surfaces
coupling)
Control

5 Enclosure A
danger hints for

hazardous areas
e. g. contact with
2) disassemble the coupling and remove
aggressive liquids /
rests of the spider
oils, ozone- danger of ignition due
influence, too high to sparking in case of
ambient metallic contact of the
temperatures etc. cams
effecting a physical
6) make sure that further physical changes
change of the spider
of the spider are excluded
premature wear of 1) put the unit out of operation
spider 2) disassemble the coupling and remove
rests of the spider
ambient / contact
temperatures which danger of ignition due
are too high for the to sparking in case of
spider, max. metallic contact of the
permissible cams
6) check and regulate ambient / contact
-20 °C / +80 °C
temperature (eventually even
elimination by using other spider
materials)
rests of the spider
premature wear of danger of ignition due 3) check coupling parts and exchange
spider (liquefaction to sparking in case of damaged coupling parts
drive vibrations
of material inside metallic contact of the 4) insert spider, assemble coupling parts
the spider cam) cams 5) check alignment, correct if necessary
6) find out the reason for the vibrations
(eventually elimination by spider with
lower or higher shore hardness)
F
ATTENTION !
KTR does not assume any liabilities or guarantees regarding the use of spare parts and
accessories which are not provided by KTR and for the damages resulting herefrom.

5 Enclosure A
5.7 Certificate of Conformity
Certificate of Conformity
corresponding to EG Standard 94/9/EG dated 23 March 1994
and to the legal regulations
The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the
flexible ROTEX® couplings

described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b)
of Standard 94/9/EG and comply with the general Safety and Health Requirements according to
enclosure II of Standard 94/9/EG.
The couplings are certified according to Type Examination Certificate IBExU02ATEXB001 X.
According to article 8 (1) of Standard 94/9/EG the technical documentation is deposited with the:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
Rheine, 06.06.02 ppa. i. V.

Date Dr. Norbert Partmann Bernd Tenfelde
Engineering Manager Product Manager

TOSHIBA ELECTRIC MOTOR INSTALLATION & MAINTENANCE MANUAL
SINGLE OIL FILTER
Series FLN
In-Line Filter
Pressures 360 psi (25 bar) • Flows to 100 gpm (400 l/min)
GENERAL
The FLN filter consists of a filter
head and screw-in filter bowl. The
standard model is supplied with
bypass valve, vent and drain
screws, and a connection for dif-
ferential clogging indicator.
• Mounting
Inline filter
• Temperature Range
-20°F to 210°F (-30°C to 100°C)
• Trip pressure of the differential
pressure clogging indicator
∆pa = 72 psi (5 bar) -10%
• Cracking pressure of the
bypass valve
43 psi (3 bar) - (standard)
No bypass - (consult factory)
FILTER ELEMENTS
HYDAC filters are tested according
to the following ISO test standards:
• ISO 3724, Verification of fatigue
characteristics
• ISO 4572, Filtration Efficiency
FLN In-Line Simplex Filter
• ISO 4572, Multi-pass method for
evaluating filtration performance Fluid Compatibility:
• ISO 3968, Evaluation of pressure Suitable for mineral oils,
drop versus flow characteristics lubrication oils, non-flammable
• ISO 2942, Bubble point test fluids, synthetic and rapidly
biodegradable oils. For use with
• ISO 2941, Verification of water, please contact our
collapse / burst resistance
technical sales department.
Reliable filter operation is only
• Clogging Indicator:
guaranteed with the original
For further types of clogging
HYDAC filter elements.
indicators and further details
The filter elements are also on indicators, please see
suitable for use in dynamic brochure no.: 02070327.
applications due to their high
• Seals:
pressure stability; maximum
FKM (Viton)
permissable ∆p across the element:
Betamicron® (BN/HC):
435 psi (30 bar)
Wire Mesh (W/HC):
435 psi (30 bar)
Model Code: Filter
FLN BN/HC 250 D E 10 A 1 . X / 12 - V - B3 .
Filter Type
FLN
Filter Material Element
BN/HC = Betamicron® (BN3HC)
W/HC = Stainless Steel Wire Mesh
Size
160, 250, 400
Operating Pressure
D = 360 psi (25 bar)
Type and Size of Port
E = SAE-20 (1 1/4”)
Filtration Rating (micron)
3 = 3µm
6 = 6µm
BN/HC
10 = 10µm
25 = 25µm
25 = 25µm
50 = 50µm
W/HC
100 = 100µm
200 = 200µm
Type of Clogging Indicator
A = no clogging indicator
B = with visual clogging indicator VM2B.0 for other
C = with electrical clogging indicator VM2C.0 clogging
D = with visual and electrical clogging indicator VM2D.0 indicators
see brochure
LE = visual-mechanical/electrical indicator VD2LE.0 # 02070327
LZ = visual-mechanical/electrical indicator with VD2LZ.0
75% and 100% switching contact
Type Code
1
Modification Number
X the latest version is always supplied
Port Configuration
12 = SAE straight thread inlet/outlet connections
Seals
V = Fluoro Rubber (FKM) (standard)
Bypass Valve
B3 = 43 psid (3 bar) (standard)
(omit) = no bypass (optional - consult factory)
Supplementary Details
L24 = Lamp for 24 volt
L48 = Lamp for 48 volt D-type clogging
L115 = Lamp for 110 volt indicator only
W = suitable for oil-water emulsions (HFA, HFC), NBR seals,
(refers exclusively to the type of clogging indicator)
EV = knurled air bleed valve (replaces standard socket head plug)
A2.2 = 32 psi (2.2 bar) Indicator trip setting
30C = 30°C Indicator thermal lockout
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
2
Model Code: Replacement Element
0250 DN 010 BN/HC / - V
Size
0160 = size 160
0250 = size 250
0400 = size 400
Type
DN
003 = 3µm
006 = 6µm
BN/HC
010 = 10µm
025 = 25µm
025 = 25µm
050 = 50µm
W/HC
100 = 100µm
200 = 200µm
Filter Material
BN/HC = Betamicron®
W/HC = Stainless Steel wire mesh
Seals
V = FKM - Fluoro Rubber (standard)
Filtration Efficiency:
Filtration Rating Specification
3 µm ß 3 ≥ 200
6 µm ß 6 ≥ 200
10 µm ß 10 ≥ 200
25 µm ß 25 ≥ 200
Element Data:
Element Specifications
ISOMTD contamination
retention capacity in grams
at ∆p = 72 psi (5 bar) for BN/HC elements
Filter Type 3 µm 6 µm 10 µm 25 µm
160 27.5 29.3 33.1 36.7
250 46.0 49.0 55.2 61.3
400 76.2 81.3 91.4 101.5
Assembly Weight:
Filter Specifications
Weight lbs(kg)
Filter Type Port Element Size
with element
160 SAE 1 1/4” 0160 DN... 4.3 (9.5)
250 SAE 1 1/4” 0250 DN... 4.9 (10.8)
400 SAE 1 1/4” 0400 DN... 5.9 (13.0)
3
Engineering Data: FLN 160, 250, and 400
Design In-Line Low Pressure Filter
Mounting Method 2 Mounting Holes on top of Filter Housing
Connections Inlet: Outlet:
SAE-20 (1 7/8-12 UN-28) SAE-20 (1 7/8-12 UN-28)
Direction of Flow In-Line
Housing Pressure Ratings Operating: 360 psi (25 bar)
Proof: 540 psi (37.5 bar)
Fatigue: 360 psi (25 bar) @ 1 million cycles
Burst: Contact HYDAC office
Element Collapse Pressure Ratings Standard Elements: BN/HC: 435 psid (30 bar)
(ISO 2941) W/HC: 435 psid (30 bar)
Fluid Temperature Range -22°F to +210°F (-30°C to 100°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Fluid Compatibility Compatible with all petroleum oils and synthetic fluids rated for use
(ISO 2943) with Fluoro Rubber seals.
Contact HYDAC office for information on special for use with water
glycols,oil/water emulsions, and HWBF.
Flow Fatigue Resistance Filter medium is supported to achieve flow fatigue resistance.
(ISO 3724) Contact HYDAC office for information.
Trip Pressure of Differential Indicator 29 psi (2 bar) ± 10% (standard)
Cracking Pressure of ∆P = 43 psid (3 bar) bar ± 10% (standard)
Bypass Valve No Bypass (optional - consult factory)
Hydraulic Symbols
with bypass (standard) without bypass (optional)
A A
VA
VA
B B
Above Subject to Technical Modifications
4
Pressure Drop Calculations:
Assembly
To calculate the pressure drop of a filter assembly use the equation:
∆P Assembly = ∆P Housing + ∆P Element
Housing Curves
The housing curve is based on test results using mineral oil with a specific gravity of 0.86. Differential pressure increases in
proportion to specific gravity of applicable fluid. To adjust the housing ∆P for the fluid being used, use the equation:
∆P Housing = ∆P Curve x Actual Specific Gravity

0.86
FLN 160, 250, & 400

0.80 12.0
0.70 10.5
0.60 9.0
0.50 p in psid 7.5
p in bar
0.40 6.0
0.30 4.5
0.20 3.0
0.10 1.5
0.00 0.0
0 13 26 40 52 66 79 92 106
Q in gpm
0 50 100 150 200 250 300 350 400

Q in L/min
Elements ∆P Calculations
All element curves are based on test results using mineral oil with a kinematic viscosity of 141 SUS and a specific
gravity of 0.86. The differential pressure across the element changes proportionally to the viscosity and specific gravity.
∆P Element = ∆P Curve x Actual Viscosity x Actual Specific Gravity

141 0.86
0160 DNXX BN/HC 3µm 0250 DNXX BN/HC 3µm

1.4 21 2.0 30
1.8 27
1.2 18
1.6 24
1.0 15 6µm
p in psid
1.4 21
p in bar
6µm
1.2 18
p in psid
p in bar
0.8 12
10µm 1.0 15
0.6 9 10µm
25µm 0.8 12
0.6 9 25µm
0.4 6
0.4 6
0.2 3
0.2 3
0.0 0 0.0 0
0 13 26 40 52 0 26 52 79 106
Q in gpm Q in gpm
0 50 100 150 200 0 100 200 300 400
Q in L/min Q in L/min
0400 DNXX BN/HC W/HC

2.0 30 0.08 1.20
size 160
1.8 27 0.07 1.05
1.6 24
0.06 0.90
p in psid
1.4 21
p in bar
3µm 0.05 0.75

1.2 18
p in psid
p in bar
size 250
1.0 15 0.04 0.60
0.8 12 6µm
0.03 0.45 size 400
0.6 9 10µm 0.02 0.30
0.4 6 25µm
0.2 3 0.01 0.15
0.0 0 0.00 0.00
0 26 52 79 106 0 13 26 40 52 66 79 92 106
Q in gpm Q in gpm
0 100 200 300 400

0 50 100 150 200 250 300 350 400
Q in L/min
Q in L/min
5
Dimensions: FLN 160, 250, and 400
1.7" SAE-2
43.5mm 1 1/4"
INLET OUTLET
3.0"
76mm
size 160
11.2"
285mm
size 250
14.3"
363mm
Drain Screw
size 400
20.2"
513mm
ø 3.9"
100mm
M10x8
2.4"
ø 5.1" ø
130mm 60mm
Indicator Plug/Port
5.9"
150mm
6
HYDAC FILTERTECHNIK
Inline Filter
FLN 160 / 250 / 400
SPARE PARTS LIST
MAINTENANCE INSTRUCTIONS
for customer Hägglunds
Only when using original HYDAC

parts and correct handling, we give
guarantee according to our conditions
of sales and delivery.
Table of contents
1. Maintenance instructions
1.1 Safety-instructions
1.2 Installation
1.3 Commissioning
2. Maintenance
2.1 General
2.2 Maintenance procedures
2.3 Interval between changing elements
3. Element-changes
3.1 Removing the element
3.2 Element-mounting
4. Spare parts
4.1 Spare part-drawing FLN
4.2 Spare parts list FLN
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
This pressure vessel complies with the provisions of article 3 paragraph 3 of the
pressure vessels directive (97/23/EC) and so must not have a CE-mark.
This pressure vessel must be commissioned only in conjunction with a machine or

system.
Information
Information
The pressure vessel must be used only according to the operating instructions of
the machine or system.
Information
Information
The user must ensure appropriate actions to avoid air formation (e.g. venting)
Warning
W i
Repairs, maintenance and commissioning must be carried out only by specialists.

Do not touch the pressure vessel until cooled down.
Warning
W i
Pay attention to operating instructions of the machine or system.
Attention pressure vessel: please ensure for all works at the pressure vessel that the
referring side of the pressure vessel (filter housing) is released of pressure.
Danger
Modificatione of the pressure vessel are not allowed (welding, drilling, forced
opening..).
Danger
The operator/owner has to ensure adherence to the National Water Resources Act as
well as local water resources laws and other related regulations.
Information
Information
Follow the rules for prevention of accidents, safety regulations and data sheets for
fluids.
Smoking and open flames/fire are not allowed while working on or near hydraulic
systems.
Hydraulic media and water-polluting fluids are not be allowed to soak into the soil,
seep into bodies of water or the sewage system. Ensure an environmentally waste
management of hydraulic oils. Adherence is to be maintained to pertinent national
and local regulations pertaining to groundwater protection, disposal of waste/spent
oil and (hazardous) waste.
Work on filters may involve leaking hot oil which may cause injury and scalding as
result of its high pressure and/or temperature.
HYDAC FILTERTECHNIK
1.2 Installation
Before installation of the system it must be checked that the permissible operating pressure of
the system is not higher than the permissible operating pressure of the filter. Take a look at
the type code label!
1.3 Commissioning
Check whether the correct filter element (1) is fitted. Moisten thread and sealing surfaces on
the filter bowl and filter head, as well as the O-ring on bowl and element with clean system
fluid. Screw in the filter housing again fully and then unscrew by one quarter-turn (the sealing
effect will not be improved by over tightening). Switch on the hydraulic system and check the
filter for leakage. Vent filter.
2. MAINTENANCE
2.1 General
This section describes maintenance work, which should be carried out periodically. The
operational safety and the service-life of the filter, and whether it is ready for use, depend to a
large degree on regular and careful maintenance.
-Spare parts must fulfil the technical requirements specified by the manufacturer. This is
always guaranteed for HYDAC original spares.
-Keep tools, working area and equipment clean.
-After disassembling the filter, clean all parts, check for damage or wear and change if
necessary.
-When changing a filter element it must be paid attention to the best cleanliness.
The filter can be equipped with a clogging indicator (visual and/or electrical or electronic) to
observe the filter element. If the clogging indicator reacts, it is necessary to change or clean
the filter element without delay. If no clogging indicator is installed, we recommend to change
the elements in intervals (the filter element change depends on the filter design and the
conditions).
Higher dynamic loads across the element might necessitate shorter intervals between
changes. Shorter intervals can also be necessary during commissioning, repairs, oil changes
etc, on the hydraulic system.
The standard clogging indicators only respond when fluid is flowing through the filter. With
electrical indicators the signal can also be converted into a continuous display on the control
panel. In this case the continuous display has to be switched off after a cold start or element
change. If the clogging indicator reacts during a cold start only, it is possible that the element
does not need to be changed yet.
HYDAC FILTERTECHNIK
3. ELEMENT-CHANGES
1. Switch off the hydraulic system.
2. Remove oil drain plug (collect fluid in a suitable container and clean or dispose of in accordance
with environmental regulations).
3. Unscrew filter housing.
4. Remove filter element from element centering pivot (examine surface of element for dirt residue
and larger particles; these can indicate damage at the components).
5. Change or clean filter element (only W,W/HC, and V-elements can be cleaned)
Please request for cleaning instructions.
6. Clean filter bowl and filter head. Especially pay attention to the cleanliness of the threads.
7. Examine filter, especially sealing surfaces and thread, for mechanical damage.
8. Check O-rings and back-up rings - if necessary replace parts.
3.2 Element mounting
1. Moisten thread and sealing surfaces on the filter bowl and filter head, as well as the o-ring with
clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Mount filter element carefully on the element centering pivot.
4. Screw in filter housing.
5. Screw in oil drain plug. Unscrew filter housing by one quarter-turn.
6. Switch on hydraulic system and vent filter on suitable part of the unit.
7. Check filter for leakage.
NOTE: Filter elements which cannot be cleaned must be disposed

in accordance to environmental regulations.
HYDAC FILTERTECHNIK
Spare Parts Drawing FLN 160 bis 400
2.4/3.3/5.6
2.1
2.2/3.1/5.4
2.3/3.2/5.5
1.2/5.1
1.1
4.3/5.3
4.2/5.2
4.1
4.4/5.7
HYDAC FILTERTECHNIK
Spare Parts List FLN 160 bis 400
cons. Article-no. Hägglunds-
Item pc. Designation
of Dimension No.
Filter Element:
1 0160 DN 006 BN3HC /-VPN-SO378-SPARE 01271034 478 3233 628
1 1 0250 DN 006 BN3HC /-VPN-SO378-SPARE 01271038 478 3233 629
1.1 1 Filter Element DN... -
1.2 1 O-ring 40,87 x 3,53 -
Clogging Indicator:
2 01271999 478 3233 644
VD 2.2 LE.1 /-30C-SO378-03043225
2.1 1 Clogging Indicator VD 2.2 LE... -
2.2 1 Profile sealing ring VD... -
2.3 1 O-ring 16 x 1 -
2.4 2 O-ring 12 x 1 -
Sealkit Clogging Indicator:
3 01272003 478 3233 651
SEALKIT-E VD /-SO378
3.2 1 O-ring 16 x 1 -
3.3 2 O-ring 12 x 1 -
Filter Bowl:
BOWL-ASS‘Y FLND160 W.0/-V 01274800
4 BOWL-ASS‘Y FLND250 W.0/-V -
01274801
4.1 1 Bowl FLN... FLN... -
4.2 1 Back-up-ring FLN... -
4.3 1 O-ring 102 x 3 -
4.4 1 Locking screw G 3/8 NA -
Repair-kit:
5 01272216 -
REPAIR-KIT-E FLN..160/250/400 W.0
5.1 1 O-Ring (element) 40,87 x 3,53 -
5.2 1 Back-up-ring (Topf) FLN... -
5.3 1 O-ring (Bowl) 102 x 3 -
5.4 1 Profile sealing ring (clogging indicator) VD... -
5.5 1 O-Ring (clogging indicator) 16 x 1 -
PRESSURE GAUGE
PRECISION INSTRUMENT COMPANY
MODEL '201L', LIQUID FILLED GAUGES
Our ‘200’ Series Gauge Line Is A High Quality Line Of Liquid Filled Gauges. The Glycerine Filling Helps
Dampen The Effects Of Pulsation And Vibration, While Also Perpetually Lubricating The Movement (And
Keeping Contaminates Such As Dirt Away From All Moving Parts) Which Will Extend The Life Of The Gauge.
This Gauge Has Been Specifically Designed With The Original Equipment Manufacturers In Mind And
Are Typically Used On Hydraulic & Pneumatic Systems As Well As Any Commercial Or Industrial Application
Not Corrosive To Brass And Bronze Wetted Parts Where Glycerine Filling Is Suitable For Use.
SPECIFICATIONS:
• Available Dial Sizes: 1 ½”, 2”, 2 ½”, 4", 6"
• Available Connection Sizes:
1/8”MNPT on 1 ½” and 2”
1/4"MNPT on 2”, 2 ½” and 4"
1/2"MNPT on 4" and 6"
• Stainless Steel Case And Bezel
• Brass Internals & Connection
• Phosphour Bronze Bourdon Tube
• Liquid Filled (Dry Available)
• Accuracy : 1 ½” and 2” Dial = 2 %
2½ ”Dial Size = 1.5 %
4” and 6” Dial Size = 1 %
• Dual Scale: PSI & Bar (x100=kPa)
Single Scale available from stock
• Ambient temperature: FILLED: 30’F to 160’F
DRY: -30’F to 180’F
RANGE CODE Major In Minor In

Some ranges not available in all dial sizes, please call with your particular application
30/0"VAC A 5 0.5
30/0/15 CB 5 0.5
30/0/30 CC 10 1
30/0/60 CD 10 1
30/0/100 CE 20 2
30/0/150 CF 20 2
30/0/300 CH 50 10
0/15 B 2 0.2
0/30 C 5 0.5
0/60 D 10 1
0/100 E 20 2
0/160 F 20 2
0/200 G 40 4
A B C D E
0/300 H 50 5
0/400 I 50 5 1 ½” In 1.88 1.06 .89 2.77 1/8”
0/500 J 100 10 Dial MM 48 27 23 58 Npt
0/600 K 100 10
2” In 2.24 1.27 .71 2.80 1/8” or
0/800 L 100 10
0/1000 M 200 20 Dial MM 57 32 23 71 ¼”npt
0/1500 N 200 20 2 ½" In 2.80 1.28 1.07 3.55 1/4“
0/2000 O 400 50 MM 71 33 27 90 Npt
Dial
0/3000 P 500 50
0/4000 Q 500 50 4" In 4.32 1.63 1.25 5.57 1/4" or
0/5000 R 1000 100 Dial MM 110 42 32 141 ½
”npt
0/6000 S 2000 200
6" In 6.54 1.70 1.68 8.22 1/4“ or
0/10,000 U 2000 200
0/15,000 V 2000 200 Dial MM 166 43 43 210 ½”npt
OIL LEVEL INDICATOR
FLUID LEVEL
INDICATORS FSA/FSK
APPLICATION
The HYDAC FSA-Visual Fluid
Level indicators and FSK-
Electrical Fluid Level Indicators
are used for monitoring fluid
levels and temperature in various
types of reservoirs. Typical
applications are hydraulic system
reservoirs and lubricating, cutting
and cooling fluid tanks. Visual and
are suitable for service in mineral
oils and phosphate-ester based
hydraulic fluids. For Water Glycols
and High Water based fluids, the
sight tube must be ordered in
glass construction. Fluid Level
Indicators can be supplied with
various types of thermometers:
Built-in Tube (FSA only), Dial
Gauge with Thermometer Probe
or Electrical Thermo-Switch.
SPECIAL FEATURES
• Attractive appearance
• Transparent Polyamide sight tube
• Thermometers furnished with
dual range for both Celsius and
Fahrenheit
• Simple and rugged construction
• Available in several sizes
• Choice of seals
• Easy mounting
• Available with Thermo-Switch
DESCRIPTION controls the oil temperature in the
hydraulic reservoir. The Thermo
The HYDAC FSA Visual Fluid Level Switch opens when the nominal
Indicator is available in five sizes. temperature is reached. The switch
The HYDAC FSK Electrical Fluid closes when the temperature is
Level Indicator is available in four approximately 36˚F (20˚ below
sizes and provides an electrical nominal temperature.)
signal at a low fluid level. This
reliable magnetically-operated
reed relay circuit is available in
two single pole single throw
(SPST) contact arrangements:
normally closed (type “O”) or
normally open (type “C”). The
HYDAC TS Thermo-Switch
TECHNICAL DATA THERMO SWITCH SELECTION CODE
Thermo Switch Switch Mounting
Code Temperature Thread
Mounting Thread TS50 50˚C/122˚F M 12
FSK or FSA................M 12 or M 10 TS60 60˚C/140˚F M 12
TS ...................................M 12 only TS70 70˚C/158˚F M 12
TS80 80˚C/176˚F M 12
Material
Housing............Anodized Alumnum
Sight Tube............Polyamide,Glass
Seals................Fluorocarbon, NBR MODEL CODE
Fluid Temperature FS A -127- 1 . 1 - - T - 12 -
-4˚F/-20˚C to176˚F/80˚C
Maximum Pressure Fluid Level Indicator
14.5 PSI (1 BAR)
Type
Thermometer A = Visual
Type T K = Electrical
(FSA only)
68˚F/20˚C to 176˚F/80˚C Size (Mounting Hole Centers)
Type FT 76 = 3 inches (FSA Only)
32˚F/0˚C to 212˚F/100˚C 127 = 5 inches
176 = 7 inches
Bolting Torque 254 = 10 inches
Max. 8 LB-FT+1 (10 Nm +2) 381 = 15 inches
see installation instructions on page 4
Electric Switch Seals
1 = NBR (FSA)
FSK...C FSK...O
2 = Fluorocarbon (FSA and FSK)
2 2
3 3 Modification Number
1 1 1 = FSA (Determined by Manufacturer)
3 = FSK (Determined by Manufacturer)
Electrical Switch
(omit) = For FSA
Contact Ratings.................Max. 8W “C”(SPST) = Normally open at Normal Level
Maximium Voltage.....50 VAC or DC “O”(SPST) = Normally closed at Normal Level
Maximum Current...............200 mA
Connection 3 not used Thermometer
TYPE C TYPE O T = Built-in Tube (FSA Only)
Normally Normally FT 200 = Probe Thermometer (200mm-7.87”LG)
Open Closed FT 300 = Probe Thermometer (300mm-11.87”LG)
TS = Thermo Switch (See Chart Above)
FSK - C FSK - O
Hex Head Bolt
12 = M12 Bolt (Standard)
10 = M10 Bolt (Optional)(Not Available with TS)
Contacts are Contacts are Sight Tube
closed at lower open at lower (omit) = Polyamide construction (not suitable for water glycols or high water
level of fluid level of fluid based fluids)
Thermo Switch Glass = Glass construction-Special Order for FSA Only. Not Available with
FSK.
TS
When ordering probe thermometer separately, please order one (1) drilled bolt, item
12, in spare parts list.
1 2
See installation procedures on page 4 to determine whether a washer is needed.
If a washer is needed, order part # 00001689
Switching Outputs 10.0 A/50 V-1 cycles

2.5 A/50 V-10,000 cycles
0.5 A/50 V-100,000 cycles
Minimum Current 50 mA
N/C Contact
2
FSA FSK
Fluid Level Indicator Fluid Level Indicator/Switch
max. .31
max. 8 max. .31 1.10
max. 8 28
.79 .20 1.34
20 5 34
M 12 or
M 10 M 12 or
M 10
CLEARANCE HOLE HYDAC

ø.51 (13mm) or CLEARANCE HOLE
ø.43 (11mm) ºC ºF ø.51 (13mm) or
80- -180
ø.43 (11mm)
70- -160
60- -140
50- -120 L2 L2
40- -100
L2 L L1 SWITCH
30- -80 LEVEL
20-
-60
10-
-40
0-
-10- -20
1.97
50
.79 20
20 5 1.34
34
1.77
45
1.77
SCREW-TYPE CONDUIT
45
FITTING PG 9
Size L L1 L2 Size L L2
inch 4.25 1.46 2.99 inch 8.07 5.00
76 127
mm 108 37 76 mm 205 127
inch 6.26 2.99 5.00 inch 10.00 6.93
127 176
mm 159 76 127 mm 254 176
inch 8.19 4.92 6.93 inch 13.07 10.00
176 254
mm 208 125 176 mm 332 254
inch 11.26 7.99 10.00 inch 18.27 15.00
254 381
mm 286 203 254 mm 464 381
inch 16.26 12.99 15.00
381
mm 413 330 381
Thermo Switch - TS FSA or FSK

Detail of Lower Connection WIth Optional Probe Thermometer (FT)
11
.67 SQ
SW 17
M 12
ø1.51
ø40
1.93
49
12
7.87" or 11.87"
200 or 300
.63 3.62
16 92
3
Recommended Installation Process
1. Drill mounting holes according to dimension L2 on page 3.
Mounting hole diameter is dependent on the bolt selected in the model code. see pages 2 & 3
2. Torque the Nut, item 9, to 8+ 1 LB-FT. If it is not possible to torque the nut, the bolt head must be torqued. To avoid
damaging the indicator a washer is recommended to be used under the bolt head.
This washer is available from HYDAC: Part Number 00001689.
Washer Dimensions: OD 18.8 mm, ID 13.10 mm, 0.5 mm thick
Spare Parts
FSA FSK
10 1
2
3
© Copyright 2001 HYDAC TECHNOLOGY CORPORATION - Brochure - Fluid Level Indicators FSA/FSK #02068184 / 9.02
9 13
4
5
6
7 14
or
15
Quanity Quanity
Item Description FSA FSK
1 Housing 1 1
2 Name Plate 1 -
3 Tube 1 1
4 O-Ring 13x2.5 2 2
5 Tube Connector 2 2
6 O-Ring 12.3x2.4 2 2
7 Sealing Washer 2 2
8 Hex Bolt 2 2
9 Hex Nut 2 2
10 Thermometer in Indicator Tube 1 -
11 Probe Thermometer (see page 3) 1 1
12 Hex Bolt for Probe Thermometer 1 1
13 Magnetic Float - 1
14 Base Assembly with Type “C” Switch - 1
15 Base Assembly with Type “O” Switch - 1
16 Washer (optional - see note 2 above) 1 1
HYDAC TECHNOLOGY CORPORATION

2260 City Line Road • Bethlehem, PA 18017
Phone (610) 266-0100 • Fax (610) 264-3540
www.hydacusa.com • powerup@hydacusa.com
4
AIR BREATHER
Breathers
Breather & Filler Breather Overview
Breather Max. Flow Element Connection Notes
BF...3/4 35/10 SCFM 3 or 10 µm Threaded Carbon Steel with External Epoxy Coating
250/80 GPM phenolic resin 1/4 to 3/4” BSPP and Zinc Plated Internals
impregnated paper (male) Pressurized (optional)
page 84
BF...30 25 SCFM 3 or 10 µm Threaded Durable Synthetic Material (PA 6)
200 GPM phenolic resin 3/8 to 3/4” BSPP Pressurized (optional)
impregnated paper (male)
page 85
500 GPM phenolic resin 1” BSPP with optional differential gauge
Replaceable
page 86
BL... & BLT... 110 SCFM 3 or 10 µm Threaded, Flanged, Spin-on elements (BL...)
850 GPM phenolic resin or Welded Dehumidifying element (BLT...)
impregnated paper
page 88
BD... (Drymicron) 100 SCFM 2µm Threaded, Silica Gel Desiccant adsorbs water
750 GPM Disposable Flanged, or then changes color to indicate
Bayonet when breather should be changed
page 91
BF...5 220 SCFM 3 or 10 µm Threaded Carbon Steel
1600 GPM phenolic resin 2 1/2” BSPP
impregnated paper (female)
Replaceable
page 87
Filler/Breather Max. Flow Element Connection Notes

ELF...3/4 35/10 SCFM 3 or 10 µm 6 hole flange/ Carbon Steel with External Epoxy Coating
250/80 GPM phenolic resin Bayonet and Zinc Plated Internals
impregnated paper Lockable models available
Pressurized (optional)
page 79
ELF...30 25 SCFM 3 or 10 µm 6 hole flange/ Durable Synthetic Material (PA 6)

200 GPM phenolic resin Threaded Pressurized (optional)
impregnated paper
page 81

500 GPM phenolic resin Threaded with optional differential gauge
impregnated paper
Replaceable
page 82
ELF...5 220 SCFM 3 or 10 µm Threaded Carbon Steel

1600 GPM phenolic resin 2 1/2” or 3” BSPP
impregnated paper (weld rings available)
Replaceable
page 83
Sizing: Maximum Flow is the greater of the maximum pump flow rate, or the maximum system return rate into
the reservoir. Flow rates given are based on a 0.6 psi initial pressure drop with a clean element in a normal
operating environment. Contact HYDAC for applications in extreme environmental conditions.
77 Accessories Catalog
Breathers
Breathers & Filler Breather Technical Overview
Importance of Breathers
Breathers are a integral component in any Hydraulic system. Breathers provide protection from contamination found in harsh industrial
environments. It is well advised to address both contaminant exclusion and removal. An old rule of thumb states that it cost 10 times
as much to REMOVE a particle from your system as it does to EXCLUDE it. Since this is true, it is easy to see that the benefits of
using a high quality breather greatly out-weigh the costs.
Recommendations
1) HYDAC recommends selecting a breather with a filtration rating (micron rating)
that is equivalent to or finer than your finest system filter.
2) Breathers do get clogged over time. HYDAC recommends the following change-out schedules:
For breathers without pressure gauges
• Change you breather annually or with every service interval
For breathers with pressure gauges
• Change your breathers at a 3 psi pressure drop, at 7 psi pressure drop the pump can cavitate
HYDAC High Quality Breathers

All HYDAC Breathers use HIGH quality filtration.
• For 3µm breathers: d100 = 3 µm
(refer to Engineering Data on page 90 for details)
Elements are made of phenolic resin impregnated paper, which provides resistance to moisture, ensuring proper filtration over the
operational service life of your breather.
Pressurized Breathers
The use of pressurized breathers adds certain benefits:
• Provides additional protection from moisture which can condense in your tank, causing oil degradation and tank erosion
• Provides positive pressure to pump suction line
• Increased breather service life due to less breathing
• Performs anti-splash function
Tank Pressure Tank Pressure

Using a Standard Breather Using a Pressurized Breather
Positive Pressure Positive Pressure Above Cracking Pressure
Tank Pressure
Tank Pressure
(tank breathes out) (tank breathes out)

Breather
Cracking Pressure
Atmospheric
No Breathing Takes Place Atmospheric
Pressure Pressure
Vacuum Vacuum
(tank breathes in) (tank breathes in)
Time Time
When fluid level rises, the tank pressure rises When fluid level rises, the existing air volume is
and air is immediately expelled through the compressed, and no air is expelled until the cracking
breather whenever positive pressure exists. pressure is surpassed.
When fluid level lowers, the tank pressure drops When fluid level lowers, the tank pressure drops
and air is immediately drawn in through the breather until a vacuum is created at which point, air will be
whenever a vacuum exists. drawn in through the breather.
Air is constantly moving through the breather Air is only expelled when the tank pressure is
in order to maintain atmospheric pressure. above the cracking pressure, and air is only
drawn in below atmospheric pressure.
The majority of the operational cycle will take place
between these two conditions.
1-877-GO HYDAC Accessories Catalog 78

Breathers
ELF...3 & ELF...4 Series Filler Breathers
Specifications: Dimensions: 2.66"
• Maximum flow rate: 35 SCFM/250 GPM ø D2
67.5mm
Tab Thickness
2.26"
ø D1 57.5mm 0.08"
• Epoxy coated steel cap 2mm
• Zinc-plated internals
H3 1.22"
• 3 or 10 micron 31mm
H1
• 500 micron plastic filler basket
Self-tapping Screw 0.83"
• Bayonet connection to access fill port M5 x 10 (DIN 963) Ø 8mm 21mm
H2
• Installs via 6 bolt circle (bolts included)
• Locking tabs (optional)
• Pressurized breather
ø D3
with relief valve (optional - ELF3 only)
Mounting Hole Patterns
Hydraulic Symbols: ELF 3
(Flange Interface to DIN 24557/T2) 0.18"
ELF 4
ø
4.5mm
(3 places)
Ø 2.36" Ø 1.18" Ø 1.63"

60mm Ø 2.87"
73mm 30mm 41.3mm
0.18"
with relief valve (ELF3 only) standard ø
4.5mm
(6 places)
Size D1 D2 D3 H1 H2 H3
2.99” 3.27” 2.05” 6.26” 3.80” 2.46”
ELF 3 Ø Ø Ø
76mm 83mm 52mm 159mm 96.5mm 62.5mm
1.73” 1.97” 1.10” 5.32” 3.21” 2.11”
ELF 4 Ø Ø Ø
44mm 50mm 28mm 135mm 81.5mm 53.5mm
Model Code: ELF...3/4

ELF P 3 F 3 W 1 . 0 / .
Filter Type
ELF = Filler Breather
ELFL = Lockable Filler Breather (not available for size 4)
Filter Element Material
P = Phenolic Resin Impregnated Paper
Size
3 = 35 SCFM (250 GPM) Max.
4 = 10 SCFM (80 GPM) Max.
Type of Connection
F = Flanged
3 = 3µm Air Filtration
Gauge Options
W = Without Indicator
Type
1 = ELF 3 and 4
4 = ELF 3 RV; Relief Cracking Pressure 10 psi; Reseat Pressure 6 psi
Modification Number (standard)
RV = Relief Valve (for use on Pressurized Tanks; ELFP3 only)
SO169H3.5 = 3.5 inch plated steel filler basket
SO169H6 = 6 inch plated steel filler basket (ELFP3 only)
SO169H8 = 8 inch plated steel filler basket
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
Breathers
ELF 3 Series Filler Breather Parts
ELF 3 Breather Caps
Part Model Code Part No.

Breather Cap ELF P 3 CAP 10 W 1.0 W/CHAIN 02080124
Breather Cap
Breather Cap ELF P 3 CAP 10 W 6.0/RV W/CHAIN 02080125
with 6 psi relief valve
6 bolt Bayonet Flange
Self Tapping
Bayonet Flange Kit
Screws
M5x10 (DIN 963)

Bayonet Flange Bayonet Flange Kit ELF3 BAYONET FLANGE KIT ASSY 00002680
Note: Parts not sold separately
Gaskets
1 for under basket
1 for on top of basket

3.5” Steel Filler Basket ELF3 STRAINER BASKET 3.5” PLATED STEEL 02701474
6-bolt Filler Basket
6” Steel Filler Basket ELF3 STRAINER BASKET 6” PLATED STEEL 02701475
4” Plastic Filler Basket ELF3 STRAINER BASKET 4” PLASTIC 01202916
Weld Neck Bayonet Flange

Installation
Cross Section
Weld Neck
Bayonet Flange

Weld Neck ELF3 WELD NECK W/CHAIN 02080126
Reservoir Wall
Drop-in Filler Basket

Drop-in Strainer ELF3 WELD NECK STRAINER 02078939

Breathers
ELF...30 Series Filler Breathers
Specifications: Dimensions:
• Maximum flow rate - 25 SCFM/200 GPM ø 83mm
ø 81mm
• Durable synthetic material (PA6)
• 3 or 10 micron
• 500 micron plastic filler basket 62mm
• Threaded connection to access fill port
83mm
• Installs via 6-bolt circle (bolts included)
• Optional dipstick (contact factory)
• Optional customer logo (contact factory)
• Pressurized breather 185mm Self
with relief valve (optional) approx. Tapping
Screw
M5 x 10 (DIN 963)
Hydraulic Symbol:
Mounting Hole Pattern
ELF 30
(Flange Interface to DIN 24557/T2)
with relief valve

Ø 2.36"
60mm Ø 2.874"
73mm
0.18"
ø
4.5mm
standard
(6 places)
Model Code: ELF...30

ELF P 30 F 10 W 1 . X / .
Filter Type
Size
30
Type of Connection
F = Flanged
Gauge Options
Type
1 = Flanged Connection to DIN 24557/T2
(omit) = standard
RV0.4 = Relief Cracking Pressure 6 psi; Reseat Pressure 3 psi
Breathers
• Maximum flow rate - 65 SCFM/500 GPM
• Durable synthetic material (PA6) ELF 7
• 3 or 10 micron
Optional
• 500 micron plastic filler basket Gauge
• Replaceable element
• Threaded connection to access fill port ø 4.72"
• Installs via 6-bolt circle (bolts included) 120mm
• Differential gauge (optional)
2.36" Clearance Required

Replacement Elements 60mm For Element Removal
Micron Model Code Part No.
ø 4.57"
3 0007L003P 00310948 116mm
10 0007L010P 00310485 1.73"
44mm
Hydraulic Symbols:
Mounting Hole Pattern 3.31"

(Flange Interface to DIN 24557/T2) 84mm
7.13"
with gauge ø 2.36" ø 2.87" 181mm
60mm 73mm Counter Sunk
3.82" Slotted Screw
97mm
ø 0.18" M5 x 10 (DIN 963)
4.5mm
(6 places)
ø 1.93"
49mm
without gauge
Model Code: ELF...7

ELF P 7 F 10 K 1 . 0.
Filter Type
Size
7
Type of Connection
F = Flanged
Gauge Options
K = With Gauge (Range: -14.5 to 9 psi)
Type
1 = (standard)

Breathers
ELF 5
• Maximum flow rate - 220 SCFM/1600 GPM 3.54" Clearance Required
90mm For Element Removal
• Steel element housing
• 240 mm Zinc-plated metal filler basket ø 6.97"
177mm
• 3 or 10 micron
• Replaceable element 4.13"
• Removable Lid to access fill port 105mm
• Installs via threaded connection

(weld ring optional)
HEX
0.98" 3.54"
25mm 90mm
13.78"
9.45" 350mm
240mm
2.68"
Replacement Elements 68mm
G3
Micron Model Code Part No. (ELF5...3.0)
3 0005L003P 00309450 G2 1/2

(ELF5...2.0)
10 0005L010P 00306097
2.56"
(ELF5...2.0)
65mm
Weld Rings Weld Ring
2.80"
(ELF5...3.0)
Size Model Code Part No. 71mm
G 2 1/2 RING WELD ELF 5 G 21/2 02065053 3.46"
Reservoir opening Ø (ELF5...2.0)
88mm
G3 RING WELD ELF 5 G 3 02065054 for weld ring
3.98"
Ø (ELF5...3.0)
101mm
Model Code: ELF...5

ELF P 5 F 3 W 1 . 0 / .
Filter Type
Size
5
Type of Connection
G = Threaded (matching threaded weld ring available see supplementary details below)
Gauge Options
Connection Type
2 = ELF 5 with G 2 1/2 threaded connection
3 = ELF 5 with G 3 threaded connection
NO WELD RING = without weld ring
W/ WELD RING = with weld ring
Breathers
BF...3 & BF...4 Series Breathers
• Epoxy coated steel cap
ø D1
• 3 or 10 micron
• Threaded connection
• Pressurized breather H1
with relief valve (optional - BF3 only)
H3
Hydraulic Symbols: HEX
D2
Size D1 D2 (male) H1 H3 HEX

BF 3...1.0 2.99” G 3/4 3.11” 0.63” 1 7/16”
with relief valve (BF3 only) Ø 76mm
BF 3...RV (ISO 228) 79mm 16mm 36mm
2.99” G 3/8 2.83” 0.47” 7/8”
BF 3...2.0 Ø 76mm (ISO 228) 72mm 12mm 22mm
2.99” G 1/2 2.99” 0.55” 1 1/16”
BF 3...3.0 Ø 76mm (ISO 228) 76mm 14mm 27mm
1.73” G 1/4 2.44” 0.53” 11/16”
standard BF 4...1.0 Ø 44mm (ISO 228) 62mm 13.5mm 17mm
Model Code: BF...3 & BF...4

BF P 3 G 10 W 1 . 0 / __
Filter Type
BF = Breather
Size
3 = 35 SCFM (250 GPM) Max.
Type of Connection
G = Threaded
Gauge Options
Tank Thread Connection (ISO 228)
1 = BF3
3/4 = G
1 = BF4
1/4 = G
2 = BF3
3/8 = G
3 = BF3
1/2 = G
4 = BF3 = G
3/4 with RV Relief Valve (Relief Cracking Pressure 10 psi) Reseat Pressure 6 psi
5 = BF3 = G
6 = BF3 = G
(omit) = (standard)
RV = Relief Valve (For Use on Pressurized Tanks)(BF3P only)

Breathers
BF...30 Series Breathers
ø 81mm
• 3 or 10 micron
• Threaded breather connection
• Optional dipstick (contact factory) 56mm
• Pressurized breather 14mm SW32 (Types 1 & 2)
with relief valve (optional) SW46 (Type 3)
16mm
O-Ring
Hydraulic Symbol: G 3/4 male

(ISO 228)
with relief valve
standard
Model Code: BF...30

BF P 30 G 10 W 1 . X / .
Filter Type
BF = Breather
Size
30
Type of Connection
G = Threaded
Gauge Options
Type
1 = G 3/4
(omit) = standard
Breathers
• Durable synthetic material Optional
• 3 or 10 micron Gauge
• Threaded breather cap connection ø 4.72"
120mm
Replacement Elements
Micron Model Code Part No. 2.36" Clearance Required for
3 0007L003P 00310948
60mm Element Removal
10 0007L010P 00310485
ø 4.57"
116mm
1.73"
Hydraulic Symbols: 44mm
4.33"
110mm
with gauge
1 5/8"
HEX
41mm
0.71"
18mm
G 1"
ISO 228
without gauge
male
Model Code: BF...7

BF P 7 G 10 K 1 . 0
Filter Type
BF = Breather
P = Impregnated Paper
Size
7
Type of Connection
G = Threaded
Gauge Options
1 = G1

Breathers
• Steel housing 3.54"
90mm
• 3 or 10 micron Clearance
• Replaceable element Required
• G2 1/2 female threaded connection ø 6.97" For
177mm Element
Removal
Micron Model Code Part No. 4.21"
3 0005L003P 00309450 107mm
10 0005L010P 00306097
G 2 1/2"
Hydraulic Symbol: (ISO 228)
female
Model Code
BF P 5 G 10 W 1 . 0
Filter Type
BF = Breather
Size
5
Type of Connection
G = Threaded
Gauge Options
1 = G 2 1/2 (standard)
Breathers
BL Series Spin-on Breathers
• Maximum flow rate H3
Clearance needed
110 SCFM/850 GPM for removal Ø D1
• 3 or 10 micron Mounting Hole Pattern for Flange Connection (F)
• Steel Canister
• 10 micron Betamicron® 2.87"
ø 73mm ø
2.36"
60mm
• Replaceable element H2
H1 ø 0.18"
4.5mm
(6 places)
Hydraulic Symbol:
D3
D2
F Connection G Connection S Connection
Size D1 D2 D3 H1 (F or S) H1 (G) H2 H3
3.67” 7” 5.4” 0.75”
BL...80 3/4” NPT 1”-12UNF-2B -
Ø 93mm 178mm 137mm 19mm
5.00” 9.25” 8.75” 7” 1.00”
BL...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 235mm 222mm 178mm 25.4mm
5.00” 13.25” 12.75” 11” 1.00”
BL...180 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 337mm 324mm 279mm 25.4mm
5.33” 9.25” 8.75” 7” 1.00”
BLT...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 136mm 235mm 222mm 178mm 25.4mm
Dimensions are for general information only, all critical dimensions should be verified by requesting a certified print.
Model Code: BL... BL P 160 G 10 W 2 . 0

Filter Type
BL = Spin-on Breather
BLT = Spin-on Breather with Dehumidifying Element (size 160 only)(in 3 micron only)
BN = Betamicron®
M = Desiccant (type BLT only)
Size
080 = 35 SCFM (250 GPM) Max.
160 = 110 SCFM (850 GPM) Max.
180 = 110 SCFM (850 GPM) Max.
Type of Connection
G = Threaded
F = Flanged Available in sizes BL 160 and BL 180 Only
S = Weld Fitting
3 = 3µm Air Filtration (paper only)
Gauge Options
Type Number
Size Tank Connection
1 = BLT 160 1 1/4” NPT Thread, Flange, or Weld Fitting
2 = 160/180 1 1/4” NPT Thread, Flange, or Weld Fitting
3 = 080 3/4” NPT Thread
Model Codes containing red selections are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability

Breathers
BL... Series Breather Components
Size 10 micron 3 micron 10 micron 3 micron
Paper Paper Betamicron BLT
0080MA010P 0080MA003P 0080MA010BN
80 N/A
02058058 02058079 02059424
0160MA010P 0160MA003P 0160MA010BN 0160MU003P
160
02058116 02058114 02059436 01265765
0180MA010P 0180MA003P 0180MA010BN
180 N/A
02058121 02057912 02059440
Adapters
Fiber Gasket Sold Separately

Order Part Number 00247102
Size G F S
Threaded Adapter Flanged Adapter Welded Adapter
ADAPTER BL 080G 3/4” NPT NBR
80 N/A N/A
02064393
160
ADAPTER BL 160/180 G 1 1/4” NPT NBR ADAPTER BL 160/180 F (PHOS) ADAPTER BL 160/180 S (PHOS)
02064394 00407646 00416311
180
Breathers
Engineering Data
Mounting Position: ELF & BF Vertical (max. 30° off vertical axis)
BL, BLT, BLG, & BLS Vertical or Horizontal
Air Filter Material: Phenolic Resin Impregnated Paper
Note: None of the air filter elements can be cleaned.
Fluid Temperature Range: -15° to 250°F (-26° to 121°C)
Please contact HYDAC for information on extreme low
temperature applications (below -15°F.)
Fluid Compatibility: Compatible with all petroleum oils.
Weights
Model lbs. kg.
ELF 3 0.55 0.25
ELF E RV 0.66 0.30
ELF 4 0.44 0.20
ELF 5 (TYPE NO. 2) 5.95 2.70
ELF 5 (TYPE NO. 3) 6.83 3.10
ELF 7 0.84 0.38
BF 3 0.62 0.28
BF 3 RV 0.73 0.33
BF 4 0.18 0.08
BF 5 4.41 2.00
BF 7 0.88 0.40
BL 160 4.63 2.10
BL 80G 1.40 0.60
BL 160G 2.60 1.20
BL 180G 3.48 1.58
BL 160S 3.86 1.75
BL 180S 4.22 1.91
BLT 160 5.31 2.41
Retention Value
dx
x refers to the percentage of particles of a particular size that the breather will filter.
i.e. d80 for a 10µm filter will capture 80% of 10 µm particles

Breathers
BD Series Drymicron Operational Features
Bi-directional Air Flow
• Air entering is cleaned and dried. Expelled air partially
regenerates the silica gel and “backflushes” the
particulate filter to prolong the life of the breather.
Durable Construction
• DRYMICRON is manufactured from rugged ABS
plastic and impact-modified Plexiglas.
Water Vapor Adsorbent
• Silica gel is chemically inert, non-toxic, and non-
corrosive. The internal structure is composed of
interconnected microscopic pores that adsorb up to
40% of its weight.
Color Indicator
• When maximum adsorption is reached, the silica gel
turns from gold to green to indicate that replacement
Description of the breather is required.
DRYMICRON breathers use a three-stage filtration
REPLACE
design to ensure optimum protection by removing GOLD
ACTIVE
water vapor and solid contaminant before they enter
the fluid system. GREEN
DRYMICRON Breathers replace the standard breather
cap or vent tube on a tank or reservoir. They are easy Safety Sealed
to install using one of several adapters designed for • Seals keep moisture from entering the units until they
different applications. are placed in service. They are easily removed without
When the fluid in the system is lowered, or pressure tools or sharp instruments.
changes occur, air is drawn in through openings under
the breather cap. First, air passes through a fine, 2
Solid Contaminant
micron solid particle filter. The air then passes through Filter (2 µm)
a diffuser to ensure maximum effectiveness within the
Air Diffuser
silica gel chamber.
Next, water vapor is removed as the air travels through
360˚ Air Flow
a bed of silica gel — the highest capacity adsorbent
available. After being dried, the air passes through a
second 2 micron solid particle filter and enters the
reservoir clean and dry!
High Capacity
Advantages Water Vapor
Adsorbent
DRYMICRON Breathers protect expensive equipment, Solid Contaminant
increase Filter (2 µm)
operation efficiency, and reduce maintenance costs by:
• eliminating corrosion
• extending life of hydraulic, lubrication, and process
fluids CLEAN DRY AIR
• minimizing component wear,

downtime, and repairs ø 5"
(128 mm)
• eliminating oil oxidation, additive
depletion, and freezing
• extending oil filter life
A
Applications
• Hydraulic Reservoirs
• Gear Boxes BD 100, 200, 400
standard 1" friction fit
• Storage Tanks (see adapter selection guide)
1.25" BD 800
(32 mm) 2"NPT only
(no adapter needed)
Breathers
Product Specifications
Performance Specification
Nominal Air Flow Rate BD 100-400 35 SCFM (990 l/min)
Equivalent of 260 gpm of fluid volume change
Nominal Air Flow Rate BD 800 100 SCFM (2850 l/min)
Solid Contamination Filtration Level 2 micron, 100% efficiency @ 35 SCFM air flow
Solid Contamination Filtration Surface area 20.6 in2 / 133 cm2
Operating Temperature Range -26˚ to 200˚F / -32˚ to 93˚C
Silica Gel: Adsorption Up to 40% of its weight of water
Chemical Resistance Resistant to alkalis, hydrocarbons, non-oxidizing
acids, salt water, and mineral or synthetic oils
Flow Rate vs Pressure Drop Unit Selection Guide (adapters sold separately)
GPM Max. H2 0
Height (A) Weight
Model Code Part No. Capacity
37 75 112 150 187 225 262 300 inches (mm) lbs (kg)
1.0 lbs (ltr)
BD 100 X 2 W 0.0 02074253 3.5 (90) 1.3 (0.6) 0.2 (0.1)
0.8
BD 200 X 2 W 0.0 02074254 5 (128) 1.9 (0.9) 0.4 (0.2)
∆P (PSI)
0.6 BD 400 X 2 W 0.0 02074465 8 (205) 3.3 (1.5) 0.9 (0.5)

0.4 BD 800 X 2 W 0.0 02075158 10 (254) 4.9 (2.2) 1.3 (0.6)
0.2
0
0 5 10 15 20 25 30 35 40
SCFM
Adapters Selection Guide (adapters sold separately - Note: no adapter needed for BD 800)
Bayonet Adapter Threaded Adapter Threaded Standpipe Adapter Flange Adapter
Part No. 02074251 Part No. 02074248 (3/4" NPT) Part No. 02077124 Part No. 02074250 (not drilled)
Part No. 02074249 (1" NPT) Part No. 02075193 (pre-drilled)
gasket not provided
1 1/2-16 UN-2B Mounting Hole Pattern

Existing Standpipe for Pre-drilled Adapter
or HYDAC: 00416311 (Flange Interface to DIN 24557/T2)
ADAPTER BL 160/180 S (PHOS) 2.874"
ø 73mm
Bayonet Flange Kit with 3.5" Steel Basket Bypass Adapter Part No. 01270816 ø 0.18"
4.5mm
Part No. 02079076 (6 places)
Press-Fit to
2.36"
Drymicron ø
60mm
1 Bayonet Fitting
2 gaskets Vent to
atmosphere
1 Filler Basket
Press-Fit to any
6 Screws Drymicron Adapter
for Installation

Breathers
HBRP Series
• Durable synthetic material
• 40 micron
• NPT threaded connection
ø
• Optional dipstick
X
Description:
This compact plastic design has a sponge element and threaded
connection with anti-splash baffle. Dipsticks are available to the D
customer’s requirements - see ordering information below. C
Construction: NPT Male Thread A

X
Cap
40 Micron Element
Wire Mesh Overall

Dipstick Length
To Full Mark
Labyrinth Baffle
Body To Add Mark

SECTION X-X
40 micron Breathers (Contact HYDAC for 10 micron)

Model Code Part No. Displace (GPM) Airflow (SCFM) A (NPT) ØB C D
1.36 1.31” 0.73”
HBRP-3/8NPT-40-1-1-A 02076916 55 7 3/8”
34.54mm 33.27mm 18.54mm
1.57” 1.56” 0.76”
HBRP-1/2NPT-40-1-1-A 02076917 75 10 1/2”
39.88mm 39.62mm 19.30mm
1.77” 1.60” 0.78”
HBRP-3/4NPT-40-1-1-A 02076109 115 15 3/4”
44.96mm 40.64mm 19.81mm
1.97” 1.93” 0.95”
HBRP-1NPT-40-1-1-A 02076918 150 20 1”
50.04mm 49.02mm 24.13mm
Ordering:
To order models without dipsticks, simply use the model code from the chart above. If a dipstick is required
(dipsticks are special order items and minimum quantities may apply), also include:
• Overall Length
• To Add Mark refer to dimension drawing above
• To Full Mark
Breathers
HBRM Series
• Chrome-plated carbon steel
• 10 or 40 micron
Description: Overall
These chrome plated breathers have a paper element and NPT Dipstick Length
threads. Dipsticks are available to the customer’s requirement. To Full Mark
See ordering information below.
To Add Mark
ØA
C B
HEX
SIZE
D
(NPT Male)
Model Micron Displacement Airflow Hex Dimensions

Code Part Number Rating (GPM) (SCFM) Size ØA B C D (NPT)
HBRM-1/4NPT-10-1-2 02080116 10 24 3 0.75” 1.85” 2.00” 0.20” 1/4”
HBRM-1/4NPT-40-1-2 02080117 40 40 5 0.75” 1.85” 2.00” 0.20” 1/4”
HBRM-3/8NPT-10-1-2 02080118 10 24 3 0.75” 1.85” 2.00” 0.20” 3/8”
HBRM-3/8NPT-40-1-2 02080119 40 40 5 0.75” 1.85” 2.00” 0.20” 3/8”
HBRM-1/2NPT-10-1-2 02080120 10 24 3 1.00” 1.75” 2.50” 0.32” 1/2”
HBRM-1/2NPT-40-1-2 02080121 40 40 5 1.00” 1.75” 2.50” 0.32” 1/2”
HBRM-3/4NPT-10-1-2 02077313 10 105 14 1.18” 3.15” 2.80” 0.5” 3/4”
HBRM-3/4NPT-40-1-2 02076096 40 190 25 1.18” 3.15” 2.80” 0.5” 3/4”
HBRM-1NPT-10-1-2 02080122 10 105 14 1.18” 3.15” 2.80” 0.5” 1”
HBRM-1NPT-40-1-2 02080123 40 190 25 1.18” 3.15” 2.80” 0.5” 1”
Ordering:
• Overall Length
• To Full Mark

TEMPERATURE/LEVEL ASSEMBLY
Electronics
Electronic Pressure Switch
ENS 3000
Operating Manual
2 ENS 3000 Manual
CONTENTS
1. ENS 3000 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Assembly and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. ENS 3000 Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Output Characteristics
5.1 Switching Ouputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.1 Switch Point Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2 Window Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Switch Point and Hysteresis Setpoint Adjustment and/or Window Function Setpoint Adjustment . . . . . . . . . . 8
5.4 Switch Point Setting Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Hysteresis Setting Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Menu Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Changing menu settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Menu settings overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. Resetting Peak Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. Setting Lock-outs
8.1 Changing the setpoint lockout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.2 Changing the main program lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11. Connection Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
12. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 ENS 3000 without Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
12.2 ENS 3000 with Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13. Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
14. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.1 Electrical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14.2 Mechanical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15. Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
16. Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENS 3000 Manual 3

1. ENS 3000 Functions
Depending on the unit ordered, the ENS 3000 offers the following functions:
• Display of the measured level in cm or inch (depending on version).
• Display of measured temperature in °C or °F.
• Display of the maximum value of the level or temperature or a switching setpoint.
• Change the switchpoint to level or temperature and adjust the setpoints independently.
• Analog output (either level or temperature).
• Menu for basic adjustment (Adapt the ENS 3000 to a particular application).
• Program lockouts.
2. Mounting
The electronic level sensor ENS 3000 is to be fastened as completely as possible to the metal tube of the connecting
piece with an assembly fitting. An assembly fitting can take and hold a metal tube with 22 mm in diameter. We recom-
mend a bulkhead union with an inserted sleeve fitting (see Accessories section). The active range is to rise up as freely as
possible into the container. For optimal function a part of the active range should be over the upper edge of the con-
tainer or over the overflow of the container.
mode
mode
mode
Device for
Metal Part Attachment
of ENS 3000 Device for
for Connection Attachment Structure
Active
Range
For safe and simple assembly use assembly accessories from HYDAC ELECTRONICS
Attention: The electronic level sensor ENS 3000 is not suitable for tanks with positive pressure. A brief pressure of up
to 3 bar is tolerated and is not harmful up to a time span of 1 minute
1 ENS 3000 Manual

For the safe operation of the ENS 3000 the following conditions should be fulfilled:
• For small plastic container installation the unit should be mounted in the center of the container
• If fastening the unit in dirty media, place it where there is strong motion (e.g. at the expiration of inlet)
• With the installation in metallic tubing (bypass) the sensor must be installed in the center of the pipe. The tubing inside
diameter must amount to at least 4.72 inches.
• Metallic articles within the container (e.g. metallic pipes, installations) must keep a minimum distance from 2.36 inches to
the active range of the sensor. Otherwise the assembly elements are recognized by the unit and the measured value
is falsified.
• With installation into metallic containers the distance between sensor and container wall must amount to at least
0.78 inches.
mode
min
0.78”
min
2.36”
Active
Range
Metallic
Tube
Additional assembling instructions, which reduce the influence of electromagnetic disturbances:

• Keep connections as short as possible
• Use wiring screen cable (e.g. LIYCY 4 x 0.5 mm2 / LIYCY = overall length)
• The cable screen is to be used depending on site conditions and for the purpose of interference suppression.
• Direct proximity to power lines or disturbing electrical or electronic devices is to be avoided if possible.
At the mechanical connecting piece is a grounding screw, which takes over the function of an electrical ground. The
earth ground must be attached, if no grounding connection is given (e.g.: with the plastic tank). It is recommended to use
as leads a cable with diameter of 1 mm2 and as short a conduit length as possible.
ENS 3000 Manual 2

3. ENS 3000 Control Elements
Display selection for

temperature sensor
4-digit
display
Display for
level sensor SP1 in SP2
mode LED display for active

switching point
Keys for adjusting switch points,

reset points, and auxillary functions
4. Digital Display
After switching on the supply voltage on the equipment the display shows ENS&niU briefly. Afterwards the value (level or
temperature) in the display appears indicated and begins with the display of the current value (basic adjustment).
2s 2s
A level below the measurable range of the electronic level sensor is recognizable by the following operational sequence
on the announcement:
2s 2s
In the basic adjustments the announcement can be changed as follows:

• Display of the maximum value of the level “n.TOP”
The highest level since the power-on of the equipment and/or the last resetting procedure, measured in the system, is
permanently indicated.
• Display of the minimum value of the level “n.MIN”
The lowest level since the power-on of the equipment and/or the last resetting procedure, measured in the system, is
• The temperature value “TEMP”
• Display of the maximum value of the temperature. “T.TOP”
The highest temperature since the power on of the equipment and/or the last resetting procedure, measured in the
system, is permanently indicated.
• Display of the minimum value of the temperature. “T.TOP”
The lowest temperature since the power on of the equipment and/or the last resetting procedure, measured in the
• Display of the switch point(s) “S.P. 1”, “S.P. 2”
Depending upon variant the switching point 1 and/or switching point 2 can be displayed.
• Display dark “oFF”
The display is switched off
3 ENS 3000 Manual

Depending on the display chosen “n.TOP”, “n.MIN”, “TEMP”, “T.TOP”, “T.MIN”, “S.P. 1”, “S.P. 2” or “oFF” is dis-
played. By using the keypad buttons or you can scroll through the display options. When the keys are not
touched for 5 seconds the display returns to the primary one chosen.
Hint:
• If the current level exceeds the nominal level range of the equipment, then it cannot not be indicated any more and
the announcement begins to flash.
• If the level of liquid falls below the lower measuring range, the display shows the value of the off set and the display
in such a way begins to flash
• During the display of the actual level; the possibility exists through pressing the key first the maximum value of
the level will be indicated. With each press of the key, the minimum value of the level, the current value, the
maximum value of the temperature, and the minimum value of the temperature are cycled through the display.
ENS 3000 Manual 4

5. Output Behavior
5.1 Switching Outputs
The ENS 3000 has 1 or 2 switching outputs. In the basic adjustments the following switching settings can be made:
5.1.1Switchpoint Function (SP)

To each switching output a switching point and a hysteresis can be set. The respective output switches if the adjusted
switching point was reached and switches back if the reset point is reached. The reset point is determined by adjusted
hysteresis (reset point = switching point minus hysteresis).
Abbreviations: “S.P.1”, “S.P.2” = Switchpoint 1 or 2

“HyS.1“, “HyS.2” = Hysteresis 1 or 2
5.1.2 Window Function (WIN)

The window function makes it possible to supervise a measured range. To each switching output, an upper and a lower
switching value can be entered, which determine the range.
The respective output switches, if the level or the temperature comes within this range. When leaving the range the
output shifts back. The lower value is just under the lower switching value (lower switching value minus 3x increment, see chap-
ter 5.4). The upper value lies just over the upper switching value (upper switching value plus 3x increment, see chapter 5.4). The
range between switching and reset value forms a security zone, which prevents unwanted oscillation of the shifting
process from taking place.
Example of switchpoint 1 (window function):
OUT
Hi. 1 plus 3xincrement Switch-back value
Hi. 1 Safety Zone Switching value
IN
IN
Lo. 1 Switching value
Safety Zone Switch-back value
Lo. 1 minus 3xincrement
OUT
t
IN
OUT
Abreviations: “HI 1”, “HI 2” = High level 1 or 2 = upper switching value 1 or 2

“Lo 1“, “Lo 2” = Low level 1 or 2 = lower switching value 1 or 2
Hint: The window function works (switching on and off) only if all switching values (including security zone) are over 0 cm or
0°C, and under the nominal measuring range.
5 ENS 3000 Manual

5.2 Analog output
Analog output signal: 4..20mA or 0..10V
(Adjustable in Menu “Basic Adjustments“)
Selection of the Analog Output: Level or Temperature

5.3 Adjusting switch points and hysteresis and/or switching values

for the window function
• Press the mode button.
• On the display, “S.P.1” or “Hi.1” appears
• Select the desired parameter by further pressing of the “mode” key (with switching point function, “S.P.1”, “hYS.1”, “S.P.2”,
“hYS.2” appears; with adjusted window function (WIN) “Hi.1”, “Lo.1”, “Hi.2” oder “Lo.2” appears).
• After 2 seconds the current selection flashes.
• Change the selection with and buttons.
• Press the mode key and choose the next setting to change and use and to modify the setting.
• After 3 seconds without key actuation the display resets and the changes are stored.
SP1 in SP2 2s SP1 in SP2 3s SP1 in SP2
mode mode mode

Display Actual
Switch Point 1
Keep pressing "mode" key Switching Point Change
until required parameter
is displayed = Decrease
= Increase
References:
• If “LOC” appears when attempting changes, the programming is locked. Programming should be changed to “free”
(see chapter 7 “programming releases”)
• When changing, if the key or is held, the value will continue to increase or decrease automatically.
• After changing the settings “PROG” appears in the display. The settings will then be stored in the unit.
ENS 3000 Manual 6

5.4 Ranges of adjustment for the switching outputs
Switching Point
Hystersis and/or
Measuring Range and/or Upper Increment
Lower Switching
in cm Switching Value in cm
Point in cm*
in cm*
26 0.4 to 26.0 0.1 to 25.7 0.1
36 0.5 to 36.0 0.2 to 35.6 0.1
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
Switching Point
Hystersis and/or
Lower Switching
in inches Switching Value in inches
Point in inches*
in inches*
10.25 0.15 to 10.25 0.05 to 10.15 0.05
14.15 0.20 to 14.15 0.05 to 14.00 0.05
5.5 Ranges of adjustment for the offset
Measuring Range Adjustment Range Increment

in cm for Offset in cm* in cm
25 0 to 104 0.1
36 0 to 144 0.1

in inches for Offset in inches* in inches
16.2 0 to 64.8 0.05
20.5 0 to 82.0 0.05
7 ENS 3000 Manual

6. Basic Adjustments
For adjustment to the respective application, the behavior of the ENS 3000 can be changed over several basic adjust-
ments. These are combined into a menu.
6.1 Changing the Basic Adjustments

Important note: When changing menu functions, no switching functions are occurring!
Activate the Basic Menu Adjustment:
SP1 SP2 3s SP1 SP2 SP1 SP2
mode mode mode

Display
(release mode key)
Hold "mode" key down

while switching on Press mode key until Change menu option with
supply voltage until the required menu point
appears.Then release key. or
the message "menu"
(for summary, see 6.2)
appears on the display
Terminate the Basic Menu Adjustment:

From the menu option “END”, select “YES” which will return the ENS 3000 to the normal display mode.
Hint: If no keys have been pressed for 25 seconds the menu is terminated automatically, without possible changes
becoming effective.
ENS 3000 Manual 8

6.2 Outline of the Adjustment Menu Points
Setting Default
Setting Point Display
Choices Setting
Association of Swith Output 1 (S.S.1)
Switch output 1 is teamed up
with the level measurement.
niv / TEMP niv

with the temperature measurment.
Switch Mode Function for Switch Output 1 (S.m.1)

Switch output 1 operates
in switch point\hysteresis mode
SP/ Win SP

in window mode.
Switching direction Switching output 1 (S 1)

Normally open function.
ON/ OFF ON
Normally closed function.
Switch-on delay switching output 1 (Ton 1)

Length of time in seconds that must expire 0..9999s 0
once the switch point has been reached
before the switch output will function.
Switch-off delay switching output 1 (Toff 1)

once the switch back point has been reached
The adjustment procedure for switch point 2 is the same as described above.
9 ENS 3000 Manual

Setting Default
Choices Setting
Primary display (primary)
Display function shown:
Actual pressure
niv/ niv
Level-Peak value n.Top/
n.Min/
Temp/
T.Top/
Level-Min value T.Min/
S.P.1/
S.P.2/
OFF
Actual Tempurature
Tempurature-Peak value
Tempurature-Min value
or Switchpoint 1 or 2
Display off
Dark display (see section 4 for detail)
Display
Display reacts slowly to pressure changes. SLOW/ FAST
FAST
Display reacts quickly to pressure changes.
Level Range Scale

Level indicated in inches.
inch/ cm
cm
Level indicated in centimeters.
Level Offset
A positive offset is able to be programmed 0
to account for baseline level adjustment.
ENS 3000 Manual 10

Setting Default
Choices Setting
Tempurature Range Scale
Tempurature indicated in °F
Fahr/ celc
celc
Tempurature indicated in °C
Analog signal output association (Select Output)

The signal output is assigned to the level.
niv/ niv
TEMP
The signal output is assigned to the tempurature.
Analog Signal Output

The analog output is set
to a 4-20 mA current sourcing. MAMP / VOLT
VOLT
The analog signal output is set

to a 0-10 Vdc output.
Software Version
Indicates the software version installed at time of manufacture.
Exit the adjustment menu

Select yes to exit the menu.
YES / NO NO
Select no to stay in the menu.
If menu adjustments were changed, then upon exiting “ProG” will be displayed. This notifies the user changes have
been made and stored.
11 ENS 3000 Manual

7. Reset the Peak Values
The equipment has the possibility of resetting the peak values of the level and the temperature (depending upon variant).
For resetting, proceed as follows.
SP1 inch SP2 6s 3s SP1 inch SP2 3s
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
ENS 3000 Manual 12

8. Programming Lockouts
The equipment had 2 programming releases the two given to be must around attitudes change. The operating pro-
gramming release can be set and/or waived during the enterprise. It offers protection from unintentional changes.
Closing programming over the main programming release causes that during the enterprise no change of the attitudes
can be made. This serves e.g. as safety function or as protection from bad changes.
8.1 Change for the operating programming release
SP1 inch SP2 6s 3s 2s SP1 inch SP2 3s
mode mode
Display
(arrow keys
released)
8.2 Change for the main programming release

Switch supply voltage off or separate equipment from supply voltage.
SP1 SP2 6s 2s SP1 inch SP2 3s
mode mode
Display
(arrow keys
released)
Hint: If a setting was changed, the display briefly changes to “ProG” after changing the setting. The new setting was
then stored in the equipment.
13 ENS 3000 Manual

9. Error Messages
If an error is recognized, an appropriate error message, will appear which must be acknowledged with depressing any
key. Possible error messages are:
E.01 The setpoint and hysteresis were adjusted in such a way that the resulting reset point is not within the per-
mitted range of adjustment.
Example: Setpoint of 10 in. and hysteresis of 15 in.
Action: Change setpoint or hysteresis.
E.10 A data error was recognized within the stored settings. Possible causes are strong electromagnetic distur-
bance or a defective component.
Action: Examine all settings (programming releases, switching points, reset points and basic adjustments) and cor-
rect these if necessary. If the error should arise more frequently, contact our service department.
E.20 A communication error was recognized within the equipment. Possible causes are strong electromagnetic
disturbance or a defective component.
Action: Acknowledge error by depressing any key. If the error should remain, please contact our service department.
ENS 3000 Manual 14

10. Start-up
Alignment of the level sensor on medium:
If the ENS 3000 is operated with any liquid for the first time, then the ENS 3000 automatically adjusts itself with the first
measurement automatically to the media. This characteristic offers the possibility for any medium to adjust themselves
and to compensate for changes within the medium.
Do not use with the following media:

• Strongly leading and adhering media (adhesive, shampoo, up-foaming media)
• Dry granulates with small density
• Media which are unhomogenously mixed and thus interfaces form (e.g.: water sump at the reason of a container filled with oil)
Example for the determination of the offset-value:

For the determination of the value for the tank offset we suggest the following procedure:
• First the ENS 3000 is built into the tank and/or bolted.
• Afterwards the display of the ENS 3000 flashes or indicates a value less than zero.
• The display flashes while gradually filling in a liquid to increase the level until the display indicates a zero value.
• Afterwards the ENS 3000 is taken again out of the tank and the level of the tank is measured with another measuring
device (such as a measuring stick).
• This value is entered in the menu option where units n.oFS is entered.
15 ENS 3000 Manual

11. Connection Diagrams
Wiring with 2 switching outputs

4-pole M12x1 connector
ENS 3X16-2
Imax 1.2 A
+ 1 4
SP 1
9 to 35 V
Imax 1.2 A
– 3 2
SP 2
Wiring with 1 switching output and 1 analog output

ENS 3X16-3
Imax 1.2 A
+ 1 4
SP 1
18 to 35 V
I = 4 to 40 mA
– 3 2
Analog
RL
Wiring with 2 switching outputs and 1 analog output

ENS 3X18-5 Imax 1.2 A
+ 1 4 SP 1
Imax 1.2 A
18 to 35 V 5
SP 2
– 3 I = 4 to 20 mA
2
Analog
RL
ENS 3000 Manual 16

12. Technical Data
12.1 ENS 3000 without Temperature Sensor
General
Level Length of Probe 16.14” or 20.47”
Active Range 10.24” or 14.17”
Inactive Range 5.91” or 6.30”
Max. Vessel Pressure only for application without pressure
Output Data
Level Repeatability ± 2% FS
Accuracy at Switch Point ± 2% FS (at hydraulic oil)
Analog Output 0 to 10 V or 4 to 20 mA selectable
temperature or level selectable
Switching Outputs 2
Type PNP transister output
selectable N.O. / N.C.
Assigning of Switch Output selectable temperature or level
Switching Current Max. 1.2 A
Switching Cycles > 100 millions
Max. Speed of Change of Levels 130 mm/s
Ambient Conditions
Nominal temperature range 32° to 176°F (0° to 80˚C)
Ambient temperature range 32° to 176°F (0° to 80°C)
Storage temperature range -40° to 176°F (-40° to 80°C)
Fluid temperature range 32° to 176°F (0° to 80°C)
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
Vibration resistance to
approx. 10 g / 0 to 500 Hz
IEC 68-2-6 at 10 to 500Hz
Safety type to DIN 40050 IP 67
Shock Resistance approx. 50 g / 1ms
Other Data
Supply voltage 20 to 32 V
Dielectric coefficient of medium >2
Residual ripple supply voltage ≤ 5%
Reverse polarity protection of
the supply voltage, and short standard
circuit protection
Parts in Contact with Media PP (polypropylene)
Display 4 digit, 7 segment LED, red,
7mm character height
17 ENS 3000 Manual

12.2 ENS 3000 with Temperature Sensor
General
Temperature Principle of Sensor semiconductor senor
Measuring Range 32° to 176°F (0° to 80˚C)
Output Data
Temperature Accuracy ± 2.7°F (± 1.5°C)
Switching Outputs 2
Ambient Conditions
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
IEC 68-2-6 at 10 to 500Hz
Other Data
circuit protection
ENS 3000 Manual 18

13. Model Code
ENS 3 X X X - X - XXXX - 400
Series
ENS 3 = 3000 series Level Sensor
Temperature Sensor
1 = with temperature sensor
2 = without temperature sensor
Mechanical Connection
1 = metric tube ø22mm for ZBM 19 & ZBM 20
Electrical Connection
6 = M12x1 plug, 4 pole (use ZBE 06 connector)
Output
2 = 2 switch outputs
3 = 1 switch + 1 analog output
Rod Length (physical)
0162 = 16.14”
0205 = 20.47”
other lengths on request
Modification
400 = US standard
19 ENS 3000 Manual

14. Accessories
14.1. Electrical Connectors
14.1.1 For output types “ 2 “ und “ 3 “
ZBE 06 (4-pol.) 1.38"
(35mm)
Quick coupling socket M12x1, right-angle
Part #: 06006788 ø 0.79"
(20mm)
1.10"
(28mm)
1.04"
ZBE 06-02 with 2m length (26.5mm)
Part #: 06006790
Colour code:
ZBE 06-05 with 5m length Pin 1: brown
Part #: 06006789 1.24"
(31.50mm)
Pin 2: white
Pin 3: blue
Pin 4: black
14.1.2 For all output variants

ZBE 08 (5-pol.) 1.38"
(35mm)
Part #: 06006786 ø 0.79"
(20mm)
1.10"
(28mm)
ZBE 08-02 (5-pol.) with 2m length

1.04"
Part #: 06006792 (26.5mm)

Part #: 06006791 Colour code:
1.26"
(32mm)
Pin 1: brown
ZBE 08S-02 (5-pol.) with 2m shielded length Pin 2: white
Part #: 06019455
Pin 3: blue
Pin 4: black
ZBE 08S-05 (5-pol.) with 5m shielded length
Pin 5: grey
Part #: 06019456

Part #: 06023102
ENS 3000 Manual 20

14.2. Mechanical Adapter
14.2.1 ZBM 19 – Straight Bulkhead Union nach ISO 8434
Fits min. 1 1/8” tank hole
1.40"
(36mm)
0.87"
(22mm)
1.50"
(38mm)
1.42"
(36mm)
3.15"
(80mm)
1.61"
(41mm)
0.74"
(19mm)
14.2.2 ZBM 20 – Straight screwing in connector piece with Lock nut

G3/4 BSPP tank hole
1.40"
(36mm)
0.87"
(22mm)
1.50"
(38mm)
1.25" 2.13"
(32mm) (54mm)
G 3/4 BSPP
21 ENS 3000 Manual

15. Dimensions
ø 1.65"
(42mm)
ø 2.15" M12x1
(54.5mm)
mode
3.68"
(93.5mm)
0162
19.82"
(503.5mm)
or
0205
24.15"
(613.5mm)
0.63" 1.13"
(16mm) (28.6mm)
Inactive Range
3.69"
(93.65mm)
0.87"
(22mm)
Active Range
10.24"
(260mm)
or
14.17”
0162 (360mm)
16.14"
(410mm)
or
0205
20.47"
(520mm) 15.02"
(381mm)
Inactive Range
1.09
(27.75mm)
ENS 3000 Manual 22

16. Application Examples
16.1 Hydraulic oil levels:
Minimum supply level monitoring with preliminary warning and alarm
With the example application a preliminary warning is to take place with 30 cm fill height and begin with the refill of the
tank. An alarm is to be sounded, if the fill height falls below 10 cm, and reset when exceeding the 15 cm level.
For the implementing the functions as described in the example, the 3000 settings and switchpoints must be made as
follows:
Menu Option Selection Numerical Value

Association of Switch Ouput 1 (S.S.1) niv
Switch Mode for Switch Output 1 SP
Switching Direction for SP 1 off
Switch-on Delay Ton 1 0
Switch-off Delay Toff 1 0
Association of Switch Output 2 (S.S.2) niv
Switching Direction for SP 2 on
Switch Point Setting Selection

Switch Ouput S.P.1 30.5
Hysteresis switching output Hi.1 0.5
Switch output S.P.2 15
23 ENS 3000 Manual

Tank. Likewise a minimum temperature is not to be fallen below. Becomes the temperature of e.g.: 20°C is spent
reached in such a way a stop signal. Furthermore the temperature is as the 4 to 20 mA signal of a SPS map to be
made available.
follows:


ENS 3000 Manual 24

25 ENS 3000 Manual
QUICK COUPLING
Hydraulic
Quick
Couplings
Quick Coupling Division

8145 Lewis Road • Minneapolis, MN 55427
B-1 www.parker.com/quickcouplings
General Purpose Couplings
Hydraulic Quick Couplings 60 Series
Special Order Information

60 Series couplings are available in zinc plated steel, brass,
303 stainless steel, and 316 stainless steel. Brass couplings
have double O-Ring seals and stainless locking balls.
Standard seal materials are Buna-N (Nitrile); optional seal
materials are available.
For 316 stainless steel products, standard seal material is
Viton™, and other seal materials are available upon request.
See Fluid Compatibility Chart at end of this catalog.
All sizes of 60 Series can be furnished with locking sleeves.
Place suffix letters “-SL” (Sleeve-Lok) after regular catalog
numbers. Example H3-62-SL. Parker 60 Series heavy duty
nipples are recommended where high cycle rates and
pressure surges are encountered. Machined from high tensile
steel and induction hardened, they are zinc plated with a
Applications yellow chromate finish. To specify a heavy duty nipple, add
Parker general purpose couplings, are used across the the prefix “HD” to the steel part number; thus: HDH2-63.
spectrum of hydraulic applications. These Double Shut-Off
couplings can be found anywhere that fluid transfer lines
need to be connected and disconnected for operation or
maintenance of equipment, and a loss of fluid is undesirable. Note
Primarily used with hydraulic fluid, general purpose Double
Shut-Off couplings are also used with chemicals, water, Protective dust plugs and caps play a crucial role in the life of
steam, and some gases. a quick coupling and no purchase of a hydraulic quick
coupling is complete without the selection of an appropriate
dust plug and cap. See pages noted in Table of Contents for
dust plugs and caps for the Parker full line of hydraulic
couplings.
Specifications
ANSI/ISO Pressure Rating: Dynamic applications with normal to moderate hydraulic Low Cycle, Non-pulsating Pressure Rating: Applications with lower cycle
shocks such as general industrial equipment, hydraulic presses, agricultural equip- life and no severe cyclic pressure fluctuations, essentially steady pressure during
ment, etc. Impulse tested at a multiple (125% to 133%) of rated pressure. an operating cycle. Typical applications include hydraulic jacks, mine roof
support systems, and high pressure fluid transfer (pumping water or slurry in
oil wells). Minor pump ripple is considered non-pulsating. Impulse tested at rated
pressure.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Pressure (PSI) Rated Pressure (PSI)
Brass 1000 1000 1000 1000 1000 1000 800 800 3000 3700 2700 3500 2200 1500 1500 1200
Stainless steel 2000 2000 1500 1500 1500 1000 1000 1000 5000 5000 5000 5000 3000 3000 1500 1500
Steel 5000 5000 4000 4000 2500 2000 1000 1000 5000 5000 4000 4000 2500 2000 1500 1500
Steel w / HD N/A 5000 4000 4000 3000 3000 N/A N/A 5000 5000 4000 4000 3000 3000 N/A N/A
nipple
Temperature Range: Standard seals (Buna-N) -40° to +250° F Optional Viton seals -10° to +400° F
Vacuum Data: 27.4 inches Hg. both connected and disconnected (1-1/2" and 2-1/2" body size 60 Series couplings are not reccommended for service in diconnected mode)
Note: Read the Safety Guide for Selecting and Using Quick Action Couplings and Related Accessories before making a coupling selection. It may be found in
Parker Hannifin Quick Coupling Divison catalogs and is available as Parker Publication No. 3800-B1.0.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Flow (GPM) .8 3 6 12 28 50 100 200

4. Hardened nipples and sleeves (steel) and solid barstock

4 construction make for a quality coupling with maximum re-
6 sistance to damage from hydraulic and mechanical shock.
5. The seal is designed to withstand high pressures and pro-
vide reliable sealing. A wide selection of optional seal ma-
terials are available, see Fluid Compatibility Chart at end
2 of this catalog for selection assistance. Steel versions fea-
9
1 ture Teflon™ back-up rings that support mating seals for
high pressure applications. Brass couplers have a double
O-ring seal for redundancy in low pressure, vacuum and
steam applications.
3 5 1 6. Durable ball-locking mechanism assures reliable connec-
tion, every time. A large number of locking balls distributes
7 2 the work load evenly while providing alignment and swivel-
ing action to reduce hose torque and prolong hose life.
7. Manufactured from brass, steel and stainless steel as
Features
standard materials. A wide range of seals allow these
1. Large flow areas machined into the body of the coupler couplings to be used with a broad range of media.
and nipple facilitate flow around the valve, for a high flow 8. Industry-wide interchangeability. Parker 60 Series couplers
capacity. and nipples are the “Industrial Interchange” design and
2. Positive valve stop. The perch maintains valve alignment meet the dimensional requirements of Series B in ISO
and provides metal to metal valve stop to ensure that the 7241-1.
valves open fully, every time. 9. Also available with a Straight Thread (ORB) end configura-
3. Captive valve seal assures “bubble tight” poppet sealing. tion available as standard, for reduced leakage.
The valve seal is positively captured by the metal poppet to
minimize seal washout or damage from high velocity fluid.
Performance
60 Series (1/8;1/4") 60 Series (3/8;1") 60 Series (11/2;21/2")
Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS
30 30 200 200
40 40
30 30
2-1/2"
20 20 100 100
80 80
20 20
1/8" 60 60
1/4" 50 50
1/2" 1" 40 40
10 10
Pressure Drop in PSID

3/8" 3/4"
9 9 30 30
8 8 10 10
9 9 1-1/2"
7 7 8 8 20 20
6 6 7 7
5 5 6 6
5 5 10 10
4 4 8 8
4 4
3 6 6
3
5 5
3 3
4 4
2 2 3 3
2 2
2 2
1 1 1 1 1
1
.2 .3 .4 .5 .6 .7 .8 .9 1 2 3 4 1 2 3 4 5 6 7 8 910 20 40 60 80 10 20 30 40 50 60 80 100 200 300
Flow in USGPM Flow in USGPM Flow in USGPM

Couplers A
Female Thread
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Flats Diameter
A B C
1/8 BH1-60 0.16 H1-62 0.16 SH1-62 0.16 SSH1-62Y** 0.15 1/8-27 – 1.90 0.68 0.96
1/8 – – H1-62-T4 0.18 SH1-62-T*4 0.10 SSH1-62Y-T4 0.17 – 7/16-20 2.06 0.68 0.96
1/4 BH2-60 0.32 H2-62 0.30 SH2-62 0.30 SSH2-62Y 0.30 1/4-18 – 2.26 0.81 1.14
1/4 – – H2-62-T6 0.31 SH2-62-T6 0.31 SSH2-62Y-T6 0.31 – 9/16-18 2.41 0.81 1.14
3/8 BH3-60 0.43 H3-62 0.40 SH3-62 0.40 SSH3-62Y 0.40 3/8-18 – 2.49 0.88 1.40
3/8 – – H3-62-T8 0.51 SH3-62-T8 0.51 SSH3-62Y-T8 0.51 – 3/4-16 2.75 1.00 1.40
1/2 BH4-60 0.80 H4-62 0.73 SH4-62 0.75 SSH4-62Y 0.76 1/2-14 – 2.87 1.12 1.77
1/2 – – H4-62-T10 0.78 SH4-62-T10 0.75 SSH4-62Y-T10 0.78 – 7/8-14 3.05 1.12 1.77
3/4 BH6-60 – H6-62 1.30 SH6-62 1.31 SSH6-62Y 1.33 3/4-14 – 3.56 1.31 2.14
3/4 – – H6-62-T12 1.39 SH6-62-T12 1.34 SSH6-62Y-T12 1.40 – 1-1/16-12 3.56 1.31 2.14
1 BH8-60 – H8-62 1.95 SH8-62 1.95 SSH8-62Y 1.95 1-11 1/2 – 4.18 1.62 2.52
1 – – H8-62-T16 1.95 SH8-62-T16 1.95 SSH8-62Y-T16 1.95 – 1-5/16-12 4.18 1.62 2.52
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Contact factory for seal options)
Contact division for BSPP port availability
Nipples D
Female Thread
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Exposed Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Length Flats Diameter
D E F G
1/8 BH1-61 0.04 H1-63 0.03 SH1-63 0.03 SSH1-63Y** 0.04 1/8-27 – 1.61 0.41 0.56 0.65
1/8 – 0.06 H1-63-T4 0.05 SH1-63-T*4 – SSH1-63Y-T4 0.06 – 7/16-20 1.32 0.57 0.69 0.79
1/4 BH2-61 0.09 H2-63 0.08 SH2-63 0.08 SSH2-63Y 0.08 1/4-18 – 1.39 0.65 0.75 0.87
1/4 – 0.11 H2-63-T6 0.10 SH2-63-T6 0.10 SSH2-63Y-T6 0.10 – 9/16-18 1.54 0.70 0.88 1.01
3/8 BH3-61 0.10 H3-63 0.12 SH3-63 0.12 SSH3-63Y 0.12 3/8-18 – 1.50 0.54 0.88 1.01
3/8 – 0.12 H3-63-T8 0.16 SH3-63-T8 0.16 SSH3-63Y-T8 0.14 – 3/4-16 1.76 0.80 1.00 1.15
1/2 BH4-61 0.25 H4-63 0.24 SH4-63 0.24 SSH4-63Y 0.24 1/2-14 – 1.75 0.69 1.12 1.30
1/2 – 0.28 H4-63-T10 0.27 SH4-63-T10 0.27 SSH4-63Y-T10 0.27 – 7/8-14 1.94 0.87 1.19 1.37
3/4 BH6-61 0.50 H6-63 0.46 SH6-63 0.45 SSH6-63Y 0.46 3/4-14 – 2.16 0.79 1.38 1.59
3/4 – 0.55 H6-63-T12 0.46 SH6-63-T12 0.50 SSH6-63Y-T12 0.50 – 1-1/16-12 2.27 0.90 1.34 1.59
1 BH8-61 0.76 H8-63 0.76 SH8-63 0.76 SSH8-63Y 0.76 1-11 1/2 – 2.91 0.99 1.62 1.88
1 – 0.80 H8-63-T16 0.80 SH8-63-T16 0.80 SSH8-63Y-T16 0.80 – 1-5/16-12 2.91 0.99 1.62 1.88*
Optional Seals Optional Seals Suffix*
60 Series W Ethylene Propylene (EPR)

Y Standard Viton™ Seals
Z Neoprene
-264 Perfluoroelastomer (Kalrez)™
* See Ordering Information at end of Section B.

A
Couplers
Female Thread
C
A B C
1 1/2 BH12-60L 4.58 H12-62L 4.70 SH12-62L 4.68 SSH12-62LY** 4.68 1 1/4-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 BH12-60N 4.58 H12-62N 4.70 SH12-62N 4.68 SSH12-62NY 4.68 1 1/2-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T20 4.72 SH12-62-T20 4.71 SSH12-62Y-T20 4.71 – 1 5/8-12 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T24 4.72 SH12-62-T24 4.71 SSH12-62Y-T24 4.71 – 1 7/8-12 4.86 2.38‡ 3.00
2 1/2 BH2016-60 11.06 H2016-62 10.58 SH2016-62 – SSH2016-62Y – 2-11 1/2 – 5.57 3.75 4.10
2 1/2 BH2020-60 11.42 H2020-62 10.91 SH2020-62 – SSH2020-62Y – 2 1/2-8 – 6.04 3.75 4.10
2 1/2 BH2024-60 – H2024-62 – SH2024-62 – SSH2024-62Y – 3-8 – 6.96 4.00 4.35
** Suffix 'Y' designates Viton Seal. (Consult factory for seal options)
‡Wrench Flat on 303 Stainless is 2.50 in.
D
Nipples E
Female Thread
G
D E F G
1 1/2 BH12-61L 2.96 H12-63L 3.10 SH12-63L 3.06 SSH12-63LY** – 1 1/4-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 BH12-61N 2.96 H12-63N 3.10 SH12-63N 3.06 SSH12-63NY – 1 1/2-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T20 3.15 SH12-63-T20 3.14 SSH12-63Y-T20 – – 1 5/8-12 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T24 3.15 SH12-63-T24 3.14 SSH12-63Y-T24 – – 1 7/8-12 4.76 2.69 2.38‡ 2.75†
2 1/2 BH2016-61 7.78 H2016-63 7.90 SH2016-63 7.92 SSH2016-63Y – 2-11 1/2 – 5.48 2.90 3.75 4.10
2 1/2 BH2020-61 8.12 H2020-63 8.16 SH2020-63 8.16 SSH2020-63Y – 2 1/2-8 – 5.95 3.37 3.75 4.10
2 1/2 BH2024-61 – H2024-63 – SH2024-63 – SSH2024-63Y – 3-8 – 6.87 4.29 4.00 4.35
† Largest diameter on Brass is 2.96" across Hex Corners
‡Hex on 303 Stainless is 2.50 in.
Replacement Parts Repair Kits

60 Series Couplers Couplers Nipples
Body Repair Kit Used For Repair Kit Used For
Body Size (in.) O-Rings - Buna N Back-Up Rings Size (in.) Part No. Part No. Part No. Part No.
3/8 H67E-62K H3-62 H67E-63K H3-63
1/8 2-013N0674-70 H67A-28 BH67E-60K BH3-60 BH67E-61K BH3-61
1/4 2-015N0674-70 H67C-28 SH67E-62 SH3-62 SH67E-63K SH3-63
3/8 2-116N0674-70 4118007 SSH67-62K SSH3-62Y SSH67E-63K SSH3-63Y
1/2 2-213N0674-70 4128002 1/2 H67F-62K H4-62 H67F-63K H4-63
3/4 2-218N0674-70 4148001 BH67F-60K BH4-60 BH67F-61K BH4-61
1 2-222N0674-70 4158001 SH67F-62 SH4-62 SH67F-63K SH4-63
1-1/2 2-124N0674-70 2-138N0552-90 SSH67F-62K SSH4-62Y SSH67F-63K SSH4-63Y
(Valve) (Fitting) 3/4 H67G-62K H6-62 H67G-63K H6-63
2-224N0674-70 BH67G-60K BH6-60 BH67G-61K BH6-61
(Body 2 req.)
SH67G-62 SH6-62 SH67G-63K SH6-63
2-1/2 2-133N0674-70 2-234N0674-70 SSH67G-62K SSH6-62Y SSH67G-63K SSH6-63Y
(Valve) (Fitting)
1 H67J-62K H8-62 H67J-63K H8-63
2-333N0674-70
(Body)
BH67J-60K BH8-60 BH67J-61K BH8-61
SH67J-62 SH8-62 SH67J-63K SH8-63
SSH67J-62K SSH8-62Y SSH67J-63K SSH8-63Y

Hydraulic Quick Couplings 60 Series Steam Couplings
Specifications
Body Size (in.) 1/4 to 1
Rated Pressure (PSI)
with saturated steam at 338°F 100
Temperature Range (std seals) Ethylene Propylene
Continuous +250°F
Intermittent +400°F
Coupler
Female Pipe Thread
Body Part Thread Dimension (in.)
Size No. Size Overall Wrench Largest Wt. (LB.)
(in.) Brass NPTF Length Flats Diameter P/Piece
A B C G
1/4 BH2-60-STM 1/4-18 2.26 0.81 1.14 0.30
3/8 H3-68 3/8-18 2.50 0.88 1.77 0.50
1/2 BH4-60-STM 1/2-14 2.87 1.12 1.77 0.75
A
3/4 BH6-60-STM 3/4-14 3.56 1.31 2.14 1.31
1 BH8-60-STM 1-11 1/2 4.18 1.62 2.52 1.95
C
Nipple
Female Pipe Thread

Size No. Size Overall Exposed Hex Largest Wt. (LB.)
(in.) Brass NPTF Length Length Size Diameter P/Piece
D E F G
1/4 BH2-61-STM 1/4-18 1.39 0.65 0.75 0.87 0.08
3/8 H3-69 3/8-18 1.50 0.52 0.88 1.01 0.13
D
E 1/2 BH4-61-STM 1/2-14 1.75 0.69 1.12 1.30 0.24

3/4 BH6-61-STM 3/4-14 2.16 0.79 1.38 1.59 0.46
1 BH8-61-STM 1-11 1/2 2.91 0.99 1.62 1.88 0.76
G
Repair Kits
Body Repair Kit Used For
Steam Coupling Size Part No. Part No.
3/8 H68E-67K H3-68
3/8 H69E-67K H3-69

Dust Plugs and Dust Caps
Hydraulic Quick Couplings
Applications
Parker offers a complete line of dust plugs and caps for their Protective dust plugs and caps play a crucial role in the use of
hydraulic quick couplings. Each series shown in this catalog quick couplings and no purchase of a hydraulic quick coupling
has a dust plug and cap specifically designed to be used with is complete without the selection of an appropriate dust plug
that style of coupling. and cap. When ordering the dust cap/plug body size must
correspond to that of the coupler or nipple.
Dust plugs and caps serve a twofold function. They keep the
mating surface clean and free of contamination and protect Parker’s full line of dust plugs and caps can be found below
the critical mating elements of the coupling halves when they and on the following pages.
are disconnected. In this way the nipple is protected from
damage that would make the total coupling unusable. Dust Plug: Used on Coupler (female half)
Dust Cap: Used on Nipple (male half)
Dust Plugs
Body Dust Plug Dust Plug Dust Cap Dust Cap
60 Series Size Part No. Part No. Part No. Part No.
(in.) Aluminum Geolast Aluminum Geolast
1/8 H1-65 H1-65M H1-66 H1-66M
1/4 H2-65 H2-65M H2-66 H2-66M
3/8 H3-65 H3-65M H3-66 H3-66M
1/2 H4-65 H4-65M H4-66 H4-66M
3/4 H6-65 H6-65M H6-66 H6-66M
1 H8-65 H8-65M H8-66 H8-66M
1 1/2 H12-65 NA H12-66 NA
2 1/2 H20P-65 NA H20P-66 NA
NA = Not Available
6600 Series Body Dust Plug Dust Cap

Size Part No. Part No.
(in.) Rubber Rubber
1/4 H1-65M H166M
3/8 TR-37 TR-37
1/2 5205-4M 5209-4M
3/4 6659-12M 6657-12M
1 6659-16M 6657-16M
SM Series Body Size Dust Plug Dust Cap

(in.) Part No. Part No. Material
1/4 PL-25 N/A Plastic
1/4 PR-25 CR-25 Rubber
1/4 P-25 C-25 Aluminum
1/2 DP-50 DC-50 Rubber

HEAT EXCHANGER [AIR-OIL]
PRESSURE SWITCH
Pressure Switches
EDS 3000
About EDS 3000 Pressure Switches:
The EDS 3000 electronic pressure switch is the result of joint development and
innovation in the field of adjustable pressure switches with display. It is a compact
unit which combines a pressure switch, digital display, and transducer for controlling
pressure in hydraulic and pneumatic applications. The most noticeable innovation
350˚ is the alignment of the serial four-digit display. After mounting, the switch may be
turned as a whole. Additionally, the front panel with push buttons may be turned.
270˚ This eliminates the need for mechanical adapters. Display units can be shown in
bar, psi, or mpa. It is also possible to scale the pressure range to any desired
engineering unit, such as force or tonage. Pressure ranges from vacuum to 9000
psi are available. Switching outputs in one or two switch versions with or without
analog output are available when choosing model code.
Technical Details:
Input Data
Applications:
Measuring ranges (type 1) 0 to 15, 50 psi
(type 3) 0 to 15, 30, 50, 150, 250, 500 psi
-14 to 75 psi
(type 4) 0 to 1000, 3000, 6000, 9000 psi
Overload pressure 200%FS max. 900 bar (13000 psi)
Burst pressure 300%FS max. 2000 bar (29000 psi)
G 1/4 A male, 1/4”-18 NPT male
Mechanical Connection SAE 6 9/16-18 UNF2A male
Tightening torque approx. 15 lb-ft (20 Nm)
Parts in contact (types 1 & 3) Stainless steel, ceramic, FPM seal
with media (type 4) Stainless steel, FPM seal
Output Data
Accuracy (B.F.S.L) ≤ ±0.5 %FS
including linearity & hysteresis
Temp. comp. zero point ≤ ±0.017%FS/°F max.
Temp. comp. over range ≤ ±0.017%FS/°F max.
4 to 20 mA, ohmic resistance ≤ 500Ω
Analog output signal, adjustable 0 to 10 V, ohmic resistance ≥ 1k Ω
Switching Outputs
Type PNP transistor output
Repeatability ≤ ±0.5%FS max.
Switching current max. 1.2 A
Switching cycles ≥ 100 million
Reaction time < 10 ms
Ambient Conditions
Nominal temperature range -13° to 185°F (-25° to 85°C)
Ambient Temperature range -13° to 176°F (-25° to 80°C)
Fluid temperature range -13° to 176°F (-25° to 80°C)
EN 61000-6-1, EN 61000-6-2
mark EN 61000-6-3, EN 61000-6-4
Vibration resistance ≤ 10g / 0 to 500Hz (IEC 60068-2-6)
Shock resistance ≤ 50g / 11ms (IEC 60068-2-29)
Safety type to DIN 40050 IP 67 (molded M12x1 connector is used)
Approvals:
Other data
Supply voltage 9 to 35 VDC for signal 1,2
18 to 35 VDC for signal 3, 5
Electrical connection M12x1 (4 pin or 5 pin)
Current consumption approx. 100 mA (without switching output)
Reverse polarity protection of the
supply voltage, excess voltage, standard
override and short circuit protection
Display 4 digit, 7 segment LED red
Weight approx. 300 g
25 Electronics Catalog
Model Code:
EDS 3 X X X - X - XXXX - 400 X 1
Series
EDS 3 = 3000 Series Electronic Sensor
Sensor Type
1 = Ceramic absolute
3 = Ceramic relative
4 = Thin-film relative
4 = G 1/4 BSPP male thread*
8 = 1/4” - 18 NPT male thread
7 = SAE-6 male thread (9/16-18 UNF2A)
6 = M12x1 plug, 4 pole for output codes 1, 2, and 3 (connector not included)
8 = M12x1 plug, 5 pole for output code 5 (connector not included)
Output
1 = 1 Switch output (only with electrical connection 6)
2 = 2 Switch outputs (only with electrical connection 6)
3 = 1 Switch with analog output (only with electrical connection 6)
Pressure Ranges
Type 1 (ceramic - absolute) Type 3 (ceramic - relative) Type 4 (thin-film, relative)
0015 = 0 to 15 psi 0015 = 0 to 15 psi 0250 = 0 to 250 psi 1000 = 0 to 1000 psi
0050 = 0 to 50 psi 0089 = -14 to 75 psi 6000 = 0 to 6000 psi
0150 = 0 to 150 psi 9000 = 0 to 9000 psi
Modification Number
400 = standard in psi
Sealing Material (in contact with media)
F = FPM seal (to be used for example with hydraulic fluid)
E = EPDM seal (to be used for example with refrigerant coolant or fluids containing ammonia)
Material for Mechanical Connection / Housing (in contact with media)
1 = Stainless Steel
* G 1/4 port sizes are available upon request
Plug Connection:
EDS 3XX6 EDS 3XX8 use with ZBE 06 (4-pole) & ZBE 08 (5-pole)
(4-pole) (5-pole) (see page 60)
4 3 4 3
1 2 1 5 2
Circuit Connection:
Model with 1 switch output Model with 1 switch output
Plug 4-pol. M12x1 and signal output Dimensions: ø 1.65"
M12x1
(42mm)
Plug 4-pol. M12x1
ø 2.15" (54.5mm)
EDS 3X46-1 EDS 3X46-3
Imax 1.2 A
+ 1 + 1 4
Imax 1.2 A SP 1
9 to 35 V 4 18 to 35 V
SP 1 I = 4 to 20 mA
– 3 – 3 2
Analog
RL
3.68"
(93.5mm)
mode
2.95"
(75mm)
Model with 2 switch outputs Model with 2 switch outputs
Plug 4-pol. M12x1 and signal output
Plug 5-pol. M12x1
EDS 3X46-2 EDS 3X48-5 Imax 1.2 A
Imax 1.2 A
+ 1 4 + 1 4
SP 1 SP 1
9 to 35 V Imax 1.2 A
Imax 1.2 A 18 to 35 V 5 0.47"
2 SP 2 (12mm)
– 3 – I = 4 to 20 mA
3 2
SP 2
Analog ø 1.16"
RL SAE 6 (29.5mm)
0.63"
6kt-SW27 (16mm)
1-877-GO HYDAC Electronics Catalog 24

OIL IMMERSION HEATER
Chromalox
®
SERVICE REFERENCE
DIVISION 4 SECTION ARTM
SALES
REFERENCE (Supersedes PD419-8) PD419-9
161-058027-001
DATE SEPTEMBER, 2002
Screwplug Immersion Heaters

(ARTM, ARTMO, ARTMS and ARTMI)
11/8” 7/ ” Dia. Hole For 1/ ” BX Connector
8 2 11/4” Pipe Outlet
(One Outlet Plugged)
1” Std. Well for 11/8” Ref.
Pipe Threads Thermostat
Bulb
35/16” 61/4”
Dia.
B ± 1/4”
53/16”± 1/16”
1” Approx. Cold End
1” Approx. Cold End 11/8”
51/16” 11/2”
Removable 3” B ± 1/4”
Cover 11/2” Type E2 Terminal Enclosure
Type E1 Terminal Enclosure Moisture Resistant/Explosion Proof
General Purpose (Rotatable) (E4 Moisture Resistant is available)
GENERAL
Chromalox types ARTM (copper sheath), ARTMO (steel sheath), (ARTMO) and stainless steel (ARTMS) and (ARTMI).
ARTMS (stainless steel sheath) and ARTMI (INCOLOY® sheath) C. Medium to high watt densities.
screwplug immersion heaters are designed for a wide variety of heat- D. Built-in thermostat standard with ranges of 0-127˚F, 60-180˚F
ing applications. and 60-240˚F.
E. Broad selection of sheath materials to operate successfully in
many corrosive solutions. Note: Proper selection of the sheath
material is the sole responsibility of the customer.
IMPORTANT: It is the responsibility of the purchaser F. E1 (General Purpose), E2 (Moisture Resistant/Explosion
of the heater to make the ultimate choice of sheath Proof) and E4 (Moisture Resistant, not shown) terminal hous-
material based upon his knowledge of the chemical ings are standard.
composition of the corrosive solution, character of the
materials entering the solution, and controls which he
maintains on the process.
Heater Construction Characteristics: The system designer is responsible for the safety of
A. High quality resistance wire held in place by compacted this equipment and should install adequate back-up
Magnesium Oxide refractory enclosed in a wide variety of controls and safety devices with their electric heating
sheath materials. equipment. Where the consequences of failure could
B. 1” NPT Screwplug is standard in brass (ARTM), steel result in personal injury or property damage, back-up
controls are essential.
INSTALLATION
This Portion of the Heater Above Liquid Level and
Expected Low Liquid Exposed to Air Will Lead to Premature Burnout of Element
ELECTRIC SHOCK HAZARD. Disconnect all power Level
before installing or servicing heater. Failure to do so
could result in personal injury or property damage.
Heater must be installed by a qualified person in accor- WRONG
dance with the National Electrical Code, NFPA 70.
RIGHT
1. Before installing, check your type ARTM immersion heater
for any damage that may have occurred during shipment. Expected Maximum
Sediment Level
2. Check to insure that the line voltage is the same as that stamped
on the nameplate. Note: Locate Heater as low as possible for maximum heated liquid storage
3. Do not bend the heating elements. If bending is necessary, capacity. Heat does not move downward.
check factory. Figure 1 - Open Tank Installation
4. IMPORTANT: Mount heater in the tank so the liquid level will
always be above the effective heated portion of the heater (see
Figure 1).
© 2002 Chromalox®, Inc
INSTALLATION
If the heater is not properly submerged, the heating elements will Drip loop recommended
overheat and create heater damage or a possible fire hazard due to to minimize passage of moisture
along wiring into terminal
Outlet
excessive sheath temperatures. wiring and connections
5. Where work will pass over or near equipment, additional protec-

tion, such as a metal guard, may be needed. Suitable
Wiring
1-1/2” 1” Approx. Cold End
Inlet
Maximum Sediment Level.

Install Heater Above
Locate Drain Pipe at Bottom of Heater. This Level But As
Sediment Deposits may be Near to it as Possible for Maximum
Removed Through Drain Pipe Heated Water Storage Capacity
Figure 4 - Closed Tank in Vertical Position
Provisions should be made to prevent damage from

Heavy Tank Walls may be drilled and tapped - if thickness is sufficient to engage any eventual leaking of tank or components.
3/4 of threads. Failure to comply could result in personal injury or
Lighter Tank Walls must be equipped with suitable pipe coupling attached with property damage.
proper solder or weld material.
9. Adjustment Instructions for Rotating Housing (E1) Only —
WARNING: Care must be taken to insure the heated portion does not extend into
the coupling area (see Dimensions). SCREWPLUG #10-32 COVER SCREWS #8-32 BASE MOUNTING
(FOR REFERENCE) 3 REQ’D (180˚ APART) (ITEM “B”) SCREWS (3 REQ’D) (ITEM “C”)
Figure 2 - Exploded View Screwplug Mounting
ROTATING BASE WITH
CONDUIT OPENING
6. Heater must not be operated in sludge.
7. Install the heater using a high quality pipe sealing compound on the
threads. Screw the heater into the opening (Figure 2). Tighten suf-
ficiently with wrench applied on the hex portion of the screwplug.
8. Closed Tank Installation ADAPTER PLATE
(ITEM “B”) NEMA 1 COVER

Figure 5 (ITEM “A”)
WARNING: When heating in closed vessels, controls A. After tightening the heater into the tank opening. The terminal
and back-up controls must be used to regulate housing can be rotated to a more convenient position to install
buildup of temperature and/or pressure. the power feed.
A. Horizontal Position (Figure 3) B. Remove the terminal box cover (Item A) by loosening the three
A1.Place heater at an elevation so that natural circulation can cover screws (Item B) (do not completely remove the screws
take place. since the cover holes are open slotted).
Note: In A Forced Circulation System,
C. To rotate the terminal housing base, loosen the three mounting
Figure 3 - Closed Tank in Horizontal Position
Use Pump On Inlet Side. screws (Item C) until the base rotates freely (do not complete-
ly remove).
D. Turn the base until the conduit opening is on the desired position.
Outlet Inlet E. Tighten the base mounting screws securely (Item C).
CAUTION: Do not over tighten.
Heater
F. Follow the rest of the screwplug installation instructions to
complete installation.
A2.Position outlet and inlet in a vertical plane, facing upward to

prevent air pockets. Be sure all trapped air is removed from the FREEZE HAZARD. This unit may be equipped with
closed tank. Bleed the air out of the liquid piping system and a thermowell for process control or over-tempera-
heater housing prior to operation. ture control. Do not allow moisture to accumulate
A3.IMPORTANT: Heater should never be located at the highest in thermowell. Freezing temperatures can cause
point of the liquid system. Provide expansion tank, if necessary. damage that may result in the heated medium
leaking into terminal enclosure.
10. To prevent moisture accumulation in cryogenic applications or
when heater is exposed to freezing temperatures:
FIRE HAZARD. If heater is not properly submerged, A. Slope conduit away from housing (drip loop).
the heating elements will overheat and could result in B. Seal all conduit openings to moisture/explosion resistant ter-
a fire or damaged equipment. minal enclosure.
B.Vertical Position (See Figure 4) C. Insulate terminal enclosure.
D. Fill thermowell(s) with silicone fluid when heater is mounted
with terminal enclosure up.
FIRE HAZARD. Since heaters are capable of devel-

oping high temperatures, extreme care should be
taken to: FIRE OR SHOCK HAZARD. Moisture accumulation in
A. Use explosion-proof terminal housing in hazardous locations. the element refractory material, element or overtem-
See Chromalox catalog for selection of explosion-proof termi- perature, or sheath, generating arcing and molten
nal housing for hazardous locations. metal. Install Ground Fault Circuit-Interrupter (GFCI)
B. Avoid contact between heaters and combustible material. to prevent personal injury or Equipment Ground Fault
C. Keep combustible materials far enough away to be free of the Protection to prevent property damage.
effects of high temperatures.
WIRING
4. If flexible cord is employed, a watertight connector should be used
for entry of the cord into the terminal housing. Outdoor applica-
ELECTRIC SHOCK HAZARD. Any installation involv- tions require liquid-tight conduit and connectors.
ing electric heaters must be performed by a quali- 5. Bring the power line wires through the opening in the terminal-
fied person and must be effectively grounded in housing. Connect line wires as shown in the wiring diagram
accordance with the National Electrical Code to (Figure 6).
eliminate shock hazard.
1. Electric wiring to heater must be installed in accordance with the Thermostat
National Electrical Code and with local codes by a qualified per-
son. Use copper conductors only.
2. When element wattages are not equal, heaters must not be con- L1
nected in series.
3. Electrical wiring to heater equipped with a moisture resistant hous-
ing should be contained in rigid conduit or in sealed flexible hose L2
to keep corrosive vapors and liquids out of the terminal housing. If
high humidity is encountered, the conduit should slope down away Figure 6
from the heater.
OPERATION
1. Do not operate heaters at voltages in excess of that stamped on the insulation resistance of less than twenty megohms. Normally, this
heater since excess voltage will shorten heater life. megohm value corrects itself after heatup and does not affect
2. Always maintain a minimum of 2” of liquid above the heated por- heater efficiency or life.
tion of the element to prevent exposure of the effective heated
length. If the heater is not properly submerged, it may overheat and A low megohm condition can be easily corrected by removing the
damage heating elements, tank or contents. DO NOT OPERATE terminal housing and baking the heater in an oven at 350˚F for sev-
HEATER IF DRY. eral hours, preferably overnight. Note: Before baking, the lid must
3. Be sure all trapped air is removed from a closed tank. Bleed the air be removed from an E2 housing. The housing and screwplug gas-
out of the liquid piping system and heater housing prior to ener- ket must be removed from E4 models.
gizing.
Note: The tank or heating chamber in closed tank systems An alternate procedure is to disconnect the thermostat and energize
must be kept filled with liquid at all times. the heater(s) at low voltage until the megohm reading returns to
4. Keep heating elements above sediment deposits. normal. When energizing heater(s) in air, the sheath temperatures
5. Low Megohm Condition — The refractory materials used in elec- should not exceed 400˚F for copper and 750˚F for steel and alloy
tric heaters may absorb moisture during transit or when subject to elements.
a humid environment. This moisture absorption results in a cold
MAINTENANCE
3. Remove any accumulated sludge deposits from heater and
from tank.
ELECTRIC SHOCK HAZARD. Disconnect all power 4. Check for loose terminal connections and tighten if necessary.
before installing or servicing heater. Failure to do 5. If corrosion is indicated in the E2 or E4 terminal housing,
so could result in personal injury or property dam- check terminal box gasket and replace if necessary. Check screw-
age. Heater must be installed by a qualified person plug gasket on E4 models and replace if necessary. Check conduit
in accordance with the National Electrical Code, layout to correct conditions that allow corrosion to enter the termi-
NFPA 70. nal housing.
1. Heaters should be checked periodically for coatings and corro- 6. Clean terminal ends of all contamination.
sion and cleaned if necessary. 7. Check thermostat for proper identification.
2. The tank should be checked regularly for sediment around
the heater as sediment can act as an insulator and shorten heater life.
RENEWAL PARTS IDENTIFICATION
Thermostats General-Purpose Terminal Enclosure

0 - 127˚F . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-019560-007 Terminal Cover . . . . . . . . . . . . . . . . . . . . . . . . .306-018167-001
60 - 180˚F . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-019560-002 Conduit Bracket . . . . . . . . . . . . . . . . . . . . . . . .027-018183-001
60 - 240˚F . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-019560-003 Cup Sub-Assembly . . . . . . . . . . . . . . . . . . . . . .194-018181-003
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and the work (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii) refund an equitable por-
performed by Chromalox when performed, will meet all applicable specification and other specific product and tion of the purchase price.
work requirements (including those of performance), if any, and will be free from defects in material and work- THE FOREGOING IS CHROMALOX'S ONLY OBLIGATION AND BUYER'S EXCLUSIVE REMEDY FOR BREACH OF
manship under normal conditions of use. All claims for defective or nonconforming (both hereinafter called defec- WARRANTY, AND IS BUYER'S EXCLUSIVE REMEDY AGAINST CHROMALOX FOR ALL CLAIMS ARISING HERE-
tive) Products, parts or work under this warranty must be made in writing immediately upon discovery, and in any UNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT
event, within one (1) year from delivery, provided, however all claims for defective Products and parts must be (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, BUYER'S FAILURE TO SUBMIT A
made in writing no later than eighteen (18) months after shipment by Chromalox. Defective and nonconforming CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF,
items must be held for Chromalox's inspections and returned to the original f.o.b. point upon request. THE FORE- INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS. IN NO EVENT SHALL BUYER BE ENTI-
GOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATU- TLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND BUYER SHALL HOLD CHROMALOX HARMLESS
TORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS THEREFROM. ANY ACTION BY BUYER ARISING HEREUNDER OR RELATING HERETO, WHETHER BASED ON
FOR A PARTICULAR PURPOSE. BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, MUST
Notwithstanding the provisions of this WARRANTY AND LIMITATION Clause, it is specifically understood that BE COMMENCED WITHIN ONE (1) YEAR AFTER THE DATE OF SHIPMENT OR IT SHALL BE BARRED.
Products and parts not manufactured and work not performed by Chromalox are warranted only to the extent and W2008M
in the manner that the same are warranted to Chromalox by Chromalox's vendors, and then only to the extent that
Chromalox is reasonably able to enforce such warranty, it being understood Chromalox shall have no obligation
to initiate litigation unless Buyer undertakes to pay all cost and expenses therefor, including but not limited to attor-
ney's fees, and indemnifies Chromalox against any liability to Chromalox's vendors arising out of such litigation.
Upon Buyer's submission of a claim as provided above and its substantiation, Chromalox shall at its option either
2150 N. RULON WHITE BLVD., OGDEN, UT 84404

Phone: 1-800-368-2493 www.chromalox.com TA - W2 - EF
Litho in U.S.A.
SUCTION BUTTERFLY VALVE
BUTTERFLY VALVES
1. General 2. Technical Data:
HyrdoWer is a globally recognized manufacturer of power unit Operating Pressures:
accessories. They have become specialists in the design of Maximum pressure: 232 p.s.i.
Butterfly Valves and Hydraulic Compensators. Negative pressure: 10 p.s.i.
Pressure difference: 58 p.s.i.
The shut off valve is installed into the pump suction line. The (per side when valve is closed)
valve has a SAE (4 - bolt flange) connection, SAE standard
J518. Material:
Body + Shift Handle : Aluminum
The valve can be actuated with or without the shift handle Seals: NBR
(option H) and the locking bolt will automatically snap the valve Other Parts: Steel Galvanized
into the open or closed position.
The optional tank flange (T-option) can be welded to the

reservior, giving a bolting surface for the butterfly valve. A limit
switch (E-option) can be mounted to the top of the valve. 3. Ordering Code:
Explosion-proof limit switches are available.
AB 16 S [NG] - T H B E Additional description
Basic equipment item #4
Limit-switch (see option #8)
Tapped bushings (see option #7)

4. Butterfly Valve: AB 16 [NG]
Shifter (see option #6)
Tank welded (see option #5)
Pump side Tank side Pump side
Mounting, screws and O-Ring

is supplied with valve.
Type [NG] Size A B D C E F G H J K L M N O SW O-Ring

SAE (in) (in) (in) (in) (mm) (mm) (in) (in) (in) (in) (in) (mm) (in) (mm) (mm) (mm)
AB 16 S 32 1 1/4" 1.19 2.31 1.38 1.42 M12 14 2.24 3.31 1.14 1.38 0.28 M6 2.28 13 9 41x3.5
AB 16 S 40 1 1/2" 1.41 2.75 1.75 1.81 M12 14 2.72 3.74 1.14 1.38 0.28 M6 2.28 13 9 52X3.5
AB 16 S 50 2" 1.69 3.06 2.13 2.20 M12 14 3.15 4.09 1.14 1.38 0.28 M6 2.28 13 9 62X3.5
AB 16 S 63 2 1/2" 2.00 3.50 2.62 2.68 M12 14 3.86 4.53 1.22 1.65 0.31 M6 2.52 13 12 75X4
AB 16 S 80 3" 2.44 4.19 3.25 3.35 M16 16 4.57 5.31 1.22 1.65 0.35 M8 2.52 17 12 92X4
AB 16 S 100 4" 3.06 5.13 4.17 4.17 M16 16 5.39 6.26 1.22 1.65 0.35 M8 2.52 17 12 114X4
AB 16 S 125 5" 3.63 6.00 5.16 5.16 M16 16 6.42 7.13 1.22 1.65 0.35 M8 2.52 17 12 140X4
Toll Free (877) - ICFLUID

www.icfluid.com
-2-
BUTTERFLY VALVES
5. Flange - Option “T”: The flange can be welded to the
Tank side Pump side reservoir, giving a bolting surface for the butterfly valve.
Type [NG] Size ØD1 ØN1 ØO1 ØP Q Q1 R

SAE (in) (in) (in) (in) (in) (in) (in)
AB 16 S 32 1 1/4" 1.38 3.54 3.15 1.69 0.12 0.16 0.55

AB 16 S 40 1 1/2" 1.65 3.94 3.54 1.93 0.12 0.16 0.55
AB 16 S 50 2" 2.17 4.33 3.94 2.40 0.12 0.16 0.55
AB 16 S 63 2 1/2" 2.68 4.92 4.53 3.07 0.12 0.16 0.67
AB 16 S 80 3" 3.31 5.71 5.31 3.58 0.12 0.16 0.67
AB 16 S 100 4" 4.13 6.89 6.50 4.57 0.12 0.16 0.67
AB 16 S 125 5" 5.12 7.87 7.48 5.59 0.12 0.16 0.67
Tank side Pump side

6. Shift Handle Option “H”:
Type W X
(in) (in)
AB 16 S 32 to 50 4.13 1.57
AB 16 S 63 to 125 4.33 1.57
90° to shut
7. Threaded Adapter Bushing Inserts - Option “B”

Threaded busing that adapts to standard SAE tapped
holes. With these bushings, it will accept the screws
provided with Butterfly valve.
Type E L1 SW1
UNC-2B in mm
AB 16 S 32 to 63 7/16 - 14 0.47 12
Threaded bushing AB 16 S 40 to 63 1/2 - 13 0.51 12
AB 16 S 80 to 125 5/8 - 11 0.51 17
8. Limit switch - option “E”

Type E L1 SW1
UNC-2B (in) (mm)
AB 16 S 32 to 63 7/16 - 14 0.47 12
Wiring diagram when AB 16 S 80 to 125 5/8 - 11 0.51 17
Butterfly valve is closed
to
to

www.icfluid.com
-3-
COMPENSATORS 1" - 4"
1. General:
The HydroWer Rubber Compensators is a product that
qualifies as one of the best kept secrets of power unit
accessories. The Hydrower Rubber Compensators are
flexible connectors with SAE-flanges. The oscillation
compensators are used for damping of oscillators and
vibrations, noises and movements in axial and
transversal direction.
The HydroWer Compensator is constructed of an inner

liner of a reinforced high strength rubber (Nitril-
caoutchouc. Perbunan). The outer and inside layers
are smooth and have an aerodynamic design that 1
Pump
eliminates cavitation. The outside rubber (neoprene 2 3 4
caoutchouc) is weather resistant. Both ends of the
Compensators have vulcanized sealing lips. With the
vulcanized sealing lips on each end, additional seals
are not necessary.
Typical Installation: Tank

1 - Tank wall
2 - Flange
3 - Butterfly Valve Pump
4 - Compensator
2. Technical Data: 4
Working Pressure: 87 p.s.i.
2
Max. Pressure: 174 p.s.i.
Tank 2 3
Burst Pressure: 290 p.s.i.
Vacuum: 20" Hg
Temperature -4°F to 176°F
Acceptable Movement
For Acceptable Movements See Tables 1, 2, 3, 4

www.icfluid.com
-4-
COMPENSATORS
Compensator with SAE to SAE Flange connecting sizes after SAE-Standard J 518c
sealing surface
with sealing lips
Size
Table 1
Type [NG] Size A B D E F G H L Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) Push/Pull Offset Angle(°) Weight (lbs.)
K 16 S 25 1" 1.03 2.06 1.69 0.43 0.43 2.17 2.76 2.56 ±0.20 in ±0.20 in 7.5° 0.8
K 16 S 32 1 1/4" 1.19 2.31 1.97 0.43 0.51 2.76 3.15 2.56 ±0.20 in ±0.20 in 7.5° 1.10
K 16 S 40 1 1/2" 1.41 2.75 2.44 0.51 0.51 3.15 3.54 3.94 ±0.39 in ±0.39 in 10° 1.76
K 16 S 50 2" 1.69 3.06 2.83 0.51 0.51 3.54 3.94 3.94 ±0.39 in ±0.39 in 10° 2.21
K 16 S 63 2 1/2" 2.00 3.50 3.43 0.55 0.51 4.13 4.53 3.94 ±0.39 in ±0.39 in 10° 2.65
K 16 S 80 3" 2.44 4.19 4.09 0.55 0.71 4.72 5.20 3.94 ±0.39 in ±0.39 in 10° 3.97
K 16 S 90 3 1/2" 2.75 4.75 4.09 0.55 0.71 5.12 5.75 3.94 ±0.39 in ±0.39 in 10° 4.19
K 16 S 100 4" 3.06 5.13 5.12 0.63 0.71 5.51 6.14 3.94 ±0.39 in ±0.39 in 10° 5.51
Compensator with SAE to DIN-Flange

SAE-Flange DIN-Flange
sealing surface
with sealing lips
connecting sizes
after SAE-Norm
(J 518ci) and
after DIN 2633 - ND 16
Table 2
Type [NG] Size A B C D E F G H K L M N Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (mm) (in) Push/Pull Offset Angle (°) Weight (lbs.)
K16SD- 25 1" 1.031 2.062 4.53 1.69 0.43 0.43 2.17 2.76 3.35 2.56 4x14 0.63 ±0.20 in ±0.20 in 7.5° 3.31
K16SD- 32 1 1/4" 1.188 2.312 5.51 1.97 0.43 0.51 2.76 3.15 3.94 2.56 4x18 0.63 ±0.20 in ±0.20 in 7.5° 3.97
K16SD- 40 1 1/2" 1.406 2.750 5.91 2.44 0.51 0.51 3.15 3.54 4.33 3.94 4x18 0.63 ±0.39 in ±0.39 in 10° 4.85
K16SD- 50 2" 1.688 3.062 6.50 2.83 0.51 0.51 3.54 3.94 4.92 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 6.17
K16SD- 63 2 1/2" 2.00 3.500 7.28 3.43 0.55 0.51 4.13 4.53 5.71 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 7.06
K16SD- 80 3" 2.438 4.188 7.87 4.09 0.55 0.71 4.72 5.20 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 8.82
K16SD- 90 3 1/2" 2.750 4.750 7.87 4.09 0.55 0.71 5.12 5.75 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 9.04
K16SD- 100 4" 3.062 5.125 8.66 5.12 0.63 0.71 5.51 6.14 7.09 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 10.58

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-5-
COMPENSATORS
Compensator with NPT Thread to NPT Thread
Table 3
Type [NG] NG L R SW1 SW2 Acceptable Movement

(in) (in) (NPT) (mm) (mm) Push/Pull Offset Angle(°) Weight (lbs.)
K 16 R 25 0.98 6.42 1" 35 54 ±0.20 in ±0.20 in 7.5° 1.54
K 16 R 32 1.26 6.97 1 1/4" 45 66 ±0.20 in ±0.20 in 7.5° 2.43
K 16 R 40 1.57 9.06 1 1/2" 53 73 ±0.39 in ±0.39 in 10° 2.87
K 16 R 50 1.97 9.45 2" 66 90 ±0.39 in ±0.39 in 10° 3.31
Check when installing
When installing the compensator, it must be in line and maintain the dimension "L" length. For compensators with NPT pipe thread
the nut SW2 must only be hand tight.
The movement absorption in static and dynamic loads and the different types of movements must be added together and the totals
are not allowed to exceed the data given.
Attention: Pressure spikes are push loads which add to the axial movement. Do not exceed given data!
Compensator with SAE-Flange to NPT Thread

sealing surface
with sealing lips
Flange connecting after

SAE-Norm J 518 -
NPT Pipe Thread
Table 4
Type [NG] Size A B D E F G H L R SW1 SW2 Acceptable Movement

SAE (in) (in) (in) (in) (in) (in) (in) (in) (in) (mm) (mm) Push/Pull Offset Angle (°) Weight (lbs.)
K16SR- 25 1" 1.03 2.06 1.61 0.43 0.43 2.17 2.76 4.49 1" 35 54 ±0.20 in ±0.20 in 7.5° 0.80
K16SR- 32 1 1/4" 1.19 2.31 1.89 0.43 0.51 2.76 3.15 4.76 1 1/4" 45 66 ±0.20 in ±0.20 in 7.5° 1.80
K16SR- 40 1 1/2" 1.41 2.75 2.32 0.51 0.51 3.15 3.54 6.18 1 1/2" 53 73 ±0.39 in ±0.39 in 10° 2.40
K16SR- 50 2" 1.69 3.06 2.76 0.51 0.51 3.54 3.94 6.42 2" 66 90 ±0.39 in ±0.39 in 10° 2.90

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-6-
SCREW-IN TYPE
CHECK VALVES
• Ball Type Poppet Design - patent pending • Pressures to 10,000 psi (700 bar) - Flows to 23 gpm (90 l/min)
• Nominal Size: 1/16 - 1/8 - 1/4 - 3/8 - 1/2 - 3/4 • Threads: BSP, Metric, and Inch sizes on request
Type: RVA Type: RVB
Type Max G L I b zxød 0-Ring Curve # Type Max G L I SW 0-Ring Curve #

GPM (90 sh) GPM (90 sh)
RVA 2-M 0.79 M6 6 3.5 3.5 4x1.2 2.5x1 1 RVB 2-M 0.53 M6 6.5 3.5 3 2.5x1 8
RVA 3-M 1.59 M8x1 6 3.5 5 6x1.6 4x1 2 RVB 3-M 1.06 M8x1 6.5 3.5 3 4x1 9
RVA 4 2.64 G 1/8 RVB 4 2.11 G 1/8 7 4 4 6x1 10
6.5 3.5 6 6x1.8 6x1 3
RVA 4-M 2.64 M 10x1 RVB 4-M 2.11 M 10x1
RVA 6 6.61 G 1/4 RVB 6 4.76 G 1/4 8 4.5 5 9x1 11
8 4.6 9 8x2.2 9x1 4
RVA 6-M 6.61 M 14x1.5 RVB 6-M 4.76 M 14x1.5
RVA 8 11.89 G 3/8 RVB 8 7.93 G 3/8
10 5.5 11 8x3 11x1.5 5 9.5 5.5 6 11x1.5 12
RVA 8-M 11.89 M18x1.5 RVB 8-M 7.93 M18x1.5
RVA 10 18.49 G 1/2 RVB 10 15.85 G 1/2
11.5 6.5 14.5 8x3.8 14x1.5 6 11.5 6.5 8 14x1.5 13
RVA 10-M 18.49 M22x1.5 RVB 10-M 15.85 M22x1.5
RVA 16 26.42 G 3/4 RVB 16 23.78 G 3/4
14 7.5 18.5 8x4.6 18.77x1.78 7 14 8 10 18.77x1.78 14
RVA 16-M 26.42 M27x2 RVB 16-M 23.78 M27x2
Techincal Data:
Operating Pressure: 10,150 psi (lock pressure)
Proof Pressure: 40,600 psi
Temperature Range: -40°F to 176°F
Viscosity Range: 5 to 500 c St
Installation Position: Any direction
Flow Rate: See section 4
Stainless Steel on Request
Type G K d T U X
RVA +RVB 2 M6 2 7 5 4.5 2.5

RVA +RVB 3 M8x1 7 3.5 7 4.5 2.5
RVA +RVB 4 G 1/8 8.7 5 8.5 6 2.5
RVA +RVB 4 M 10x1 9
RVA +RVB 6 G 1/4 11.7 8 9 6 3
RVA +RVB 6 M 14x1.5 12.5
RVA +RVB 8 G 3/8 15.2
10 11 6 8
RVA +RVB 8 M18x1.5 16.5
RVA +RVB 10 G 1/2 19
12 13 9.5 3.5
RVA +RVB 10 M22x1.5 20.5
RVA +RVB 16 G 3/4 24.5
It is absolutely necessary 16 17 12.5 4.5
RVA +RVB 16 M27x2 25
to maintain the "x" dimension
of the cavity (item #5) X - Thread run-out. It can be smaller, but not larger.
T - Minimum depth without plug, thread joint, transverse drill and so on.
In case of stronger impacts and vibration, it is recommended to
secure the valves with loctite or similar.
*All dimensions in mm.
Oil viscosity measured at 50 cSt.
Warning: In case of sudden loading of the check-valve in flow direction, for example behind tank or hoses, the specified flow quantity
must not be exceeded.
www.icfluid.com
-7-
SPIDER CONTROL SYSTEM [E01P X10-2347]
DOCUMENTATION FOR SPIDER CONTROL SYSTEM
E01P X10-2347
Customer : THYSSENKRUPP ROBINS

Job 2005 033
Specification Page 1/1
Control system: Spider Ind. No: E01P X10-2347

Ordering code: Spider 2- B102-01000-1
Art. No: 276 0023-801
Card number 2386-0504
Card revision: R2D
Software: Spider version 4.1.2

Note. Parameter settings that have been changed from
DEFAULT are shown in Parameter list at delivery.
Connection: As drawing CD-2005 033 shows.
Notes:
E01PX10-2347.txt
Printout time: 2005-09-27 11:56:52
Printed by SpiderCom2 version: 4.1.4 Build 8
Parameter file name: E01PX10-2347.s2p
Parameter file version: 2
SpiderII software version: 4.1.2 2
Main settings
Function
MAA01 - System function BASIC
Configuration
MAB01 - E-motor connection for P1 E-motor 1
MAB02 - E-motor connection for P2 OFF
MAB05 - Drive connection for P1 Drive 1
MAB06 - Drive connection for P2 OFF
MAB09 - Separate or common Separate
MAB10 - Shutdown ramp time 0
MAB11 - Emerg. stop mem bypass off
Language
MAC01 - Display language selection English
Protection
MAD01 - Security code - setup menu yes (*)
MAD02 - Security code 0533 (*)
Pump outputs
Pump 1
POA01 - Forward min current 183 (*)
POA02 - Forward max current 315 (*)
POA03 - Reverse min current 175 (*)
POA04 - Reverse max current 305 (*)
POA05 - Coil resistance 41 (*)
POA06 - PWM-frequency 200
Pump 2
POB01 - Forward min current 0
POB02 - Forward max current 0
POB03 - Reverse min current 0
POB04 - Reverse max current 0
POB05 - Coil resistance 40
POB06 - PWM-frequency 200
Pump 3
POC01 - Forward min current 0
POC02 - Forward max current 0
POC03 - Reverse min current 0
POC04 - Reverse max current 0
POC05 - Coil resistance 40
POC06 - PWM-frequency 200
Pump 4
POD01 - Forward min current 0
POD02 - Forward max current 0
POD03 - Reverse min current 0
POD04 - Reverse max current 0
POD05 - Coil resistance 40
POD06 - PWM-frequency 200
Friction
POE01 - Pump friction Off
POE02 - Pump low friction limit 0
POE03 - Pump high friction limit 200
POE04 - Friction up ramp time 2.0
POE05 - Friction down ramp time 2.0
Page 1
E01PX10-2347.txt
Digital inputs
Digital in 1 - 22
DIN01 - Digital input 1, DI1:3 14 START 1 (*)
DIN02 - Digital input 2, DI1:4 15 REV 1 (*)
DIN03 - Digital input 3, DI1:5 21 OFF (*)
DIN04 - Digital input 4, DI1:6 07 MN LEVEL
DIN05 - Digital input 5, DI1:7 07 LO LEVEL
DIN06 - Digital input 6, DI1:8 06 DRF 100
DIN07 - Digital input 7, DI2:4 06 RF100 P1
DIN08 - Digital input 8, DI2:5 05 SUCTION1
DIN09 - Digital input 9, DI2:6 03 C PRA P1 (*)
DIN10 - Digital input 10, DI2:7 01 H APR P1
DIN15 - Digital input 15, DI2:12 21 OFF
Digital in 23 - 43
Digital outputs
Digital out 1
DOA01 - Digital output function 11 COOLCONI (*)
DOA02 - Inverted function no
DOA03 - Delay time for digital output 5.0
DOA04 - Delay function for output NO
Digital out 2
DOB01 - Digital output function 01 A1 (*)
DOB02 - Inverted function no
DOB03 - Delay time for digital output 5.0
DOB04 - Delay function for output NO
Digital out 3
DOC01 - Digital output function 01 W1 (*)
DOC02 - Inverted function no
DOC03 - Delay time for digital output 5.0
Page 2
E01PX10-2347.txt
DOC04 - Delay function for output NO
Digital out 4
DOD01 - Digital output function 02 START 1 (*)
DOD02 - Inverted function no
DOD03 - Delay time for digital output 5.0
DOD04 - Delay function for output NO
Digital out 5
DOE01 - Digital output function 04 REMOTE 1 (*)
DOE02 - Inverted function no
DOE03 - Delay time for digital output 5.0
DOE04 - Delay function for output NO
Digital out 6
DOF01 - Digital output function 03 READY 1 (*)
DOF02 - Inverted function no
DOF03 - Delay time for digital output 5.0
DOF04 - Delay function for output NO
Digital out 7
DOG01 - Digital output function 15 OFF
DOG02 - Inverted function no
DOG03 - Delay time for digital output 0.0 (*)
DOG04 - Delay function for output NO
Digital out 8
DOH01 - Digital output function 15 OFF
DOH02 - Inverted function no
DOH03 - Delay time for digital output 0.0 (*)
DOH04 - Delay function for output NO
Digital out 9
DOI01 - Digital output function 15 OFF
DOI02 - Inverted function no
DOI03 - Delay time for digital output 5.0
DOI04 - Delay function for output NO
Digital out 10
DOJ01 - Digital output function 15 OFF
DOJ02 - Inverted function no
DOJ03 - Delay time for digital output 5.0
DOJ04 - Delay function for output NO
Digital out 11
DOK01 - Digital output function 15 OFF
DOK02 - Inverted function no
DOK03 - Delay time for digital output 5.0
DOK04 - Delay function for output NO
Digital out 12
DOL01 - Digital output function 15 OFF
DOL02 - Inverted function no
DOL03 - Delay time for digital output 5.0
DOL04 - Delay function for output NO
Digital out 13
DOM01 - Digital output function 15 OFF
DOM02 - Inverted function no
DOM03 - Delay time for digital output 5.0
DOM04 - Delay function for output NO
Pulse inputs
Drive 1
P1I01 - Pulses/rev 3600 (*)
P1I02 - Units for REG109 rpm
P1I03 - Decimals for REG109 0
P1I04 - Scaling for REG109 1.00
P1I05 - Filter time for speed reading 0.0
P1I06 - Polarity - digital speed signal 1
P1I07 - Encoder type 1
Drive 2
P2I01 - Pulses/rev 1000
Page 3
E01PX10-2347.txt
Analog inputs
Setpoint 1
AIA01 - Input type 4-20 mA
AIA02 - Zero point adjustment 0
AIA03 - Max point adjustment 0
AIA04 - Reading for REG101 %
Setpoint 2
AIB01 - Input type 4-20 mA
AIB02 - Zero point adjustment 0
AIB03 - Max point adjustment 0
AIB04 - Reading for REG201 %
Analog in 1
AIF01 - Input type 4-20 mA
AIF02 - Zero point adjustment 0
AIF03 - Max point adjustment 0
AIF04 - Min input, REG401 0
AIF05 - Max input, REG401 200
AIF06 - Units for REG401 bar
AIF07 - Decimals for REG401 0
AIF08 - Scaling for REG401 1.00
AIF09 - Function for input OFF
AIF10 - High indication level 200
AIF11 - Low indication level 0
AIF12 - Function for min indication OFF
AIF13 - Function for high indication OFF
AIF14 - Function for low indication OFF
Analog in 2
AIG01 - Input type 4-20 mA
AIG02 - Zero point adjustment 0
AIG03 - Max point adjustment 0
AIG04 - Min input, REG402 0
AIG05 - Max input, REG402 200
AIG06 - Units for REG402 bar
AIG07 - Decimals for REG402 0
AIG08 - Scaling for REG402 1.00
AIG09 - Function for input OFF
AIG10 - High indication level 200
AIG11 - Low indication level 0
AIG12 - Function for min indication OFF
AIG13 - Function for high indication OFF
AIG14 - Function for low indication OFF
Analog in 3
AIH01 - Input type 4-20 mA
AIH02 - Zero point adjustment 0
AIH03 - Max point adjustment 5 (*)
AIH04 - Min input, REG403 -25 (*)
AIH05 - Max input, REG403 100 (*)
AIH06 - Units for REG403 °C (*)
AIH07 - Decimals for REG403 1 (*)
AIH08 - Scaling for REG403 1.00
AIH09 - Function for input TANK A (*)
AIH10 - High indication level 60 (*)
AIH11 - Low indication level 0 (*)
AIH12 - Function for min indication OFF
AIH13 - Function for high indication OFF
AIH14 - Function for low indication OFF
Page 4
E01PX10-2347.txt
Analog in 4
AII01 - Input type 4-20 mA
AII02 - Zero point adjustment 0
AII03 - Max point adjustment 0
AII04 - Min input, REG404 0
AII05 - Max input, REG404 69 (*)
AII06 - Units for REG404 bar
AII07 - Decimals for REG404 0
AII08 - Scaling for REG404 1.00
AII09 - Function for input PR1 (*)
AII10 - High indication level 69
AII11 - Low indication level 0
AII12 - Function for min indication OFF
AII13 - Function for high indication OFF
AII14 - Function for low indication OFF
Analog in 5
AIJ01 - Input type 4-20 mA
AIJ02 - Zero point adjustment 0
AIJ03 - Max point adjustment 0
AIJ04 - Min input, REG405 0
AIJ05 - Max input, REG405 414 (*)
AIJ06 - Units for REG405 bar
AIJ07 - Decimals for REG405 0
AIJ08 - Scaling for REG405 1.00
AIJ09 - Function for input SP1 (*)
AIJ10 - High indication level 325 (*)
AIJ11 - Low indication level 10 (*)
AIJ12 - Function for min indication OFF
AIJ13 - Function for high indication OFF
AIJ14 - Function for low indication OFF
Analog in 6
AIK01 - Input type 4-20 mA
AIK02 - Zero point adjustment 0
AIK03 - Max point adjustment 0
AIK04 - Min input, REG406 0
AIK05 - Max input, REG406 200
AIK06 - Units for REG406 bar
AIK07 - Decimals for REG406 0
AIK08 - Scaling for REG406 1.00
AIK09 - Function for input OFF
AIK10 - High indication level 200
AIK11 - Low indication level 0
AIK12 - Function for min indication OFF
AIK13 - Function for high indication OFF
AIK14 - Function for low indication OFF
Analog in 7
AIL01 - Input type 4-20 mA
AIL02 - Zero point adjustment 0
AIL03 - Max point adjustment 0
AIL04 - Min input, REG407 0
AIL05 - Max input, REG407 200
AIL06 - Units for REG407 bar
AIL07 - Decimals for REG407 0
AIL08 - Scaling for REG407 1.00
AIL09 - Function for input OFF
AIL10 - High indication level 200
AIL11 - Low indication level 0
AIL12 - Function for min indication OFF
AIL13 - Function for high indication OFF
AIL14 - Function for low indication OFF
Analog in 8
AIM01 - Input type 4-20 mA
AIM02 - Zero point adjustment 0
Page 5
E01PX10-2347.txt
AIM03 - Max point adjustment 0
AIM04 - Min input, REG408 0
AIM05 - Max input, REG408 200
AIM06 - Units for REG408 bar
AIM07 - Decimals for REG408 0
AIM08 - Scaling for REG408 1.00
AIM09 - Function for input OFF
AIM10 - High indication level 200
AIM11 - Low indication level 0
AIM12 - Function for min indication OFF
AIM13 - Function for high indication OFF
AIM14 - Function for low indication OFF
Analog in 9
AIN01 - Input type 4-20 mA
AIN02 - Zero point adjustment 0
AIN03 - Max point adjustment 0
AIN04 - Min input, REG409 0
AIN05 - Max input, REG409 200
AIN06 - Units for REG409 bar
AIN07 - Decimals for REG409 0
AIN08 - Scaling for REG409 1.00
AIN09 - Function for input OFF
AIN10 - High indication level 200
AIN11 - Low indication level 0
AIN12 - Function for min indication OFF
AIN13 - Function for high indication OFF
AIN14 - Function for low indication OFF
Tank temp
AIP01 - Zero point adjustment 0
AIP02 - Max point adjustment 0
AIP03 - Units for REG410 °F (*)
Power limit
AIR01 - Power limitation E-motor 1 1101 (*)
AIR02 - Power limitation E-motor 2 400
Analog outputs
Analog out 1
AOA01 - Analog output REG109 (*)
AOA02 - 4-20mA or 2-10V ouput on
AOA03 - Zero point adjustment 0
AOA04 - Max point adjustment 0
Analog out 2
AOB01 - Analog output REG403 (*)
AOB02 - 4-20mA or 2-10V ouput on
AOB03 - Zero point adjustment 0
AOB04 - Max point adjustment 0
Analog out 3
AOC01 - Analog output REG405 (*)
AOC02 - 4-20mA or 2-10V ouput on
AOC03 - Zero point adjustment 0
AOC04 - Max point adjustment -15 (*)
Analog out 4
AOD01 - Analog output OFF
AOD02 - 4-20mA or 2-10V ouput off (*)
AOD03 - Zero point adjustment 0
AOD04 - Max point adjustment 0
Bus
Type && Function
BTF01 - Type of bus communication OFF
BTF02 - Max com. drop time 1
BTF03 - Function at com. drop Interlock
Page 6
E01PX10-2347.txt
Digital in
BDI01 - Digital input 1 21 OFF
Analog in 1
BAA01 - Min input, REG501 0
BAA02 - Max input, REG501 200
BAA03 - Units for REG501 %
BAA04 - Decimals for REG501 0
BAA05 - Function for input OFF
Analog in 2
BAB01 - Min input, REG502 0
BAB02 - Max input, REG502 200
BAB03 - Units for REG502 %
BAB04 - Decimals for REG502 0
BAB05 - Function for input OFF
Analog in 3
BAC01 - Min input, REG503 0
BAC02 - Max input, REG503 200
BAC03 - Units for REG503 °
BAC04 - Decimals for REG503 0
BAC05 - Function for input OFF
Analog in 4
BAD01 - Min input, REG504 0
BAD02 - Max input, REG504 200
BAD03 - Units for REG504 bar
BAD04 - Decimals for REG504 0
BAD05 - Function for input OFF
Analog out
BAK01 - Analog output register OFF
Pump monitor
Pump 1
PMA01 - Charge pr. interlock delay 5 sec
PMA02 - Delay, Charge pr. A 0.5 sec
Page 7
E01PX10-2347.txt
PMA03 - Delay, Charge pr. B 0.5 sec
PMA04 - Delay, Suction line 0.0 sec
PMA05 - Delay, Return filter 75% 7.0 sec
PMA07 - Return filter alarm OFF
PMA08 - Delay, High work pr. A 7.0 sec
PMA09 - Mem bypass, work pr. A off
PMA10 - Delay, High work pr. B 7.0 sec
PMA11 - Mem bypass, work pr. B off
PMA12 - Signal plausibility check on
PMA13 - Error limits between in/out 50
PMA14 - Analog pressure sensor off
Pump 2
PMB01 - Charge pr. interlock delay 5 sec
PMB02 - Delay, Charge pr. A 0.5 sec
PMB03 - Delay, Charge pr. B 0.5 sec
PMB04 - Delay, Suction line 0.0 sec
PMB05 - Delay, Return filter 75% 7.0 sec
PMB07 - Return filter alarm OFF
PMB08 - Delay, High work pr. A 7.0 sec
PMB09 - Mem bypass, work pr. A off
PMB10 - Delay, High work pr. B 7.0 sec
PMB11 - Mem bypass, work pr. B off
PMB12 - Signal plausibility check on
PMB13 - Error limits between in/out 50
PMB14 - Analog pressure sensor off
Pump 3
PMC01 - Charge pr. interlock delay 5 sec
PMC02 - Delay, Charge pr. A 0.5 sec
PMC03 - Delay, Charge pr. B 0.5 sec
PMC04 - Delay, Suction line 0.0 sec
PMC05 - Delay, Return filter 75% 7.0 sec
PMC07 - Return filter alarm OFF
PMC08 - Delay, High work pr. A 7.0 sec
PMC09 - Mem bypass, work pr. A off
PMC10 - Delay, High work pr. B 7.0 sec
PMC11 - Mem bypass, work pr. B off
PMC12 - Signal plausibility check on
PMC13 - Error limits between in/out 50
PMC14 - Analog pressure sensor off
Pump 4
PMD01 - Charge pr. interlock delay 5 sec
PMD02 - Delay, Charge pr. A 0.5 sec
PMD03 - Delay, Charge pr. B 0.5 sec
PMD04 - Delay, Suction line 0.0 sec
PMD05 - Delay, Return filter 75% 7.0 sec
PMD07 - Return filter alarm OFF
PMD08 - Delay, High work pr. A 7.0 sec
PMD09 - Mem bypass, work pr. A off
PMD10 - Delay, High work pr. B 7.0 sec
PMD11 - Mem bypass, work pr. B off
PMD12 - Signal plausibility check on
PMD13 - Error limits between in/out 50
PMD14 - Analog pressure sensor off
Tank monitor
Digital
TMA01 - Delay, Low oil level warn. 0.0 sec
TMA02 - Delay, Min oil level alarm 0.0 sec
TMA03 - Delay, Min temp alarm 0.0 sec
Page 8
E01PX10-2347.txt
TMA04 - Delay, High temp warn. 0.0 sec
TMA05 - Delay, Max temp alarm 0.5 sec
TMA06 - Delay, Drain 75% warn. 7.0 sec
TMA08 - Drain filter alarm OFF
TMA09 - Min oil temp function A
Analog
TMB01 - Analog temp sensor on
TMB03 - Max oil temp alarm level 60
TMB04 - High oil temp warning level 55
TMB05 - Cooling temp on level (rise) 40
TMB06 - Cooling hysteresis 3
TMB07 - Filter interlock temp level 18 (*)
TMB08 - Heating temp on level (fall) 15
TMB09 - Heating hysteresis 3
TMB10 - Min oil temp alarm level 10
TMB11 - Flushing temp on level (fall) 30
TMB12 - Flushing hysteresis 3
Aux monitor
Aux 1
AMA01 - Aux function W D1
AMA02 - Aux delay time 0.1 (*)
AMA03 - Aux memory bypass on (*)
AMA04 - Aux configurable text Eng Stop (*)
AMA05 - Aux inverted input off
Aux 2
AMB01 - Aux function W D1
AMB02 - Aux delay time 1.0
AMB03 - Aux memory bypass off
AMB04 - Aux configurable text AUX 2
AMB05 - Aux inverted input off
Aux 3
AMC01 - Aux function W D1
AMC02 - Aux delay time 1.0
AMC03 - Aux memory bypass off
AMC04 - Aux configurable text AUX 3
AMC05 - Aux inverted input off
Aux 4
AMD01 - Aux function W D1
AMD02 - Aux delay time 1.0
AMD03 - Aux memory bypass off
AMD04 - Aux configurable text AUX 4
AMD05 - Aux inverted input off
Aux 5
AME01 - Aux function W D1
AME02 - Aux delay time 1.0
AME03 - Aux memory bypass off
AME04 - Aux configurable text AUX 5
AME05 - Aux inverted input off
Aux 6
AMF01 - Aux function W D1
AMF02 - Aux delay time 1.0
AMF03 - Aux memory bypass off
AMF04 - Aux configurable text AUX 6
AMF05 - Aux inverted input off
Aux 7
AMG01 - Aux function W D1
AMG02 - Aux delay time 1.0
AMG03 - Aux memory bypass off
AMG04 - Aux configurable text AUX 7
AMG05 - Aux inverted input off
Aux 8
Page 9
E01PX10-2347.txt
AMH01 - Aux function W D1
AMH02 - Aux delay time 1.0
AMH03 - Aux memory bypass off
AMH04 - Aux configurable text AUX 8
AMH05 - Aux inverted input off
Aux 9
AMI01 - Aux function W D1
AMI02 - Aux delay time 1.0
AMI03 - Aux memory bypass off
AMI04 - Aux configurable text AUX 9
AMI05 - Aux inverted input off
Aux 10
AMJ01 - Aux function W D1
AMJ02 - Aux delay time 1.0
AMJ03 - Aux memory bypass off
AMJ04 - Aux configurable text AUX 10
AMJ05 - Aux inverted input off
Aux 11
AMK01 - Aux function W D1
AMK02 - Aux delay time 1.0
AMK03 - Aux memory bypass off
AMK04 - Aux configurable text AUX 11
AMK05 - Aux inverted input off
Aux 12
AML01 - Aux function W D1
AML02 - Aux delay time 1.0
AML03 - Aux memory bypass off
AML04 - Aux configurable text AUX 12
AML05 - Aux inverted input off
Aux 13
AMM01 - Aux function W D1
AMM02 - Aux delay time 1.0
AMM03 - Aux memory bypass off
AMM04 - Aux configurable text AUX 13
AMM05 - Aux inverted input off
Aux 14
AMN01 - Aux function W D1
AMN02 - Aux delay time 1.0
AMN03 - Aux memory bypass off
AMN04 - Aux configurable text AUX 14
AMN05 - Aux inverted input off
Aux 15
AMO01 - Aux function W D1
AMO02 - Aux delay time 1.0
AMO03 - Aux memory bypass off
AMO04 - Aux configurable text AUX 15
AMO05 - Aux inverted input off
Aux 16
AMP01 - Aux function W D1
AMP02 - Aux delay time 1.0
AMP03 - Aux memory bypass off
AMP04 - Aux configurable text AUX 16
AMP05 - Aux inverted input off
Aux 17
AMQ01 - Aux function W D1
AMQ02 - Aux delay time 1.0
AMQ03 - Aux memory bypass off
AMQ04 - Aux configurable text AUX 17
AMQ05 - Aux inverted input off
Aux 18
AMR01 - Aux function W D1
AMR02 - Aux delay time 1.0
AMR03 - Aux memory bypass off
Page 10
E01PX10-2347.txt
AMR04 - Aux configurable text AUX 18
AMR05 - Aux inverted input off
Aux 19
AMS01 - Aux function W D1
AMS02 - Aux delay time 1.0
AMS03 - Aux memory bypass off
AMS04 - Aux configurable text AUX 19
AMS05 - Aux inverted input off
Aux 20
AMT01 - Aux function W D1
AMT02 - Aux delay time 1.0
AMT03 - Aux memory bypass off
AMT04 - Aux configurable text AUX 20
AMT05 - Aux inverted input off
Drive monitor
Start interlock
DMA01 - Start alternative, drive 1 and
DMA02 - Start delay time, drive 1 5 sec
Drive 1
DMB01 - Delay, charge pressure A 0.5 sec
DMB02 - Delay, charge pressure B 0.5 sec
DMB03 - Delay, E-motor temp 0.0 sec
DMB04 - Delay, work pressure A 7.0 sec
DMB05 - Mem bypass, work pr. A off
DMB06 - Delay, work pressure B 7.0 sec
DMB07 - Mem bypass, work pr. B off
DMB08 - Analog pressure sensor off
Drive 2
DMC01 - Delay, charge pressure A 0.5 sec
DMC02 - Delay, charge pressure B 0.5 sec
DMC03 - Delay, E-motor temp 0.0 sec
DMC04 - Delay, work pressure A 7.0 sec
DMC05 - Mem bypass, work pr. A off
DMC06 - Delay, work pressure B 7.0 sec
DMC07 - Mem bypass, work pr. B off
DMC08 - Analog pressure sensor off
Emotor interlock
DMD01 - Delay, Interlock E-motor 1 1.0
Drive 1 basic
Setpoint
D1A01 - Speed setpoint Local/Remote (*)
D1A02 - Type of command signal Unidirectional (*)
D1A03 - Reset of local setpoint yes
D1A04 - Reverse input on (*)
D1A05 - Reverse command setpoint -10.0 (*)
D1A06 - Digital forward setpoint 10.0
D1A07 - Digital reverse setpoint -10.0
D1A08 - Drive front panel buttons on
Ramp
D1C01 - Up ramp time forward 2.0
D1C02 - Down ramp time forward 2.0
D1C03 - Up ramp time reverse 2.0
D1C04 - Down ramp time reverse 2.0
Regulator
D1D01 - Regulator on (*)
D1D02 - Feed forward function on
D1D03 - Proportional regulator on (*)
Page 11
E01PX10-2347.txt
D1D04 - Integrating regulator on (*)
D1D05 - Derivation regulator off
D1D06 - Proportional gain 0.1
D1D07 - Integration time 10.0
D1D08 - Derivation time 0.10
D1D09 - Derivation decline time 0.1
D1D10 - Max feedback deviation 50
D1D11 - Regulated or nonregulated Switching (*)
Feedback
D1E01 - Max motor shaft speed 8.0 (*)
D1E02 - Feedback selection Digital
D1E03 - Filter time for feedback 0.0
Power limitation
D1F01 - Delay time, power limitation 0.0 (*)
D1F02 - Ramp time, power limitation 20.0
Drive 2 basic
Setpoint
D2A01 - Speed setpoint Local
D2A02 - Type of command signal Bidirectional
D2A04 - Reverse input off
D2A05 - Reverse command setpoint -20.0
Ramp
Regulator
D2D01 - Regulator off
D2D03 - Proportional regulator off
D2D04 - Integrating regulator off
D2D11 - Regulated or nonregulated Non-regulated
Feedback
D2E01 - Max motor shaft speed 10.0
Power limitation
D2F01 - Delay time, power limitation 0.5
Shredder 1
Function
SHA01 - Reverse control Pressure, separate
SHA02 - Reverse stop function Going to forward
SHA03 - Delay before reversal 3.0
SHA04 - Reversal time 10.0
SHA05 - Reverse delay SHA02 3.0
SHA06 - Forward time 10.0
SHA07 - Shredder automatic dir. off
SHA08 - Forward time interval 60
SHA09 - Reverse time interval 60
SHA10 - Selection of regulated dr. Unregulated
Page 12
E01PX10-2347.txt
Setpoint
SHB01 - Reverse command setpoint Forward
SHB02 - Scale factor for reverse 100
SHB03 - Analog pressure sensor off
SHB04 - High pr. level, forward 200
SHB05 - High pr. level, reverse 200
Counter
SHC01 - Window time for counter 60
SHC02 - Reversal counter 5
Shredder 2
Function
SHG01 - Reverse control Pressure, separate
SHG02 - Reverse stop function Going to forward
SHG03 - Delay before reversal 3.0
SHG04 - Reversal time 10.0
SHG05 - Reverse delay SHG02 3.0
SHG06 - Forward time 10.0
SHG07 - Shredder automatic dir. off
SHG08 - Forward time interval 60
SHG09 - Reverse time interval 60
SHG10 - Selection of regulated dr. Unregulated
Setpoint
SHH01 - Reverse command setpoint Forward
SHH02 - Scale factor for reverse 100
SHH03 - Analog pressure sensor off
SHH04 - High pr. level, forward 200
SHH05 - High pr. level, reverse 200
Counter
SHI01 - Window time for counter 60
SHI02 - Reversal counter 5
Synchro
Function
SYA01 - Type of synchronisation RATIO
SYA02 - Master command D1 Master - D2 Slave
Drive 1 reset
SYB01 - Counter reset command Reset by start
SYB02 - Enable of counter reset E-motors start
Drive 2 setpoint
SYC01 - Drive 2 low friction limit 0
SYC02 - Drive 2 high friction limit 200
SYC03 - Offset reset by motor start off
SYC04 - Offset for Drive 2 0.0
Drive 2 indication
SYD01 - Synchro indication limit 5
SYD02 - Sync time 1.0
Drive 2 reset
SYE01 - Counter reset command Reset by start
SYE02 - Enable of counter reset E-motors start
Master setpoint
SYF01 - Up ramp time forward 2.0
SYF02 - Down ramp time forward 2.0
SYF03 - Up ramp time reverse 2.0
SYF04 - Down ramp time reverse 2.0
Drive 1 setpoint
SYG01 - Drive 1 low friction limit 0
SYG02 - Drive 1 high friction limit 200
Pressure 1
Function
PRA01 - Pressure control off
PRA02 - Reverse dir. of ctrl action off
Page 13
E01PX10-2347.txt
PRA03 - Low pressure control off
PRA04 - High pressure control off
PRA05 - Filter time, low pr. control 5
PRA06 - Filter time, high pr. control 5
Pr. setpoint
PRB01 - Pressure setpoint Local
PRB02 - Local pressure setpoint 200
PRB03 - Low limit, pressure setpoint 25
PRB04 - High limit, pressure setpoint 25
PRB05 - Low limit, PID output 10
PRB06 - High limit, PID output 10
PRB07 - Max pressure 250
Regulator
PRC01 - Proportional regulator off
PRC02 - Integrating regulator off
PRC03 - Derivation regulator off
PRC04 - Proportional gain 0.1
PRC05 - Integration time 10.0
PRC06 - Derivation time 0.10
PRC07 - Derivation decline time 0.1
PRC08 - Filter time for pr. feedback 0.0
Pressure 2
Function
PRG01 - Pressure control off
PRG02 - Reverse dir. of ctrl action off
PRG03 - Low pressure control off
PRG04 - High pressure control off
PRG05 - Filter time, low pr. control 5
PRG06 - Filter time, high pr. control 5
Pr. setpoint
PRH01 - Pressure setpoint Local
PRH02 - Local pressure setpoint 200
PRH03 - Low limit, pressure setpoint 25
PRH04 - High limit, pressure setpoint 25
PRH05 - Low limit, PID output 10
PRH06 - High limit, PID output 10
PRH07 - Max pressure 250
Regulator
PRI01 - Proportional regulator off
PRI02 - Integrating regulator off
PRI03 - Derivation regulator off
PRI04 - Proportional gain 0.1
PRI05 - Integration time 10.0
PRI06 - Derivation time 0.10
PRI07 - Derivation decline time 0.1
PRI08 - Filter time for pr. feedback 0.0
Reading 1
Scroll menu
R1A01 - Text for reading 1 HIGH PSI (*)
R1A02 - Reading 1 REG405 (*)
R1A03 - Text for reading 2 TANKTEMP (*)
R1A05 - Text for reading 3 READING3
R1A06 - Reading 3 OFF
Page 14
E01PX10-2347.txt
Left upper
R1B01 - Reading REG102
Right upper
R1C01 - Reading REG106
Left lower
R1D01 - Reading REG109
Right lower
R1E01 - Reading REG311
Reading 2
Scroll menu
Left upper
Right upper
Left lower
Right lower
(*) Not default value
Page 15
SPIDER USERS MANUAL
Users Manual
SPIDER 2
Program Release v 2
Software Version 4.1.2
SPIDER AS
Engineering manual
Preface
04-04-02, New
Preface
Hägglunds is one of the worlds leading manufacturers of large hydraulic Drive Systems. A leading position,
made possible by unbeatable service spirit and of continuing development of both products and markets
all over the world. Our drives are to be found in most industrial and marine segments, where there are
extremely high demands for efficiency and reliability. Our main office and production plant is in Mellansel,
Sweden and we have our own sales- and representation offices in some 40 different countries.
This Engineering manual provides necessary information for Spider control system. In order to find particular
information, just search for the wanted section as listed in the table of contents. However, changes in the
equipment may occur. We therefore reserve the right to introduce amendments in the manual as we deem
necessary without notice or obligations.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will cause
personal injury or substantial property damage. Depending on the probability of the hazard, and how
serious the injury or property damage could be, there are three levels of classification.



AS-1
Spider Introduction
Engineering manual 04-04-02
1.1 Description
The Spider unit is a microcontroller based system, configurable to suit different application
needs. It is designed to match the two or three door power unit also with one door unit added.
The control system can control pumps with double coil (Denison 9A, Brueninghaus EP, Sauer
Sundstrand KA or similar pumps) or single coil in one direction (Denison 5A).
The unit can be mounted inside the power unit, in the power unit door, on the outside of the
power unit or delivered separate with wall brackets or panel flange to be wired in by the
customer. Cable sets can be supplied as an option.
The configuration of the pre-programmed system functions is done using the front panel with
help from the text displays or via a serial connection from a laptop. The configuration mode can
be protected with a password.
The Spider unit can control the system with different settings of electric motor/pump
configuration.
• One to four pumps for one drive:
EM EM EM EM
DRIVE P DRIVE P P P
EM EM EM EM EM
DRIVE P P
DRIVE P P
P P
• Two to four pumps for two drives with separate function:
EM EM
P P
DRIVE P P
DRIVE
EM EM
DRIVE P P
DRIVE
EM EM EM
DRIVE P P P
DRIVE
-------
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(7)
AS1, Introduction, Engineering manual 04-04-02
• Two to four pumps for two drives with common function. If one stops by a fault the other will
also stop:
EM EM EM
DRIVE P
DRIVE P
DRIVE P
DRIVE P
EM EM EM EM
DRIVE P P
DRIVE P P
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P
DRIVE P P
EM EM EM
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P P
DRIVE P
The Monitor function can health monitor the power unit switches and give information on the text
display about warnings or alarms. An alarm will stop the electric motor or motors if the digital
interlock output is connected via a relay to the starter interlock circuit. Up to 4 pumps can be
controlled in parallel for the same drive
M M M
M M
The Basic function has added functions for power limitation and closed loop speed feedback via
a PID-regulator. Inputs are available for analog or digital speed encoders.
The unit can also monitor analog signals on the display such as speed, E-motor current,
pressure etc.
The Shredder function has the same functions as Basic and added functions for reversing by an
overload-stopped drive. It is possible to maximise the number of reversals within a time limit and
stop the drive when exceeded. The drive can be set to change direction after an adjustable time
interval.
The Friction function has the same functions as Basic and added functions for control of two
hydraulic drives driven together with a ratio between the motors.
The Friction slave function has the same functions as Basic and added functions for control of
two hydraulic drives driven together with a ratio in relation to the master setpoint.
The Synchro function has the same functions as Basic and added functions for position control
between two hydraulic drives. It is possible by an external signal to set the angle between the
rolls. Ratio drive is also possible. This mode requires digital speed encoders.
The pressure control function output is added to the ramped flow command. The function
compares actual pressure to a setpressure and gives a positive or negative output depending on
sign of the difference and action direction of regulation.
The Spider unit front has push-buttons for start and stop of the drive, local/remote, speed
setpoint by increase and decrease in local mode, inch reverse, regulated/non-regulated drive
and auto/manual drive in shredder mode. These push-button functions can be bypassed in the
configuration of the system functions.
All inputs and outputs are configurable and can be connected to pre-programmed functions in
the setup of the system. All signals are as standard wired to contact terminals or via fieldbus port
(optional).
The digital inputs can be configured to functions for eg. start/stop, reverse, reset, monitoring of
the power unit, auxiliary monitor where it is possible to set the function and display monitor text.
The digital outputs can be configured to functions for eg. common alarm/warning, ready to use,
drive started, shredder blocked, cooler and heater control. The outputs are of dry relay contact
type.
The analog inputs can be configured to functions for eg. tank temp, speed, pressure, power for
monitoring and control. The inputs can be configured for current loop or voltage.
The analog outputs can be configured to monitor eg. speed, pressure, temp. The outputs can be
configured for current loop or voltage.
The system includes a drive monitoring function with drive time counters, alarm/warning list and
8 scalable log channels with data download via serial interface. A remote drive monitoring
system with access via GSM can be added as an option.
1.5 Ordering code
AS-2
Spider Technical data
2.1 Mechanical
2.1.1 Mechanical data
Cubicle dimension W=400mm H=300mm D=145mm

Encapsulation class IP 65
Ambient temperature -20..+70°C *
Material enclosure Stainless steel
Material front Polyester film
Mounting Wall brackets or flange
Weight 8kg
(10kg with brackets or flange)
Cable size Max 2.5mm²
* Heater supplied as option
2.1.2 Wall bracket mounting
AS2, Technical data, Engineering manual 04-04-02
2.1.3 Flange mounting
2.1.4 Polyester front

Chemical resistance to:
- Alcohols
- Dilute acids
- Dilute alkalis
- Esters
- Hydrocarbons
- Ketones
- Household cleaning agents
2.2 Supply and output voltage

2.2.1 Supply voltage
Main supply voltage Autoranging 90-132, 180-264 VAC

47-63Hz (No configuration needed)
Power consumption 175VA (150W supply unit 376 0071-802)
300VA (250W supply unit 376 0071-801)
(+50VA with heater)*
Inrush current Max 30A
Main fuse 6A
Card supply 24VDC±10% , Max 8A
Card consumption (without 320mA
Load)
2.2.2 Output voltage
Analog reference voltage +10VDC 35mA

(isolated) -10VDC 35mA
Digital input supply 1 +24VDC 0.3A
Digital encoder supply +24VDC 0.3A
Analog input supply +24VDC 0.3A
Emergency stop supply +24VDC 0.3A
Digital output supply +24VDC 0.8A
E-motor interlock supply +24VDC 0.3A
2.3 Inputs
2.3.1 Analog inputs
No Description Type Impedance

1 Speed set point Drive 1 ±0-5VDC 100kΩ
or Friction set point Drive 1 ±0-10VDC 100kΩ
(isolated) ±4-20mA 250Ω
±0-20mA 250Ω
±0-20mA 250Ω
2 Configurable analog inputs +0-5VDC 100kΩ
(isolated) +0-10VDC 100kΩ
+4-20mA 250Ω
+0-20mA 250Ω
(diffrential) +0-10VDC 100kΩ
+4-20mA 250Ω
+0-20mA 250Ω
1 Tank temp input, -29...+107ºC PT100
AS2, Technical data, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
2.3.2 Digital inputs
No Description Type Impedance Max input

1 Digital speed feedback Drive 1 logical 0=0-3,9VDC
Differential or single with logical 1=6,6-32VDC
direction signal
1 Zero position input Drive 1 logical 0=0-3,9VDC
logical 1=6,6-32VDC
direction signal
logical 1=6,6-32VDC
1 Electric motor 1 started logical 0=0-3,9VDC 1kΩ
from starter unit logical 1=6,6-32VDC
43 Configurable inputs logical 0=0-3,9VDC 3kΩ
logical 1=6,6-32VDC
1 Emergency stop input logical 0=0-4,7VDC 3kΩ
logical 1=8,0-32VDC
2.4 Outputs
2.4.1 Pump control
No Description Type Impedance Max output

4 Stroker output, dual coil PWM (Pulse width 5-100Ω** 2A*
modulated)
*Total current for all outputs 5A
**Max output reduced above 10Ω to 20/Impedance (A)
2.4.2 Digital outputs
No Description Type Max load

1 Starter interlock E-motor 1 Relay contact 3A, 30VDC, 250VAC
13 Configurable outputs Relay contact 3A, 30VDC, 250VAC
2.4.3 Analog outputs

4 Configurable analog outputs +0-10VDC 1kΩ
(isolated, needs external +2-10VDC 1kΩ
supply, min.21,0VDC) +0-20mA 500Ω
+4-20mA 500Ω
04-04-02
2.5 Communication
2.5.1 PC connection
No Description Type Connection to PC

1 RS-232 connection for setup 9-pole male D-sub Null modem cable
and drive log download
2.5.2 Fieldbus connection
No Description Type Connection

1 Connection for fieldbus module Profibus
(optional module) Modbus
AS-3
Spider Connection
Engineering manual
04-04-02
3.1 Wiring
Shielded cables are preferred for the installation.
The wire must be min 0,5mm2 for input signals and min 1mm2 for supply and output cables.
Max distance between control system and power unit is 50m.
3.2 Supply
SUPPLY VOLTAGE & HEATER

HEATER WITH THERMOSTAT
SUPPLIED AS OPTION
AS-3 Connection, Engineering manual 04-04-02
3.3 Input signals

3.3.1. Remote speed setpoint.
The input for remote speed setpoint are isolated and can be bidirectional (forward and reverse
speed setpoint) or unidirectional (forward speed setpoint and fixed reverse speed if needed).
The setpoint can be a voltage or a current signal. The selection is made with a jumper on the
board (see also AS4.3) and in the set up menu (see AS5.2.6).
SETPOINT DRIVE 1
I I
SETPOINT DRIVE 2
I I
3.3.2.1 Configurable isolated analog inputs.

The signal for the configurable analog inputs must be positive. The input can be a voltage or
a current signal. The selection is made with a jumper on the board (see also AS4.3) and in
the set up menu (see AS5.2.6).
CONFIGURABLE ANALOG INPUT 1
I I
I I
3.3.2.2 Configurable analog inputs.

a current signal. The selection is made with a jumper on the board (see AS4.5.2) and in the
set up menu (see AS5.2.6).
I I
I I
I I
I I
I I
I I
I I
CONNECTION OF ANALOG 2-WIRE SENSOR
3.3.2.3 Tank temperature analog input.

The tank temperature can be measured with a PT100 sensor.
PT-100 TANK TEMPERATURE INPUT
3.3.3. Digital speed encoder.

If a differential encoder is used and the input 2 pulse comes before the input 1 pulse, the Rpm
signal will be positive.
If a single pulse encoder is used, a low level on the direction signal will give positive sign of
the Rpm signal. If the signal has wrong sign the polarity can be changed with parameter P1I06
for drive 1 and parameter P2I06 for drive 2.
DIGITAL SPEED ENCODER DRIVE 1
3.3.4. Electric motor started inputs.

The inputs must be high (switch closed) when the motor is stopped and open at motor start.
The inputs are used for bypass of charge pressure alarm and delay of drive start.
INPUT SIGNALS FROM STARTER UNIT
3.3.5. Emergency stop input.

Emergency stop input must be connected for the system to operate. If the input is opened, the
output to fte pumps will be set to zero without ramp to destroke the pumps as quickly as
possible.The electric motor interlock contacts will open after a time delay set with parameter
DMD 0x and with a rotary switch on top left of main board (see AS4.5.4).
EMERGENCY STOP INPUT
3.3.6. Configurable digital inputs.

The input functions are configured in the set up menu (see AS5.2.3). All inputs are
configurable but the first 24 inputs are as first choice selected for monitoring of the power unit
switches.
DIGITAL INPUT SIGNALS
3.4 Output signals

3.4.1. Pump strokers.
Pumps with separate coils for A and B side can be used. If pumps with a common coil for both
directions is used, the drive can only be controlled in one direction.
3.4.2. Starter interlock outputs.

The normally open contact of the auxiliary relay must be connected in the stop circuit for the
electric motors. The output will open at alarm.
Note! The polarity for the freewheeling diode over the relay coil. The function of the diode is to
protect against induced voltage at switch off and should be mounted close to the relay coil.
STARTER INTERLOCK
3.4.3. Configurable digital outputs.

The output functions are configured in the set up menu (see AS5.2.4).
DIGITAL OUTPUT SIGNALS
Note! All outputs must be protected against induced voltage at switch off by e.g. free wheeling
diode (see 3.4.2), varistor, RC circuit or other overvoltage protection device mounted close to
the load.
3.4.4. Configurable analog outputs.

The outputs are isolated and needs external supply. If no isolation is needed the card can be
supplied from Spider terminals. The output functions are configured in the set up menu (see
AS5.2.7).
CONFIGURABLE ANALOG OUTPUT 1
3.5 Interconnection terminal

For internal connection use.
INTERCONNECTION TERMINAL
AS-3 Connection, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
3.6 Serial ports

3.6.1. SpiderCom port.
Connector for RS232 serial communication. Port is used for log data dump and for setup of system
via a PC and SpiderCom software.
SERIAL CONNECTOR PINOUT
1 2 3 4 5
6 7 8 9
Pin1 CD, Carrier detect

Pin2 RXD, Receive data
Pin3 TXD, Transmit data
Pin4 DTR, Data terminal ready
Pin5 GND, System ground
Pin6 DSR, Data set ready
Pin7 RTS, Request to send
Pin8 CTS, Clear to send
Pin9 RI, Ring indicator
3.6.2. Optional fieldbus connection.

Profibus connection for external serial control
PROFIBUS CONNECTOR PINOUT
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not connected
Pin3 B-line, Pos TXD/RXD
Pin5 GND BUS
Pin6 +5V BUS
Pin7 Not connected
Pin8 A-line, Neg TXD/RXD
Pin9 Not connected
In normal applications A-Line, B-Line and shield are used.
04-04-02
Modbus connection for external serial control
MODBUS CONNECTOR PINOUT
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not used
Pin3 Not used
Pin4 Not connected
Pin5 GND
Pin6 +5V
Pin7 RS485 B-line
Pin8 RS485 A-line
Pin9 Not connected
3.7 Terminal functions

Table of terminal functions.
Row Type Name No. Function

1 Power Input DC1 4 24V_IN (+)
3 24V_IN (+)
2 GND (-)
1 GND(-)
Pump 4 PO4 4 Common pump 4
3 Stroker conn. Pump 4. High B
2 Common pump 4
1 Stroker conn. Pump 4. High A
2 Common pump 3
2 Common pump 2
2 Common pump 1
2 Digital outputs DO1 14 Configurable Digital output 6

13 Configurable Digital output 6
2 24V_DO
1 GND

11 Common Digital output 11-13
2 24V_DO
1 GND
4 E-motor interlocks EO1 8 Interlock Electric motor 3

7 Interlock Electric motor 3
2 24V_DO
1 GND
5 E-motor started EI 8 E-motor 3 started

inputs 7 E-motor 2 started
6 E-motor 1 started
5 24V_EI
4 24V_EI
3 GND
Em stop EM 2 Em.stop
1 24V_EM
6 Digital speed DE1 8 Pulse 0 Drive 1+

encoder Drive 1 7 Pulse 2 Drive 1 -
6 Pulse 2 Drive 1+
5 Pulse 1 Drive 1 -
4 Pulse 1 Drive 1+
3 12V+
2 24V_DE
1 GND

6 Pulse 2 Drive 2+
5 Pulse 1 Drive 2 -
4 Pulse 1 Drive 2+
3 12V+
2 24V_DE
1 GND

8 Configurable DI1 8 Config input 6 (Drain filter)
digital inputs 7 Config input 5 (Low oil level in tank)
Predefined 6 Config input 4 (Min oil level in tank)
monitoring inputs 5 Config input 3 (Min oil temperature in tank)
4 Config input 2 (High oil temperature in tank)
3 Config input 1 (Max oil temperature in tank)
2 24V_DI_1
1 GND
9 Configurable DI2 12 Config input 15

digital inputs 11 Config input 14 (Work pressure, pump 2)
Predefined 10 Config input 13 (Charge pressure, pump 2)
monitoring inputs 9 Config input 12 (Suction line, pump 2)
8 Config input 11 (Return filter 100%, pump 2)
7 Config input 10 (Work pressure, pump 1)
6 Config input 9 (Charge pressure, pump 1)
5 Config input 8 (Suction line, pump 1)
3 24V_DI_1
2 24V_DI_1
1 GND

3 24V_DI_1
2 24V_DI_1
1 GND

digital inputs 11 Config input 32
10 Config input 31
9 Config input 30
8 Config input 29
7 Config input 28
6 Config input 27
5 Config input 26
4 Config input 25
3 24V_DI_2
2 24V_DI_2
1 GND

10 Config input 41
9 Config input 40
8 Config input 39
7 Config input 38
6 Config input 37
5 Config input 36
4 Config input 35
3 Config input 34
2 24V_DI_2
1 GND
13 Analog inputs AI1 12 Config input 2 -

Isolated 11 Config input 2+
10 Config input 1 -
9 Config input 1+
8 Remote speed setpoint Drive 2 -
7 Remote speed setpoint Drive 2 +
4 Isolated 10VREF -
3 Isolated 10VREF+
2 Isolated GND
1 Isolated GND

Not isolated 11 Config input 6+
10 Config input 5 -
9 Config input 5+
8 Config input 4 -
7 Config input 4+
6 Config input 3 -
5 Config input 3+
4 24V_AI
3 24V_AI
2 GND
1 GND

15 Analog inputs AI3 14 Tank temp, force high
Not isolated 13 Tank temp, sense high
12 Tank temp, sense low
11 Tank temp, force low
10 Config input 9 -
9 Config input 9+
8 Config input 8 -
7 Config input 8+
6 Config input 7 -
5 Config input 7+
4 24V_AI
3 24V_AI
2 GND
1 GND
16 Analog outputs AO2 6 Current output 4

5 Voltage output 4
4 Current output 3
3 Voltage output 3
2 24VDC (externally supplied)
1 GND (external)
AO1 6 Current output 2
5 Voltage output 2
4 Current output 1
3 Voltage output 1
1 GND (external)
17 CAN1 CA 8 DATA2-
7 NC
6 DATA2+
5 0VCAN2
CAN2 4 DATA1-
3 NC
2 DATA1+
1 0VCAN1
Spare terminals IC 6 For interconnection purpose
5 For interconnection purpose
AS-4
Spider Indication and setting
4.1 Display information

POWER UP E-MOTOR STOPPED
boot v1.1 OFF EXT

E-MOTOR STOPPED
0% 0%
0rpm 0Amp
Indication that e-motor is off
boot version
START UP TIME E-MOTOR STARTING
HÄGGLUNDS DRIVES OFF REM

SPIDER II STARTING UP
0% 0%
ver. 4.0.0 0rpm 0Amp
Indication of e-motor start
Software version
E-MOTOR STARTED
TESTING HARDWARE
SYSTEM READY TO USE
TESTING HARDWARE OFF REM

READY TO USE
0% 0%
0rpm 0Amp
DRIVE MODE
OFF REM
-> TANKTEMP 34°C <-
0% 0%
0rpm 0Amp
AS4, Indication and setting, Engineering manual 04-04-02
4.2 Information on normal drive and alarms
DRIVE INDICATION
WARN = Common Warning
ALARM = Common Alarm
INT = Interlock
ON = Drive Started
OFF = Drive Stopped
REM = Remote speed command
LOC = Local speed command
BUS = Fieldbus remote speed command
"Blank" = Open loop drive
REG = Closed loop speed feedback drive
WARN ON REM REG AUT MAN = Manual mode (Only in Shredder function)
AUT = Auto mode (only in Shredder function)
> TANKTEMP 35°C <
85 % 92 %
Scroll list shown
20.5 rpm 120 kW
Four settable registers to be displayed
ALARM INDICATION WARNING INDICATION
ALARM DRIVE 1 WARNING DRIVE 1

MIN OIL LEVEL LOW OIL LEVEL
INTERLOCK INDICATION
INTERLOCK DRIVE 1
NO EXT FEED
4.3 Reset of alarms and warnings
RESET OF ALARMS/WARNINGS
ALARM OFF REM OFF REM
E-MOTOR STOPPED E-MOTOR STOPPED
0% 0% 0% 0%
0.0 rpm 0 mA 0.0 rpm 0 mA
DRIVE 1 3 sec.
DRIVE 1
OR
OR
DRIVE 2 3 sec.
DRIVE 2
ALARM DRIVE 1
LOW CHARGE PRESS P1
NO MORE ALARMS OR
WARNINGS
MORE THAN ONE

ALARM OR WARNING
ALARM DRIVE 1
MIN OIL LEVEL
4.4 Front panel buttons

4.4.1 Set up buttons
Go down one level in display menu.
Accept a change in parameter.
Reset alarm, warning or interlock
Go up one level in display menu.

Escape without change of parameter.
Select Drive 1 scroll list (short time press)
Select Drive 1 alarm list (press for 3 sec.)

V
Scroll up in display menu.

Go to next alarm / warning.
Increase parameter.
Scroll down in display menu.

V Go to previous alarm / warning.
Decrease parameter.
Press 3 sec. to enter setup list
Inrease contrast on display
V Decrease contrast on display
4.4.2 Drive buttons
Switching between manual and auto drive mode.

MAN/AUTO (Only avaliable in Shredder function)
Switching between front panel setpoint

and external setpoint if this function
is selected.
INCREASE
Increase speed setpoint when driving
in local mode (front panel setpoint).
Decrease speed setpoint when driving

DECREASE
FORWARD
Manual forward in Shredder function.
Same
button Switching between open and closed loop
REG/UNREG
speed control when speed feedback used.
(Not avaliable in Shredder function)
Inch reverse with fixed speed.
REVERSE Manual reverse in Shredder function.
START Start of drive.
STOP Stop of drive.
P24
To displays
P23
P27
1 Jtag programming port for Microcontroller IC4
2 1 2
P25
Microcontroller TP2 1 2
TP5 TP4
1
Contact for Spidercom connection
TP23
SW1 5
TP21
TP22 P22
IC15 1
Jtag programming port for CPLD
4.5.1 Revision A
P28
TMS To memory card
CPLD TDI
TP3 TMO
TCK
GND To front keypad
+3V3
C137 C138
Watchdog
indicator TP19 TP16
TP18 TP15
D1 SW3
J1 2 TP17
TP20
W-DOG
1
ON
OFF
TP1 Display type selection

Optional Fieldbus card
TP14 Restart of program
RESET
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN

SW2
1
TP9 P47
4.5 Main card jumpers and indications
12
Logger connection
TP10
TP6
REL15
REL16
REL14
TP7
+
+ TP13
TP12
DC1
- TP11 Supply voltage
indicators
1
Jumpers for analog
P3
- Supply voltage indicators current loop inputs
Jumpers for analog TP8
REL17
current loop inputs
D170 D171 D172 D173 D174 D175 D176 D181
U
AS4, Indication and setting, Engineering manual
I Logger connections
AI6 I AI7 I AI8 I AI9 I AI3 I AI4 I AI5
DO EM EI DE DI1 DI2 AI DE D116 D117
12V 1 1 1 1 1 1 1
PO4
PO4
I I I I P43 P44 P45 P46 P40 P41 P42
SP SP AI_1 AI_2
D1 D2 + - 10V
P2
CA2
CA1
REL18
REL6
REL5
REL9
REL8
REL4
REL7
REL11
REL10
REL3
REL12
REL13
REL1
REL2
PO3
PO3
AO2
1
CA1
CA1
1
P21
P19
1
AO2
PO2
PO2
P1
IC1
IC1
P20
DO1 DO2 EO1 EI/ DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
EM
P14
PO1
PO1
P18
P9
P10
P16
P11
P15
P17
1
1
1
1
1
1
1
1
1
P7
P8
P12
P13
P6
P5
P4
1
1
1
1
1
1
DO1 DO2 EO1 EI/EM DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
05-01-21, replaces 04-04-02
6(14)
04-04-02
4.5.2 Jumpers
Function Jumper Settings

name
Signal type for speed setpoint, SP D1 Upper position = voltage signal
Drive 1 Lower position = current signal
Signal type for configurable AI1 Upper position = voltage signal
analog input 1 Lower position = current signal
Signal type for configurable AI 6 Upper position = voltage signal
4.5.3 Indicators
Function Indicator Note

name
Shutdown D1, red Normally off. Will be active by
(W-DOG) microprocessor watchdog error.
Digital output supply D170, green Normally on. Indicates supply to digital
(DO) outpus. Will be off by external short circuit
or by emergency stop.
Emergency stop supply D171, green Normally on. Will be off by external short
(EM) circuit
E-motor input supply D172, green Normally on. Will be off by external short
(EI) circuit
Encoder supply 24V D173, green Normally on. Will be off by external short
(DE) circuit
Digital input supply 1 D174, green Normally on. Will be off by external short
(DI1) circuit
(DI2) circuit
Analog input supply D176, green Normally on. Will be off by external short
(AI) circuit
(DE 12V) circuit
+10V ref. voltage for D116, green Normally on. Will be off by external short
potentiometer (+10V) circuit
-10V ref. voltage for D117, green Normally on. Will be off by external short
potentiometer (-10V) circuit
AS4, Indication and setting, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
4.5.4 Switches
Function Pot. Note

name
Emergency stop shutdown SW1 Timer for backup emergency stop
shutdown
Display type SW3-1 On = LCD display type (standard)

Off = VFD display type
SW3-2 No function
4.5.5 Contacts
Function Contact Note

name
Display P24
Front keypad P22
Memory card P23
Spidercom connection P26 RS232
Memory programming port P27 JTAG connection
CPLD programming port P28 JTAG connection
Fieldbus card connection J1 Optional card
DC supply DC1
Pump output 1 PO1 4 pole contact
Digital output 1 DO1 14 pole contact
Electric motor output EO1 8 pole contact
Electric motor input EI/EM 8 pole contact
Emergency stop input
Digital encoder 1 DE1 8 pole contact
Digital input 1 DI1 8 pole contact
Analog input 1 AI1 12 pole contact
Analog output 1 AO1 6 pole contact
Internal connection IC 6 pole contact
CAN bus 1 CA1 6 pole contact
-4.6 Power supply
24V OK
DC connection
Fuse
Main switch
Main connection
04-04-02
4.7 Fieldbus card

4.7.1 Profibus
Main board connector
Profibus connector
Termination switch
D5
S1
ON
S3 S2
1 2
LED indicators
901 901
23
23
78
78
456 456
4 3
Address switches
4.7.1.1 Indicators
Indicator Description Function Information
name
D1 Not used Not used Normal function
D2 On line Green Module is On-Line and ready, data

exchange is possible.
Off Module is not On-Line.
D3 Off line Red Module is Off-Line.
Off Module is not Off-Line.

D4 Diagnostics Red flashing 1 Hz Configuration error. Data length.
Red flashing 2 Hz Configuration error. User

parameters.
Red flashing 4 Hz Initialisation error of the Profibus

communication ASIC.
Off No error.
D5 Watchdog Green flashing 1Hz Initialized and running OK.
Green flashing 2Hz Not initialised.
Red Unspecified internal error or running

in bootloader mode.
Red flashing 1 Hz RAM failure.
Red flashing 2 Hz ASIC or FLASH failure.
Red flashing 4 Hz DPRAM failure.
04-04-02
4.7.1.2 Switches
Indicator Function Information
name
S1 Terminating switch On= Enabled (if first or last in a network)
Off= Disabled
S2 Node Address x1 for the node address setting
4.7.2 Modbus

D12
Modbus connector
Termination switch
S1
ON
S2 S3
1 2
LED indicators
3 4
1 2 3 4 5 6 7 8 1 2 3 4
Parity switches
Baudrate switches
Node Address switches
4.7.2.1 Indicators
name
D1 Processing Green flashing Receiving Query and building
response.
Off No Query
D2 Bus error Red Bus error
Off Normal operation.

D3 Bus ready Red Module is Off-Line.

D4 HW setting status Green Bus ready. Normal operation.
Red Bus timeout error.
Off Bus not initialized correctly.


in bootloader mode.

04-04-02
4.7.2.2 Switches
Indicator Function Setting Information
name
S1 Terminating switch On Enabled (if first or last in a
network)
Off Disabled
S2: 1-7 Node Address Binary value:
Switch: 1234567
0000000 Not valid
0000001 1
0000010 2
0000011 3
… …
… …
1111111 127
S2: 8 Baud rate Binary value:
S3: 1-2 Switch: 812
000 Not valid
001 1200
010 2400
011 4800
100 9600
101 19200 (Default)
110 38400
111 57600
S3: 1-2 Parity Binary value:
Switch: 34
00 Not valid
01 None(Default)
10 Even
11 Odd
4.9 Error codes

4.9.1 Program start
WARNING EEPROM READING FAILED
This error message indicates that the Spider software can't read saved parameter values from the memory
card. This error can occur if : No memory card connected, memory card defect or wrongly mounted or the
information on the memorycard is corrupt. Spider software will start with default values on parameters.
WARNING WRONG EEPROM VERSION
This error message indicates that the Spider software can't use the parameter values that's stored on
the memorycard because the parameter format stored on the memorycard not is compatible with the Spider
software used. Spider software will start with default values on parameters.
WARNING WRONG CPLD VERSION
This error message indicates that the Spider software version used not is compatible with the software
version in the CPLD (Complex Programmable Logic Device). The CPLD is used for digital in and outputs,
counters, display and Anybus. The Spider will work in an unpredictable way.
WARNING LOG INIT ERROR
This error message indicates that the Spider software can't read the real time clock, saved alarms, warnings,
drive times or setpoints from the memory card. Theese functions will not function.
This error can occur if : No memory card connected, memory card defect or wrongly mounted or the
information on the memorycard is corrupt.
WARNING 3D-LOG INIT ERROR
This error message indicates that the Spider software can't read the 3D-log on the memorycard.
The 3D -log function will not function. This error can occur if : No memorycard connected, memory card
defect or wrongly mounted or the information on the memorycard is corrupt.
4.9.2 Hardware monitoring

HW ERROR, FC 1
This test is to verify that the delay for electric motor interlock set in hardware with SW1 matches the
delay set in the Spider parameters (for electric motor interlock). If emergency stop is actuated the relays in
the hardware will open after set time 2-32 sec. (in 2 sec. steps). If this test not performes within the
below shown limits, the error message ”HW ERROR, FC 1” will be displayed.
The test is performed upon system start up.
HW delay < SW delay Software stops
HW delay > Only Warning, press a button for OK.

SW delay + 4s
HW delay > Software stops
SW delay + 5s
When the software stops both Hardware(M) time and Software(S) time is displayed in 1/10 sec so that
the times can be verified/corrected.
HW ERROR, FC 2
This test is to verify that the relay that feeds the PWM-outputs opens. If emergency stop is actuated
the Spider hardware for emergency stop open this relay. This test is performed when all e-motors are
stopped. If the relay doesn't open on this test, error message ”HW ERROR, FC 2” is displayed and
the software stops.
HW ERROR, FC 3
This test is to verify that the electric motor interlock relays opens. When electric motor interlock is
OK the relay is closed and open when interlock not is OK. If the relay not opens, error message ”HW
ERROR, FC 3” is displayed and the software stops. This test is performed at power on and once when all
electric motors are stopped.
HW ERROR, FC 4
Watchdog indication should not be acived during normal program execution. If it happens during normal
program execution, error message ”HW ERROR, FC 4” is displayed and the software stops. This test is
performed continiously.
HW ERROR, FC 5
If measured current is 50% greater than max configured current a shortcircuit is assumed,
error message ”HW ERROR, FC 5” is displayed and the software stops. This test is performed continiously.
4.9.3 Software monitoring

WATCHDOG TIMEOUT
If the software halts or executes incorrect in that way that the control loop or the user interface loop
can't execute within set time limits, error message ”WATCDOG TIMEOUT” is displayed and the software
stops. Program address where the execution stopped is also displayed.
4.9.4 Bus
BUS FAIL
Anybus function is selected but the communication does not function. This error is likely to occur if the bus
cable not is connected.
BUS HW FAIL
Anybus function is selected but the hardware is not functioning. This error is likely to occur if the bus module
is missing or defect.
AS-5
Spider Parameters V4.1.x
5.1 Parameter tree

Overview of configurable parameters.
Drive log Drive 1

Drive 2
AMA
AMB
Aux Monitor (26) Aux 1 AMC
Aux 2 AMD
Aux 3 AME
Aux 4 AMF
Setup Password MAin settings (2) Function MAA Aux 5
Configuration MAB AMG
Aux 6 AMH
Language MAC Aux 7 AMI
Protection MAD Aux 8 AMJ
Reset MAE Aux 9 AMK
Aux 10 AML
Pump Outputs (3) Pump 1 POA
Aux 11 AMM
Pump 2 POB
Contrast Aux 12 AMN
Pump 3 POC
Aux 13 AMO
Pump 4 POD
Aux 14 AMP
Friction POE
Aux 15 AMR
Digital Inputs (5) DIN Aux 16 AMS
Aux 17 AMT
Digital Outputs (9) Digital out 1 DOA Aux 18 AMU
Digital out 2 DOB Aux 19
HW Calibration Digital out 3 DOC Aux 20
Digital out 4 DOD
Digital out 5 DOE Drive Monitor (29) Start interlock DMA
Digital out 6 DOF Drive 1 DMB
Digital out 7 DOG Drive 2 DMC
Digital out 8 DOH Emotor interlock DMD
Digital out 9 DOI
Drive 1 basic (30) Setpoint D1A
Digital out 10 DOJ
Ramp D1B
Digital out 11 DOK
Regulator D1C
Digital out 12 DOL
Feedback D1D
Digital out 13 DOM
Power limitation D1E
Pulse Inputs (13) Drive 1 P1I
Drive 2 P2I
Ramp D2B
Regulator D2C
Analog Inputs (14) Setpoint 1 AIA Feedback D2D
Setpoint 2 AIB Power limitation D2E
Analog in 1 AIF
Analog in 2 AIG SHredder 1 (34) Function SHA
Analog in 3 AIH Setpoint SHB
Analog in 4 AII Counter SHC
Analog in 5 AIJ
Analog in 6 AIK SHredder 2 (35) Function SHG
Analog in 7 AIL Setpoint SHH
Analog in 8 AIM Counter SHI
Analog in 9 AIN
SYnchro (36) Function SYA
Tank temp AIP
Drive 1 reset SYB
Power limit AIR
Drive 2 setpoint SYC
Analog Outputs (19) Analog out 1 AOA Drive 2 indication SYD
Analog out 2 AOB Drive 2 reset SYE
Analog out 3 AOC Master setpoint SYF
Analog out 4 AOD Drive 1 setpoint SYG
Bus (20) Type&Function BTF PRessure 1 (37) Function PRA

Digital in BDI Pr.setpoint PRB
Analog in 1 BAA Regulator PRC
Analog in 2 BAB
Analog in 3 BAC PRessure 2 (38) Function PRG
Analog in 4 BAD Pr.setpoint PRH
Analog out BAO Regulator PRI
Pump Monitor (23) Pump 1 PMA Reading 1 (39) Scroll menu R1A
Pump 2 PMB Left upper R1B
Pump 3 PMC Right upper R1C
Pump 4 PMD Left lower R1D
Right lower R1E
Tank Monitor (25) Digital TMA
Analog TMB Reading 2 (40) Scroll menu R2A
Left upper R2B
Right upper R2C
Left lower R2D
Right lower R2E
Drive log (42) Password Time/Date

Log 1
Log 2
Log 3
Log 4
Log 5
Log 6
Log 7
Log 8
Reset time
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2 Configurable Parameters

5.2.1 Main settings
Main settings-Function
Switch Description Type Default Min Max
MAA01 System function

BASIC = Monitor and Basic function BASIC BASIC
SHREDDER = Shredder function SHREDDER
SYNCHRO = Synchro and Friction SYNCHRO
function
Main settings-Configuration
MAB01 E-motor connection for Pump 1 E-motor 1 E-motor 1

E-motor 2
E-motor 3
OFF
MAB02 E-motor connection for Pump 2 E-motor 1
E-motor 2
E-motor 3 OFF
OFF
E-motor 2
E-motor 3 OFF
OFF
E-motor 2
E-motor 3 OFF
OFF
MAB05 Drive connection for Pump 1 Drive 1 Drive 1
Drive 2
OFF
MAB06 Drive connection for Pump 2 Drive 1
Drive 2
OFF OFF
Drive 2
OFF OFF
Drive 2
OFF OFF
MAB09 Separate= One drive or two separate Separate Separate
drives
Common= Two drives with common Common
function
MAB10 Shutdown ramp time 1sec 0sec 0sec 20sec
MAB11 Emergency stop memory bypass ON/OFF OFF
Main settings-Language
MAC01 Display language selection English English

German
French
Spanish
Portuguese
Italian
Japanese
Dutch
Finnish
Swedish
Short
Chinese
Main settings-Protection
MAD01 Security code for set up menu yes/no no

MAD02 Security code change* AB12 CODE
*Characters changed with ∧ and ∨ buttons and selected with >button.
Main settings-Reset
MAE01 Reset parameters to default Y/N N
5.2.2 Pump outputs
Pump outputs-Pump1
POA01 Forward min current 1mA 0 0 1000

POA02 Forward max current 1mA (POA01) (POA01) 2000
POA03 Reverse min current 1mA 0 0 1000
POA04 Reverse max current 1mA (POA03) (POA03) 2000
POA05 Coil resistance 1ohm 40 5 100
POA06 PWM-frequency 100Hz 200 100 2000
Pump outputs-Pump2
POB01 Forward min current 1mA 0 0 1000

POB02 Forward max current 1mA (POB01) (POB01) 2000
POB03 Reverse min current 1mA 0 0 1000
POB04 Reverse max current 1mA (POB03) (POB03) 2000
POB05 Coil resistance 1ohm 40 5 100
POB06 PWM-frequency 100Hz 200 100 2000
Pump outputs-Pump3
POC01 Forward min current 1mA 0 0 1000

POC02 Forward max current 1mA (POC01) (POC01) 2000
POC03 Reverse min current 1mA 0 0 1000
POC04 Reverse max current 1mA (POC03) (POC03) 2000
POC05 Coil resistance 1ohm 40 5 100
POC06 PWM-frequency 100Hz 200 100 2000
Pump outputs-Pump4
POD01 Forward min current 1mA 0 0 1000

POD02 Forward max current 1mA (POD01) (POD01) 2000
POD03 Reverse min current 1mA 0 0 1000
POD04 Reverse max current 1mA (POD03) (POD03) 2000
POD05 Coil resistance 1ohm 40 5 100
POD06 PWM-frequency 100Hz 200 100 2000
Pump outputs-Friction
POE01 Pump friction: 0, 3, 4 0

0=off, 3=Pump 3, 4=Pump 4
POE02 Pump low friction limit 1% 0 0 300
POE03 Pump high friction limit 1% 200 0 300
POE04 Friction up ramp time 0.1sec 2.0 0.0 600.0
POE05 Friction down ramp time 0.1sec 2.0 0.0 600.0
Digital Inputs
Switch Description Type Default
DIN01 Digital input 1, terminal DI1-3 * 08 MAX TEMP

DIN02 Digital input 2, terminal DI1-4 * 08 HI TEMP
DIN03 Digital input 3, terminal DI1-5 * 08 MIN TEMP
DIN04 Digital input 4, terminal DI1-6 * 07 MN LEVEL
DIN05 Digital input 5, terminal DI1-7 * 07 LO LEVEL
DIN06 Digital input 6, terminal DI1-8 * 06 DRF 100
DIN07 Digital input 7, terminal DI2-4 * 06 RF 100P1
DIN08 Digital input 8, terminal DI2-5 * 05 SUCTION1
DIN09 Digital input 9, terminal DI2-6 * 03 C PRB P1
DIN10 Digital input 10, terminal DI2-7 * 01 H APR P1
DIN15 Digital input 15, terminal DI2-12 * OFF
DIN27 Digital input 27, terminal DI4-6v * OFF
* Possible digital input function settings:

01 H APR P1 High pressure A-side monitor function for pump 1
01 H BPR P1 High pressure B-side monitor function for pump 1
02 H APR D1 High pressure A-side monitor function for drive 1

02 H BPR D1 High pressure B-side monitor function for drive 1
02 H APR 12 High pressure A-side monitor function for drive 1 and 2
02 H BPR 12 High pressure B-side monitor function for drive 1 and 2
03 C PRA P1 Low charge pressure A-side monitor function for pump 1

03 C PRB P1 Low charge pressure B-side monitor function for pump 1
04 C PRA D1 Low charge pressure A-side monitor function for drive 1

04 C PRB D1 Low charge pressure B-side monitor function for drive 1
05 SUCTION1 Suction line monitor for pump 1

06 RF 75P1 Monitor of return filter for pump 1 clogged to 3/4

06 RF 100P1 Monitor of return filter for pump 1 fully clogged
06 DRF 75 Monitor of drain filter clogged to 3/4
06 DRF 100 Monitor of drain filter fully clogged
06 F TEMP Interlock of filter warning inputs
07 LO LEVEL Low oil level monitor for tank

07 MN LEVEL Min oil level monitor for tank
08 MAX TEMP Max oil temp monitor for tank

08 HI TEMP High oil temp monitor for tank
08 MIN TEMP Low oil temp monitor for tank
09 ALARM R Remote reset of alarms and warnings

09 BUS R Reset of alarms and warnings via bus
09 BUS 1 Switching to Bus command signals, Drive 1
09 BUS M Switching to Bus command signal, External master
10 SHR A D1 Shredder forward stop, Drive 1

10 SHR B D1 Shredder reverse stop, Drive 1
10 SHR 1+2A Shredder forward stop, Drive 1 and 2
10 SHR 1+2B Shredder forward stop, Drive 1 and 2
10 INTERV1 Interval control of shredder, Drive 1
10 SH RES 1 External reset of Shredder blocked function, Drive 1
10 SH RES12 External reset of Shredder blocked function, Drive 1 and 2
11 PL1 Activate power limitation for Drive 1

12 RES EN 1 External enable of counter reset in Synchro mode, Drive 1

12 RES EN2 External enable of counter reset in Synchro mode, Drive 2
12 FRICTION Friction drive in Synchro counter mode
12 INV M Inverting of master speed command in Synchro mode, Drive 1
13 AUX 1 Connected to Monitor Auxiliary 1

13 AUX 2 Connected to Monitor Auxiliary input 2
14 START 1 Drive start in Remote mode, Drive 1

14 START 12 Drive start in Remote mode, Drive 1 and Drive 2
NOTE1
14 L START1 Drive start in Local mode, Drive 1
NOTE1
14 L STOP1 Drive stop in Local mode, Drive 1
NOTE1
NOTE1
15 FORW 1 Forward drive with fixed speed, Drive 1

15 REV 1 Reverse drive with fixed speed, Drive 1
15 FORW 1+2 Forward drive with fixed speed, Drive 1 and Drive 2
15 REV 1+2 Reverse drive with fixed speed, Drive 1 and Drive 2
15 L REV 1 Local Reverse drive with fixed speed, Drive 1
15 L FORW 1 Local forward drive in manual mode, Shredder Drive 1
15 INV 1 Reverse with inverted command at unidirectional command, Drive 1
16 SP UP1 Increase set point in Local mode, Drive 1

16 SP DN1 Decrease set point in Local mode, Drive 1
16 SP RES1 Reset of set point in Local mode, Drive 1
16 REM 1 Activated input = remote mode Drive 1, Open input = local mode
16 REM 1+2 Activated input = remote mode Drive 1 and 2, Open input = local mode
17 AUTO 1 Activated input = auto mode Drive 1, Open input = manual mode
17 AUTO 1+2 Activated input = auto mode Drive 1 and 2, Open input = manual mode
18 REG 1 Activated input = Closed loop speed feedback active Drive 1, Open input = Open loop
18 REG 1+2 Activated input = Closed loop speed feedback active Drive 1+2, Open input = Open loop
18 ERR1 RES External reset of Error too large function, Drive 1
18 ERR1+2 R External reset of Error too large function, Drive 1 and 2
19 EMOTOR 1 High temp electric motor 1 monitor function

20 PR REM 1 Switching between local and remote pressure setpoint, drive 1

20 PR HI 1 Force pressure output to high level, drive 1
20 PR LO 1 Force pressure output to low level, drive 1
20 PR ON 1 Switch on pressure regulator, drive 1
21 OFF Not used

NOTE1
The input will be active for drive start/stop in:
− local mode
− in remote mode if a digital input not is used for start
Digital Outputs -Digital out 1

DOA01 Digital output function * OFF

DOA02 Inverted function yes/no no
DOA03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOA04 Delay function for output
ON=On delay 1
OFF=Off delay 2
PULSE=Output changes during delay
time
NO=No delay NO

DOB01 Digital output function * OFF

DOB02 Inverted function yes/no no
DOB03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOB04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOC01 Digital output function * OFF

DOC02 Inverted function yes/no no
DOC03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOC04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOD01 Digital output function * OFF

DOD02 Inverted function yes/no no
DOD03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOD04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOE01 Digital output function * OFF

DOE02 Inverted function yes/no no
DOE03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOE04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOF01 Digital output function * OFF

DOF02 Inverted function yes/no no
DOF03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOF04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOG01 Digital output function * OFF

DOG02 Inverted function yes/no no
DOG03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOG04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOH01 Digital output function * OFF

DOH02 Inverted function yes/no no
DOH03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOH04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOI01 Digital output function * OFF

DOI02 Inverted function yes/no no
DOI03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOI04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOJ01 Digital output function * OFF

DOJ02 Inverted function yes/no no
DOJ03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOJ04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOK01 Digital output function * OFF

DOK02 Inverted function yes/no no
DOK03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOK04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOL01 Digital output function * OFF

DOL02 Inverted function yes/no no
DOL03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOL04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO

DOM01 Digital output function * OFF

DOM02 Inverted function yes/no no
DOM03 Delay time for digital output 0,1sec 5,0 0,0 60,0
DOM04 Delay function for output
ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO
* Possible function settings:

01 A1 Alarm, Drive 1
01 A1+A2 Alarm, Drive 1 or Drive2
01 W 1 Warning, Drive 1
01 W1+W2 Warning, Drive 1 or Drive 2
01 INT 1 Interlock, Drive 1
01 INT 1+2 Interlock, Drive 1 or Drive 2
02 START 1 Drive 1 started

02 START1+2 Drive 1 or Drive 2 started
02 START1*2 Drive 1 and Drive 2 started
03 READY 1 Ready to use, Drive1 (also to be used for Fail safe valve, Drive 1)
03 READY1+2 Drive 1 or Drive 2 ready
03 READY1*2 Drive 1 and Drive 2 ready
04 REMOTE 1 Drive 1 in remote mode

05 AUTO 1 Drive 1 in automatic mode (Shredder)

05 REG 1 Drive 1 in regulated mode (Basic and Synchro)
06 PLIM 1 Power limit active, Drive 1

06 PLIM 1+2 Power limit active, Drive 1 or Drive 2
06 PLIM Power limit active
07 FORW 1 Drive 1 running forward (positive command signal)

07 REV 1 Drive 1 running reverse (negative command signal)
08 C ZERO Indication for found zero position in Synchro counter function (synchro activated)
08 SYNCHRO Synchro within limits set in parameter L22
09 AOUT 1- Selected register reading for analogue output 1 has negative sign
10 EMOT D1 Electric motor(s) for drive 1 started

10 EMOTD1+2 Electric motor(s) for drive 1 or 2 started
10 EMOTD1*2 Electric motor(s) for drive 1 and 2 started
11 LOW TEMP Low temp active indicator

11 HI TEMP High temp active indicator
11 MAX TEMP Max temp active indicator
11 COOL CONI Cooler control interlocked by electric motor start when using analog temp sensor
11 COOL COND Cooler control without interlock when using analog temp sensor
11 HEAT CON Heater control when using analog temp sensor
11 FLUSHCON Flushing control when using analog temp sensor
12 P1 C ACT Pressure control active, drive 1

12 P1 HI CA Pressure control high active, drive 1

12 P1 LO CA Pressure control low active, drive 1
13 SH BLCK1 Shredder blocked, drive 1

14 AUX1 Auxillary function 1 active

OFF Not used
5.2.5 Pulse inputs
Pulse inputs-Drive 1
P1I01 Pulses/rev 1 1000 1 10000

P1I02 Units for REG109 * rpm
P1I03 Number of decimals for REG109 1 0 0 2
P1I04 Scaling for REG109 0.01 1.00 0.01 20.00
P1I05 Filter time for speed reading 0.1sec 0.0 0.0 5.0
P1I06 Polarity for digital speed signal
1=Normal 1 1
2=Inverted 2
P1I07 Encoder type
1=Quad 1 1
2=Single pulse with direction 2
3=Single pulse without direction 3
P2I01 Pulses/rev 1 1000 1 10000

1=Normal 1 1
2=Inverted 2
P2I07 Encoder type
1=Quad 1 1
* Possible units of measure settings: rpm, m/m, m/s, f/m, f/s
5.2.6 Analog inputs
Analog inputs-Setpoint 1 (isolated)

AIA01 Input type, speed Set point Drive 1 * 4-20mA

AIA02 Zero point adjustment Set point Drive1 1bit 0bit -102bit 102bit
AIA03 Max point adjustment Set point Drive1 1bit 0bit -102bit 102bit
AIA04 Reading for REG101 % %
%=% value Actual
Actual = Actual external input value
(AIA01)

AIB01 Input type, speed Set point Drive 2 * 4-20mA

AIB02 Zero point adjustment Set point Drive2 1bit 0bit -102bit 102bit
AIB03 Max point adjustment Set point Drive2 1bit 0bit -102bit 102bit
AIB04 Reading for REG201 % %
%=% value Actual
(AIB01)
Analog inputs-Analog in 1 (isolated)

AIF01 Input type * 4-20mA

AIF02 Zero point adjustment 1bit 0bit -102bit 102bit
AIF03 Max point adjustment 1bit 0bit -102bit 102bit
AIF04 Min input, REG401 1 0 -1000 2000
AIF05 Max input, REG401 1 200 (AIF04) 9999
AIF06 Units for REG401 *** bar
AIF07 Number of decimals for REG401 1 0 0 2
AIF08 Scaling for REG401 0.01 1.00 0.01 20.00
AIF09 Function for input ***** OFF
AIF10 High indication level AIF07 AIF05 AIF04 AIF05
AIF11 Low indication level AIF07 AIF04 AIF04 AIF05
AIF12 Function for min indication at 4-20mA ****** OFF
input type
AIF13 Function for high indication ** OFF
AIF14 Function for low indication ** OFF
Analog inputs- Analog in 2 (isolated)

AIG01 Input type * 4-20mA

AIG02 Zero point adjustment 1bit 0bit -102bit 102bit
AIG03 Max point adjustment 1bit 0bit -102bit 102bit
AIG04 Min input, REG402 1 0 -1000 2000
AIG05 Max input, REG402 1 200 (AIG04) 9999
AIG06 Units for REG402 *** bar
AIG07 Number of decimals for REG402 1 0 0 2
AIG08 Scaling for REG402 0.01 1.00 0.01 20.00
AIG09 Function for input ***** OFF
AIG10 High indication level AIG07 AIG05 AIG04 AIG05
AIG11 Low indication level AIG07 AIG04 AIG04 AIG05
AIG12 Function for min indication at 4-20mA ****** OFF
input type
AIG13 Function for high indication ** OFF
AIG14 Function for low indication ** OFF
Analog inputs- Analog in 3

AIH01 Input type * 4-20mA

AIH02 Zero point adjustment 1bit 0bit -102bit 102bit
AIH03 Max point adjustment 1bit 0bit -102bit 102bit
AIH04 Min input, REG403 1 0 -1000 2000
AIH05 Max input, REG403 1 200 (AIH04) 9999
AIH06 Units for REG403 *** bar
AIH07 Number of decimals for REG403 1 0 0 2
AIH08 Scaling for REG403 0.01 1.00 0.01 20.00
AIH09 Function for input ***** OFF
AIH10 High indication level AIH07 AIH05 AIH04 AIH05
AIH11 Low indication level AIH07 AIH04 AIH04 AIH05
AIH12 Function for min indication at 4-20mA ****** OFF
input type
AIH13 Function for high indication ** OFF
AIH14 Function for low indication ** OFF

AII01 Input type * 4-20mA

AII02 Zero point adjustment 1bit 0bit -102bit 102bit
AII03 Max point adjustment 1bit 0bit -102bit 102bit
AII04 Min input, REG404 1 0 -1000 2000
AII05 Max input, REG404 1 200 (AII04) 9999
AII06 Units for REG404 *** bar
AII07 Number of decimals for REG404 1 0 0 2
AII08 Scaling for REG404 0.01 1.00 0.01 20.00
AII09 Function for input ***** OFF
AII10 High indication level AII07 AII05 AII04 AII05
AII11 Low indication level AII07 AII04 AII04 AII05
AII12 Function for min indication at 4-20mA ****** OFF
input type
AII13 Function for high indication ** OFF
AII14 Function for low indication ** OFF

AIJ01 Input type * 4-20mA

AIJ02 Zero point adjustment 1bit 0bit -102bit 102bit
AIJ03 Max point adjustment 1bit 0bit -102bit 102bit
AIJ04 Min input, REG405 1 0 -1000 2000
AIJ05 Max input, REG405 1 200 (AIJ04) 9999
AIJ06 Units for REG405 *** bar
AIJ07 Number of decimals for REG405 1 0 0 2
AIJ08 Scaling for REG405 0.01 1.00 0.01 20.00
AIJ09 Function for input ***** OFF
AIJ10 High indication level AIJ07 AIJ05 AIJ04 AIJ05
AIJ11 Low indication level AIJ07 AIJ04 AIJ04 AIJ05
AIJ12 Function for min indication at 4-20mA ****** OFF
input type
AIJ13 Function for high indication ** OFF
AIJ14 Function for low indication ** OFF

AIK01 Input type * 4-20mA

AIK02 Zero point adjustment 1bit 0bit -102bit 102bit
AIK03 Max point adjustment 1bit 0bit -102bit 102bit
AIK04 Min input, REG406 1 0 -1000 2000
AIK05 Max input, REG406 1 200 (AIK04) 9999
AIK06 Units for REG406 *** bar
AIK07 Number of decimals for REG406 1 0 0 2
AIK08 Scaling for REG406 0.01 1.00 0.01 20.00
AIK09 Function for input ***** OFF
AIK10 High indication level AIK07 AIK05 AIK04 AIK05
AIK11 Low indication level AIK07 AIK04 AIK04 AIK05
AIK12 Function for min indication at 4-20mA ****** OFF
input type
AIK13 Function for high indication ** OFF
AIK14 Function for low indication ** OFF

AIL01 Input type * 4-20mA

AIL02 Zero point adjustment 1bit 0bit -102bit 102bit
AIL03 Max point adjustment 1bit 0bit -102bit 102bit
AIL04 Min input, REG407 1 0 -1000 2000
AIL05 Max input, REG407 1 200 (AIL04) 9999
AIL06 Units for REG407 *** bar
AIL07 Number of decimals for REG407 1 0 0 2
AIL08 Scaling for REG407 0.01 1.00 0.01 20.00
AIL09 Function for input ***** OFF
AIL10 High indication level AIL07 AIL05 AIL04 AIL05
AIL11 Low indication level AIL07 AIL04 AIL04 AIL05
AIL12 Function for min indication at 4-20mA ****** OFF
input type
AIL13 Function for high indication ** OFF
AIL14 Function for low indication ** OFF

AIM01 Input type * 4-20mA

AIM02 Zero point adjustment 1bit 0bit -102bit 102bit
AIM03 Max point adjustment 1bit 0bit -102bit 102bit
AIM04 Min input, REG408 1 0 -1000 2000
AIM05 Max input, REG408 1 200 (AIM04) 9999
AIM06 Units for REG408 *** bar
AIM07 Number of decimals for REG408 1 0 0 2
AIM08 Scaling for REG408 0.01 1.00 0.01 20.00
AIM09 Function for input ***** OFF
AIM10 High indication level AIM07 AIM05 AIM04 AIM0
5
AIM11 Low indication level AIM07 AIM04 AIM04 AIM0
5
AIM12 Function for min indication at 4-20mA ****** OFF
input type
AIM13 Function for high indication ** OFF
AIM14 Function for low indication ** OFF

AIN01 Input type * 4-20mA

AIN02 Zero point adjustment 1bit 0bit -102bit 102bit
AIN03 Max point adjustment 1bit 0bit -102bit 102bit
AIN04 Min input, REG409 1 0 -1000 2000
AIN05 Max input, REG409 1 200 (AIN04) 9999
AIN06 Units for REG409 *** bar
AIN07 Number of decimals for REG409 1 0 0 2
AIN08 Scaling for REG409 0.01 1.00 0.01 20.00
AIN09 Function for input ***** OFF
AIN10 High indication level AIN07 AIN05 AIN04 AIN05
AIN11 Low indication level AIN07 AIN04 AIN04 AIN05
AIN12 Function for min indication at 4-20mA ****** OFF
input type
AIN13 Function for high indication ** OFF
AIN14 Function for low indication ** OFF
Analog inputs-Tank temp

AIP01 Zero point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP02 Max point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP03 Units for REG410 **** °C
Analog inputs-Power limit

AIR01 Level for power limitation, E-motor 1 1 400 0 1250

* Possible input type settings:

4-20mA
0-20mA
0-5V
0-10V
** Possible function settings:

13 AUX1-AUX20 Auxiliary monitor function



05 SHPRA D1 Shredder pressure A-side function for drive 1

05 SHPRB D1 Shredder pressure B-side function for drive 1
OFF Not used
*** Possible units of measure settings: rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm, A, kW, hp, °, %
rps, lpm, gpm, mm, “, l, gal
**** Possible units of measure settings: °C, °F
***** Possible function settings:

EC1 = Electric motor 1 current (A)
AS1 = Analogue speed, Drive 1 (rpm)
AS1+2 = Analogue speed, Drive 1 and Drive 2 (rpm)
SP1 = Shredder pressure, Drive 1 (bar)
SM = Synchro master speed setpoint, Drive 2 (%)
SO = Synchro offset, Drive 2(°)
SP1+2 = Shredder pressure, Drive 1 and Drive 2 (bar)
PR1 = Actual pressure for pressure control, Drive 1 (bar)
PR1+2 = Actual pressure for pressure control, Drive 1 and Drive 2 (bar)
PR1 SET = Set pressure for pressure control, Drive 1 (bar)
TANK A = Tank analog monitor function (°C)
P FRICT = Friction control of pump (%)
OFF = Not used
****** Possible function settings:

AUX1-AUX20 Auxiliary monitor function
Analog outputs-Analog out 1

AOA01 Analog output, terminal xx(V), xx(mA) * OFF

AOA02 4-20mA or 2-10V output ON/OFF** ON
AOA03 Zero point adjustment 1bit 0bit -65bit 65bit
AOA04 Max point adjustment 1bit 0bit -65bit 65bit
Analog outputs- Analog out 2

AOB01 Analog output, terminal xx(V), xx(mA) * OFF

AOB02 4-20mA or 2-10V output ON/OFF** ON
AOB03 Zero point adjustment 1bit 0bit -65bit 65bit
AOB04 Max point adjustment 1bit 0bit -65bit 65bit

AOC01 Analog output, terminal xx(V), xx(mA) * OFF

AOC02 4-20mA or 2-10V output ON/OFF** ON
AOC03 Zero point adjustment 1bit 0bit -65bit 65bit
AOC04 Max point adjustment 1bit 0bit -65bit 65bit

AOD01 Analog output, terminal xx(V), xx(mA) * OFF

AOD02 4-20mA or 2-10V output ON/OFF** ON
AOD03 Zero point adjustment 1bit 0bit -65bit 65bit
AOD04 Max point adjustment 1bit 0bit -65bit 65bit
* Possible register readings for output:

Drive 1 Pump signals
REG101 = Remote input command REG350 = Pump friction
REG102 = Speed setpoint
REG103 = Input command
REG104 = Feed forward command Analog in
REG105 = Error signal REG401 = Analog in 1
REG106 = Amplifier command REG402 = Analog in 2
REG109 = Digital speed REG403 = Analog in 3
REG110 = Speed feedback REG404 = Analog in 4
REG111 = Pressure command REG405 = Analog in 5
REG112 = Regulated pressure command REG406 = Analog in 6
REG113 = Pressure compensation REG407 = Analog in 7
REG114 = Master command REG408 = Analog in 8
REG409 = Analog in 9
Drive 2 REG410 = Tank temp
REG201 = Remote input command
REG202 = Speed setpoint Bus command in
REG203 = Input command REG501 = Bus in 1
REG204 = Feed forward command REG502 = Bus in 2
REG205 = Error signal REG503 = Bus in 3
REG206 = Amplifier command
REG209 = Digital speed
REG504 = Bus in 4
REG210 = Speed feedback
OFF =Output off
REG211 = Pressure command
REG212 = Regulated pressure command
** Possible output settings
REG213 = Pressure compensation
OFF = 0-20mA or 0-10V output
REG214 = Offset (Synchro)
ON = 4-20mA or 2-10V output
5.2.8 Bus
Bus – Type&Function
BTF01 Type of bus communication OFF OFF

Profibus
Modbus
BTF02 Max communication drop time 1s 1 0 10
BTF03 Function at communication drop Alarm
Interlock Interlock
Bus - Digital Inputs

BDI01 Digital input 1 * OFF

* Possible digital input function settings: Same as Digital in (DIN)
Bus – Analog in 1
BAA01 Min input, REG501 1 0 0 100

BAA02 Max input, REG501 1 200 (BAA01) 9999
BAA03 Units for REG501 ** %
BAA04 Number of decimals for REG501 1 0 0 2
BAA05 Function for input *** OFF
Bus – Analog in 2
BAB01 Min input, REG502 1 0 0 100

BAB02 Max input, REG502 1 200 (BAB01) 9999
BAB03 Units for REG502 ** %
BAB04 Number of decimals for REG502 1 0 0 2
BAB05 Function for input *** OFF
Bus – Analog in 3
BAC01 Min input, REG503 1 0 0 100

BAC02 Max input, REG503 1 200 (BAC01) 9999
BAC03 Units for REG503 ** °
BAC04 Number of decimals for REG503 1 0 0 2
BAC05 Function for input *** OFF
Bus – Analog in 4
BAD01 Min input, REG504 1 0 0 100

BAD02 Max input, REG504 1 200 (BAD01) 9999
BAD03 Units for REG504 ** bar
BAD04 Number of decimals for REG504 1 0 0 2
BAD05 Function for input *** OFF
** Possible units of measure settings: %, rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm,
A, kW, hp, °, rps, lpm, gpm
*** Possible function settings:
BSO = Synchro offset (Synchro function)
BP1 = Pressure setpoint, Drive 1 (Pressure function)
BMS = Master speed setpoint (Synchro function)
PF = Pump friction
OFF = Not used
Bus – Analog out

BAK01 Analog output register **** OFF

**** Possible register readings for output:

Drive 1 REG109 = Digital speed
REG101 = Remote input command REG110 = Speed feedback
REG102 = Speed setpoint REG111 = Pressure command
REG103 = Input command REG112 = Regulated pressure command
REG104 = Feed forward command REG113 = Pressure compensation
REG105 = Error signal REG114 = Master command

REG203 = Input command Analog in
REG204 = Feed forward command REG401 = Analog in 1
REG214 = Offset (Synchro) REG409 = Analog in 9
REG410 = Tank temp
OFF =Output off
5.2.9 Pump monitor
Pump monitor-Pump 1
PMA01 Charge pressure interlock delay 1 5, 10, 15, 5sec

20, 25sec
PMA02 Delay time, Charge pressure A-side * 0.5sec
PMA03 Delay time, Charge pressure B-side * 0.5sec
PMA04 Delay time, Suction line * 0sec
PMA05 Delay time, Return filter 75% warning ** 7sec
PMA07 Return filter alarm **** Off
PMA08 Delay time, High A-side work pressure *** 7sec
PMA09 Memory bypass, A-side work pressure On/Off Off
PMA10 Delay time, High B-side work pressure *** 7sec
PMA11 Memory bypass, B-side work pressure On/Off Off
PMA12 Signal plausibility check On/Off On
PMA13 Error limits between input and output 1% 50% 5% 120%
PMA14 Analog pressure sensor On/Off Off
Pump monitor-Pump 2
PMB01 Charge pressure interlock delay 1 5, 10, 15, 5sec

20, 25sec
PMB02 Delay time, Charge pressure A-side * 0.5sec
PMB03 Delay time, Charge pressure B-side * 0.5sec
PMB04 Delay time, Suction line * 0sec
PMB05 Delay time, Return filter 75% warning ** 7sec
PMB07 Return filter alarm **** Off
PMB08 Delay time, High A-side work pressure *** 7sec
PMB09 Memory bypass, A-side work pressure On/Off Off
PMB10 Delay time, High B-side work pressure *** 7sec
PMB11 Memory bypass, B-side work pressure On/Off Off
PMB12 Signal plausibility check On/Off On
PMB13 Error limits between input and output 1% 50% 5% 120%
PMB14 Analog pressure sensor On/Off Off
Pump monitor-Pump 3
PMC01 Charge pressure interlock delay 1 5, 10, 15, 5sec

20, 25sec
PMC02 Delay time, Charge pressure A-side * 0.5sec
PMC03 Delay time, Charge pressure B-side * 0.5sec
PMC04 Delay time, Suction line * 0sec
PMC05 Delay time, Return filter 75% warning ** 7sec
PMC07 Return filter alarm **** Off
PMC08 Delay time, High A-side work pressure *** 7sec
PMC09 Memory bypass, A-side work pressure On/Off Off
PMC10 Delay time, High B-side work pressure *** 7sec
PMC11 Memory bypass, B-side work pressure On/Off Off
PMC12 Signal plausibility check On/Off On
PMC13 Error limits between input and output 1% 50% 5% 120%
PMC14 Analog pressure sensor On/Off Off
Pump monitor-Pump 4
PMD01 Charge pressure interlock delay 1 5, 10, 15, 5sec

20, 25sec
PMD02 Delay time, Charge pressure A-side * 0.5sec
PMD03 Delay time, Charge pressure B-side * 0.5sec
PMD04 Delay time, Suction line * 0sec
PMD05 Delay time, Return filter 75% warning ** 7sec
PMD07 Return filter alarm **** Off
PMD08 Delay time, High A-side work pressure *** 7sec
PMD09 Memory bypass, A-side work pressure On/Off Off
PMD10 Delay time, High B-side work pressure *** 7sec
PMD11 Memory bypass, B-side work pressure On/Off Off
PMD12 Signal plausibility check On/Off On
PMD13 Error limits between input and output 1% 50% 5% 120%
PMD14 Analog pressure sensor On/Off Off
* Possible delay time settings: 0 / 0.1 / 0.5 /1.0 seconds

** Possible delay time settings: 7.0 /10.0 / 30.0 / 60.0 seconds, 3.0 / 5.0 / 8.0 / 10.0 / 12.0 / 15.0 minutes
*** Possible delay time settings: 0 / 1.0 / 5.0 / 7.0 / 10.0 / 20.0 / 30.0 / 60.0 seconds
**** Possible delay time settings: 2, 4, ..., 22, 24h, Off
5.2.10 Tank monitor
Tank monitor-Digital
TMA01 Delay time, Low oil level warning * 0sec

TMA02 Delay time, Min oil level alarm * 0sec
TMA03 Delay time, Min temp alarm * 0sec
TMA04 Delay time, High temp warning * 0sec
TMA05 Delay time, Max temp alarm * 0.5sec
TMA06 Delay time, Drain filter 75% warning ** 7sec
TMA08 Drain filter alarm *** off
TMA09 Min oil temp function A, W, Off A
Tank monitor-Analog
TMB01 Analog temp sensor on/off on

TMB02 Not used
TMB03 Max oil temp alarm level 1 60°C 40°C 75°C
TMB04 High oil temp warning level 1 55°C 40°C 70°C
TMB05 Cooling temp on level (rising) 1 40°C 30°C 40°C
TMB06 Cooling hysteresis 1 3°C 0°C 5°C
TMB07 Filter interlock temp level 1 0°C 0°C 50°C
TMB08 Heating temp on level (falling) 1 15°C 5°C 20°C
TMB09 Heating hysteresis 1 3°C 0°C 5°C
TMB10 Min oil temp alarm level 1 10°C 0°C 15°C
TMB11 Flushing temp on level (falling) 1 30°C 5°C 30°C
TMB12 Flushing hysteresis 1 3°C 0°C 5°C

*** Possible delay time settings: 2, 4, ..., 22, 24h, Off
5.2.11 Aux monitor
Aux monitor-Aux1
AMA01 Aux function * W D1

AMA02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMA03 Aux memory bypass on/off off
AMA04 Aux configurable text *** AUX1
AMA05 Aux inverted input on/off off
Aux monitor-Aux2
AMB01 Aux function * W D1

AMB02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMB03 Aux memory bypass on/off off
AMB04 Aux configurable text *** AUX2
AMB05 Aux inverted input on/off off
Aux monitor-Aux3
AMC01 Aux function * W D1

AMC02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMC03 Aux memory bypass on/off off
AMC04 Aux configurable text *** AUX3
AMC05 Aux inverted input on/off off
Aux monitor-Aux4
AMD01 Aux function * W D1

AMD02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMD03 Aux memory bypass on/off off
AMD04 Aux configurable text *** AUX4
AMD05 Aux inverted input on/off off
Aux monitor-Aux5
AME01 Aux function * W D1

AME02 Aux delay time, 0,1sec 1,0 0,1 900,0
AME03 Aux memory bypass on/off off
AME04 Aux configurable text *** AUX5
AME05 Aux inverted input on/off off
Aux monitor-Aux6
AMF01 Aux function * W D1

AMF02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMF03 Aux memory bypass on/off off
AMF04 Aux configurable text *** AUX6
AMF05 Aux inverted input on/off off
Aux monitor-Aux7
AMG01 Aux function * W D1

AMG02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMG03 Aux memory bypass on/off off
AMG04 Aux configurable text *** AUX7
AMG05 Aux inverted input on/off off
Aux monitor-Aux8
AMH01 Aux function * W D1

AMH02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMH03 Aux memory bypass on/off off
AMH04 Aux configurable text *** AUX8
AMH05 Aux inverted input on/off off
Aux monitor-Aux9
AMI01 Aux function * W D1

AMI02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMI03 Aux memory bypass on/off off
AMI04 Aux configurable text *** AUX9
AMI05 Aux inverted input on/off off
Aux monitor-Aux10
AMJ01 Aux function * W D1

AMJ02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMJ03 Aux memory bypass on/off off
AMJ04 Aux configurable text *** AUX10
AMJ05 Aux inverted input on/off off
Aux monitor-Aux11
AMK01 Aux function * W D1

AMK02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMK03 Aux memory bypass on/off off
AMK04 Aux configurable text *** AUX11
AMK05 Aux inverted input on/off off
Aux monitor-Aux12
AML01 Aux function * W D1

AML02 Aux delay time, 0,1sec 1,0 0,1 900,0
AML03 Aux memory bypass on/off off
AML04 Aux configurable text *** AUX12
AML05 Aux inverted input on/off off
Aux monitor-Aux13
AMM01 Aux function * W D1

AMM02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMM03 Aux memory bypass on/off off
AMM04 Aux configurable text *** AUX13
AMM05 Aux inverted input on/off off
Aux monitor-Aux14
AMN01 Aux function * W D1

AMN02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMN03 Aux memory bypass on/off off
AMN04 Aux configurable text *** AUX14
AMN05 Aux inverted input on/off off
Aux monitor-Aux15
AMO01 Aux function * W D1

AMO02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMO03 Aux memory bypass on/off off
AMO04 Aux configurable text *** AUX15
AMO05 Aux inverted input on/off off
Aux monitor-Aux16
AMP01 Aux function * W D1

AMP02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMP03 Aux memory bypass on/off off
AMP04 Aux configurable text *** AUX16
AMP05 Aux inverted input on/off off
Aux monitor-Aux17
AMQ01 Aux function * W D1

AMQ02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMQ03 Aux memory bypass on/off off
AMQ04 Aux configurable text *** AUX17
AMQ05 Aux inverted input on/off off
Aux monitor-Aux18
AMR01 Aux function * W D1

AMR02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMR03 Aux memory bypass on/off off
AMR04 Aux configurable text *** AUX18
AMR05 Aux inverted input on/off off
Aux monitor-Aux19
AMS01 Aux function * W D1

AMS02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMS03 Aux memory bypass on/off off
AMS04 Aux configurable text *** AUX19
AMS05 Aux inverted input on/off off
Aux monitor-Aux20
AMT01 Aux function * W D1

AMT02 Aux delay time, 0,1sec 1,0 0,1 900,0
AMT03 Aux memory bypass on/off off
AMT04 Aux configurable text *** AUX20
AMT05 Aux inverted input on/off off
* Possible function settings: A D1( connected to Alarm Drive 1 )
A D2( connected to Alarm Drive 2 )
W D1 ( connected to Warning Drive 1 )
A D1 D2( connected to Alarm Drive 1 and Alarm Drive 2)
W D1 D2( connected to Warning Drive 1 and Warning Drive 2)
INT D1 ( connected to Interlock Drive 1 )
INT D1 D2 ( connected to Interlock Drive 1 and Interlock Drive 2 )
OFF (Not connected to output)
***Characters changed with ∧ and ∨ buttons and selected with >button.
5.2.12 Drive monitor
Drive monitor-Start interlock

DMA01 Start alternative, drive 1* AND AND

OR
DMA02 Start delay time, drive 1 5, 10, 15, 5sec
20, 25sec
OR
20, 25sec
Drive monitor-Drive 1
DMB01 Delay time, Charge pressure A-side ** 0.5sec

DMB02 Delay time, Charge pressure B-side ** 0.5sec
DMB03 Delay time, High E-motor temp alarm ** 0sec
DMB04 Delay time, High A-side work pressure *** 7sec
DMB05 Memory bypass, A-side work pressure on/off off
DMB06 Delay time, High B-side work pressure *** 7sec
DMB07 Memory bypass, B-side work pressure on/off off
DMB08 Analog pressure sensor On/Off Off
DMC01 Delay time, Charge pressure A-side ** 0.5sec

DMC02 Delay time, Charge pressure B-side ** 0.5sec
DMC03 Delay time, High E-motor temp alarm ** 0sec
DMC04 Delay time, High A-side work pressure *** 7sec
DMC05 Memory bypass, A-side work pressure on/off off
DMC06 Delay time, High B-side work pressure *** 7sec
DMC07 Memory bypass, B-side work pressure on/off off
DMC08 Analog pressure sensor On/Off Off
Drive monitor-E-motor interlock

DMD01 Delay time, Interlock E-motor 1 0.1sec 1.0 0.1 30.0

* AND = All selected E-motors for the drive must be started to allow drive start.
* OR = Drive start allowed if any E-motor for the drive is started
** Possible delay time settings: 0 / 0.1 / 0.5 /1.0 seconds
*** Possible delay time settings: : 0 / 1.0 / 5.0 / 7.0 / 10.0 / 20.0 / 30.0 / 60.0 seconds
5.2.13 Drive 1 basic
Drive 1 basic-Setpoint
D1A01 Speed setpoint

1=Local 1 1
2=Remote 2
3=Local/remote 3
D1A02 Type of command signal
1=Unidirectional command 1
2=Bidirectional command 2 2
D1A03 Reset of local setpoint in remote yes/no yes
mode
D1A04 Reverse input on/off off
D1A05 Reverse command setpoint 0.1% -20.0 -100.0 -0.1
D1A06 Digital forward command setpoint 0.1% 10.0 0.1 100.0
(Active with Digital input =
FORW 1)
D1A07 Digital reverse command setpoint 0.1% -10.0 -100.0 -0.1
REV 1)
D1A08 Front panel button function on/off on
Drive 1 basic-Ramp
D1C01 Up ramp time forward 0.1sec 2.0 0.0 600.0

D1C02 Down ramp time forward 0.1sec 2.0 0.0 600.0
D1C03 Up ramp time reverse 0.1sec 2.0 0.0 600.0
D1C04 Down ramp time reverse 0.1sec 2.0 0.0 600.0
Drive 1 basic-Regulator
D1D01 Regulator on/off off

D1D02 Feed forward function on/off on
D1D03 Proportional regulator on/off off
D1D04 Integrating regulator on/off off
D1D05 Derivation regulator on/off off
D1D06 Proportional gain 0.1 0.1 0.0 10.0
D1D07 Integration time 0.1sec 10.0 0.5 60.0
D1D08 Derivation time 0.01sec 0.10 0.01 60.00
D1D09 Derivation decline time 0.1sec 0.1 0.1 10.0
D1D10 Max feedback deviation 1% 50% 0% 100%
D1D11 Selection of regulated or non-
regulated drive
1=Non-regulated drive ( ) 1 1
2=Regulated drive (REG) 2
3=Switching between regulated and 3
non-regulated drive
Drive 1 basic-Feedback
D1E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D1E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D1E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
Drive 1 basic-Power limitation

D1F01 Delay time, power limitation 0.1sec 0.5 0.0 25.0

D1F02 Ramp time, power limitation 0.1sec 20.0 0.0 600.0

1=Local 1 1
2=Remote 2
3=Local/remote 3
mode
FORW 2)
REV 2)
Drive 2 basic-Ramp


regulated drive
non-regulated drive
3=No feedback 3


5.2.15 Shredder 1
Shredder 1-Function
SHA01 Reverse control

1=Pressure, separate sensors 1 1
2=Speed 2
3= Pressure, common sensor 3
SHA02 Reverse stop function
1=Reverse stop 1
2=Going to forward 2 2
SHA03 Forward delay time before reversal 0.1sec 3.0 0.1 60.0
SHA04 Reversal time 0.1sec 10.0 0.1 60.0
SHA05 Reverse delay time before stop or 0.1sec 3.0 0.1 60.0
going to forward (SHA02)
SHA06 Forward time 0.1sec 10.0 0.1 60.0
SHA07 Shredder automatic direction function on/off off
SHA08 Forward time interval for direction 1sec 60 1 600
change
SHA09 Reverse time interval for direction 1sec 60 1 600
change
SHA10 Selection of regulated drive
1=Unregulated drive (no feedback) 1 1
2=Regulated drive (feedback) 2
Shredder 1-Setpoint
SHB01 Reverse command set point

1= Forward command, local or 1 1
remote 2
2=Reverse command set point
(D1A05)
SHB02 Scale factor for reverse command if 1% 100 1 100
SHB01 = 1
SHB03 Analog pressure sensor on/off off
SHB04 High pressure level, forward direction 1 bar 200 1 500
SHB05 High pressure level, reverse direction 1 bar 200 1 500
Shredder 1-Counter
SHC01 Window time for reverse counter 1sec 60 1 600

SHC02 Reversal counter 1 5 1 20
5.2.16 Shredder 2
Shredder 2-Function
SHG01 Reverse control

2=Speed 2
SHG02 Reverse stop function
1=Reverse stop 1
SHG03 Forward delay time before reversal 0.1sec 3.0 0.1 60.0
SHG04 Reversal time 0.1sec 10.0 0.1 60.0
SHG05 Reverse delay time before stop or 0.1sec 3.0 0.1 60.0
going to forward (SHG02)
SHG06 Forward time 0.1sec 10.0 0.1 60.0
SHG07 Shredder automatic direction function on/off off
SHG08 Forward time interval for direction 1sec 60 1 600
change
SHG09 Reverse time interval for direction 1sec 60 1 600
change
SHG10 Selection of regulated drive
Shredder 2-Setpoint
SHH01 Reverse command set point

remote 2
(D2A05)
SHH02 Scale factor for reverse command if 1% 100 1 100
SHB01 = 1
SHH03 Analog pressure sensor on/off off
SHH04 High pressure level, forward direction 1 bar 200 1 500
SHH05 High pressure level, reverse direction 1 bar 200 1 500
Shredder 2-Counter
SHI01 Window time for reverse counter 1sec 60 1 600

SHI02 Reversal counter 1 5 1 20
5.2.17 Synchro
Synchro-Function
SYA01 Type of synchronisation:

RATIO = By ratio input (friction) RATIO RATIO
COUNTER = By digital counter COUNTER
(synchro)
SYA02 Master command
1=Drive 1 Master – Drive 2 Slave 1 1
2=External master - Both drives 2
slaved
Synchro- Drive 1 reset

SYB01 Counter reset command, Drive 1

1=Reset by start 1 1
2=External reset 2
SYB02 Input for enable of counter reset,
Drive1:
1=Electric motors drive 1 start 1 1
2=Drive 1 start 2
3=Digital input, RES EN 1 3
Synchro-Drive 2 setpoint
SYC01 Drive 2 low friction limit 1% 0 -300 300

SYC02 Drive 2 high friction limit 1% 200 -300 300
SYC03 Offset reset by motor start on/off off
SYC04 Offset for Drive 2 0.1% 0 -49.9 50.0
Synchro- Drive 2 indication

SYD01 Synchro indication limit 1% 5 1 50

SYD02 Sync time 0.1sec 1.0 0.0 600.0

SYE01 Counter reset command, Drive 2:

2=External reset 2
SYE02 Input for enable of counter reset,
Drive2:
2=Drive 2 start 2
Synchro- External Master

SYF01 Up ramp time forward 0.1sec 2.0 0.0 60.0

SYF02 Down ramp time forward 0.1sec 2.0 0.0 60.0
SYF03 Up ramp time reverse 0.1sec 2.0 0.0 60.0
SYF04 Down ramp time reverse 0.1sec 2.0 0.0 60.0
SYG01 Drive 1 low friction limit 1% 0 -300 300

SYG02 Drive 1 high friction limit 1% 200 -300 300
5.2.18 Pressure 1
Pressure 1-Function
PRA01 Pressure control On/Off Off

PRA02 Reverse direction of control action On/Off Off
PRA03 Low pressure control On/Off Off
PRA04 High pressure control On/Off Off
PRA05 Filter time, low pressure control 1sec 5 1 30
PRA06 Filter time, high pressure control 1sec 5 1 30
Pressure 1-Pr.setpoint
PRB01 Pressure set-point 1

1=Local 1
2=Remote 2
3=Local/Remote 3
PRB02 Local pressure set-point 1bar 200 50 250
PRB03 Low limit, pressure set-point 1bar 25 5 50
PRB04 High limit, pressure set-point 1bar 25 5 50
PRB05 Low limit, PID output 1% 10% 1% 50%
PRB06 High limit, PID output 1% 10% 1% 50%
PRB07 Max pressure 1bar 250 0 600
Pressure 1-Regulator
PRC01 Proportional regulator on/off Off

PRC02 Integrating regulator on/off Off
PRC03 Derivation regulator on/off Off
PRC04 Proportional gain 0.1 0.1 0.0 10.0
PRC05 Integration time 0.1sec 10.0 0.5 60.0
PRC06 Derivation time 0.01sec 0.10 0.01 60.00
PRC07 Derivation decline time 0.1sec 0.1 0.1 10.0
PRC08 Filter time for pressure feedback 0.1sec 0.0 0.0 2.0
5.2.19 Pressure 2
Pressure 2-Function
PRG01 Pressure control On/Off Off

PRG02 Reverse direction of control action On/Off Off
PRG03 Low pressure control On/Off Off
PRG04 High pressure control On/Off Off
PRG05 Filter time, low pressure control 1sec 5 1 30
PRG06 Filter time, high pressure control 1sec 5 1 30
PRH01 Pressure set-point 1

1=Local 1
2=Remote 2
3=Local/Remote 3
PRH02 Local pressure set-point 1bar 200 50 250
PRH03 Low limit, pressure set-point 1bar 25 5 50
PRH04 High limit, pressure set-point 1bar 25 5 50
PRH05 Low limit, PID output 1% 10% 1% 50%
PRH06 High limit, PID output 1% 10% 1% 50%
PRH07 Max pressure 1bar 250 0 600
PRI01 Proportional regulator on/off Off

PRI02 Integrating regulator on/off Off
PRI03 Derivation regulator on/off Off
PRI04 Proportional gain 0.1 0.1 0.0 10.0
PRI05 Integration time 0.1sec 10.0 0.5 60.0
PRI06 Derivation time 0.01sec 0.10 0.01 60.00
PRI07 Derivation decline time 0.1sec 0.1 0.1 10.0
PRI08 Filter time for pressure feedback 0.1sec 0.0 0.0 2.0
5.2.20 Reading 1
Reading 1-Scroll menu

R1A01 Text for reading 1 Text Tank temp

R1A02 Reading 1 * REG410
R1A03 Text for reading 2 Text Reading 2
R1A04 Reading 2 * OFF
R1A09 Text for reading 5 Text (R1A10)
Reading 1-Left upper

R1B01 Reading * REG102
Reading 1-Right upper

R1C01 Reading * REG106
Reading 1-Left lower

R1D01 Reading * REG109
Reading 1-Right lower

R1E01 Reading * REG311
5.2.21 Reading 2






* Possible register readings for display:

Drive 1 Analog in
REG101 = Remote input command (%,Actual) REG401 = Analog in 1
REG102 = Speed setpoint (%) REG402 = Analog in 2
REG103 = Input command (%) REG403 = Analog in 3
REG104 = Feed forward command (%) REG404 = Analog in 4
REG105 = Error signal (%) REG405 = Analog in 5
REG106 = Amplifier command (%) REG406 = Analog in 6
REG107 = Speed setpoint (rpm) REG407 = Analog in 7
REG108 = Feed forward command (rpm) REG408 = Analog in 8
REG110 = Speed feedback (%) REG410 = Tank temp
REG112 = Regulated pressure command Bus command in
REG113 = Pressure compensation REG501 = Bus in 1
REG114 = Master command REG502 = Bus in 2
REG115 = Emergency stop angle (°) REG503 = Bus in 3
REG504 = Bus in 4
Drive 2 REG511 = Bus digital in 1-8
REG201 = Remote input command (%,Actual) REG512 = Bus digital in 9-16
REG202 = Speed setpoint (%) REG513 = Bus digital in 17-24
REG203 = Input command (%)
REG204 = Feed forward command (%)
REG205 = Error signal (%) Diagnostic readings
REG206 = Amplifier command (%) REG901 = Control task (ms)
REG207 = Speed setpoint (rpm) REG902 = Control task max (ms)
REG208 = Feed forward command (rpm) REG903 = UI task (ms)
REG209 = Digital speed REG904 = UI task max (ms)
REG210 = Speed feedback (%) REG905 = CPU load (%)
REG211 = Pressure command REG906 = CPU load max (%)
REG212 = Regulated pressure command REG907 = Stack usage, control task (%)
REG213 = Pressure compensation REG908 = Stack usage, UI task (%)
REG214 = Offset (Synchro) REG909 = Stack usage, serial port (%)
REG215 = Emergency stop angle (°) REG911 = Calc. resistance pump 1 (ohm)
REG912 = Calc. resistance pump 2 (ohm)
Pump signals REG913 = Calc. resistance pump 3 (ohm)
REG310 = Amplifier 1 command (%) REG914 = Calc. resistance pump 4 (ohm)
REG311 = Pump 1 current (mA)
REG320 = Amplifier 2 command (%) OFF =Output off
REG330 = Amplifier 3 command (%)
REG350 = Pump friction (%)
5.2.22 Drive log
Log function – Time/Date

Setting of time and date for the log function
Log function – Log 1

STA Status for log register OFF / ON / OFF

RESET
MT Measuring time 1h 100 10 5000
LHI Setting of upper limit 350 -100 7250
LLO Setting of lower limit 0 -100 7250
REG Choice of register for logging * OFF


RESET


RESET


RESET


RESET


RESET


RESET
LHIX Setting of upper limit, X axis 100 -100 7250
LLOX Setting of lower limit, X axis 0 -100 7250
REGX Choice of register for X axis logging * REG410
LHIY Setting of upper limit, Y axis 100 -100 7250
LLOY Setting of lower limit, Y axis 0 -100 7250
REGX Choice of register for Y axis logging * REG109
LHIZ Setting of upper limit, Z axis 300 -100 7250
LLOZ Setting of lower limit, Z axis 0 -100 7250
REGZ Choice of register for Z axis logging * REG401


RESET
* Possible register setting

REG101 = Remote input command REG310 = Amplifier 1 command (%)
REG102 = Speed setpoint REG311 = Pump 1 current (mA)
REG103 = Input command REG320 = Amplifier 2 command (%)
REG104 = Feed forward command REG321 = Pump 2 current (mA)
REG105 = Error signal REG330 = Amplifier 3 command (%)
REG106 = Amplifier command REG331 = Pump 3 current (mA)
REG109 = Digital speed REG340 = Amplifier 4 command (%)
REG110 = Speed feedback REG341 = Pump 4 current (mA)
REG111 = Pressure command REG350 = Pump friction
REG113 = Pressure compensation Analog in
Drive 2 REG403 = Analog in 3
REG201 = Remote input command REG404 = Analog in 4
REG202 = Speed setpoint REG405 = Analog in 5
REG203 = Input command REG406 = Analog in 6
REG209 = Digital speed REG410 = Tank temp
REG211 = Pressure command Bus command in
REG212 = Regulated pressure command REG501 = Bus in 1
REG214 = Offset (Synchro) REG503 = Bus in 3
REG504 = Bus in 4
OFF =Output off
Log function – Reset Time
Reset of time counters for time in use
AS-6
Spider Software settings and function
Contents
Introduction ............................................................................................................. 2
6.1 General system setup ....................................................................................... 3
6.2 Speed command............................................................................................... 4
6.3 Ramp ................................................................................................................ 4
6.4 Output ............................................................................................................... 5
6.5 Speed feedback ................................................................................................ 6
6.6 Power limitation................................................................................................. 9
6.7 Monitoring ....................................................................................................... 10
6.8 Analog inputs .................................................................................................. 11
6.9 Digital inputs ................................................................................................... 12
6.10 Digital outputs ............................................................................................... 19
6.11 Signal monitor ............................................................................................... 21
6.12 Shredder ....................................................................................................... 23
6.13 Synchro......................................................................................................... 24
6.14 Pressure control............................................................................................ 25
6.15 Bus Communication...................................................................................... 28
6.16 Drive monitoring log ...................................................................................... 33
6.17 Analog outputs .............................................................................................. 35
6.18 Language selection....................................................................................... 35
6.20 Emergency stop ............................................................................................ 37
6.21 Program update ............................................................................................ 38
6.22 Hardware calibration ..................................................................................... 38
AS-6
Introduction
Settings of the basic blocks in the software. All settings are for drive 1. The same procedure is done for
drive 2 but with the parameter letter in ().
This also describes the logical order for the system set up.
The list of parameters is found in AS5 and block diagrams with parameters are found in AS7.
The choice of parameters are made by using the directional buttons (◄, ►, ▲ & ▼) (see AS5.1). After a
change, the choice must be updated with the enter button (◄┘). The parameters are updated in the
memory when going back to the Main status reading in the display.
The settings can be protected by a password (MAIN SETTINGS Æ PROTECTION: MAD01-02).
The drive monitoring function is protected by a separate password under SETUP-LOG FUNCTION.
El.m. current signal(s)

El.m. started
Starter(s) El.m. interlock
Setpoint(s)
Customer
Drive control
El.m. 1 El.m. 2 El.m. 3 Spider 2 Digital/analog
Stroker current(s)
indications
Analog indicators
Speed encoder signal(s)

Monitor switches
Pump1 Pump2 Pump3
Pump4
Function:
Drive 1 Basic
Friction
Syncro
Drive 2 Shredder
Pressure
AS6, Software settings and function, Engineering manual 04-04-02
6.1 General system setup

6.1.1 System function
In MAIN SETTINGS Æ FUNCTION: MAA01 the basic function for the drive is selected. The selectable
functions for the system are (see also block diagrams in AS1 and AS7):
• BASIC – The basic and most common function. The function includes monitoring, speed feedback
and power limitation. This is the function that also is selected for monitoring type unit.
• SHREDDER – Same as for BASIC with added functions for reversing by an overload stopped
drive.
• SYNCHRO – Same as for BASIC with two drives driven together with FRICTION ratio or position
control between the motors.
The PRESSURE function can be used with BASIC, SHREDDER and FRICTION basic function.
6.1.2 System layout configuration
The configuration is needed for the system to

know how the electric motors are connected to the El.m. 1 El.m. 2 El.m. 3
pumps and how the pumps are connected to the
drives.
Setup procedure in MAIN SETTINGS Æ

CONFIGURATION: Pump1 Pump2 Pump3
• To setup the electric motor to pump
connection, set MAB01-04 (pump1-4) to
electric motor 1, 2 or 3. Pump4
• To setup the pump to drive connection, set
MAB05-MAB08 (pump1-4) to drive 1 or 2.
• Finally set the parameter MAB09 to Drive 1
common or separate when using two
drives depending if the drive have common
function or separate. Drive 2
6.1.3 Front control button bypass
The functions for the drive buttons at the front can be bypassed by setting parameter D1A08 (D2A08)
off.
6.2 Speed command

In ANALOG INPUTS-SETPOINT1 (2): AIA(B)01 - 04 the speed
setpoint command source is selected.
yes
Remote setpoint command is a voltage or current signal connected Local/remote
switching
to the terminals. The type must be set with parameter AIA(B)01 and
with jumper SP D1(2), see AS4.5. Remote setopint can also be set no
D1(2)A01=3
via fieldbus (foe settings see AS6.15).
The local command is set with the increase and decrease buttons yes
Local command
on the front. If external increase/decrease is needed, the local
setpoint function can be paralleled by using configurable digital
no
inputs (See AS5.2.3).
The speed command can be locked to local or remote control or be D1(2)A01=1 D1(2)A01=2
switchable with the local/remote button (set with DxA01).
At local/remote switching the local setpoint command can
automatically be set to zero if DxA03 is set to yes. Otherwise the Set type of
setting will be held when switching to remote mode. The reset can command signal
D1(2)A02
also be done by using a configurable digital input
Local increase/decrease will not effect the local setpoint when
running in remote mode.
The remote input must be calibrated as described for the analog inputs (see example in AS6.8).
Inputs for fixed speed forward(set with DxA06) and reverse(set with DxA07) can be selected with
configurable digital inputs.
6.3 Ramp
The start ramp time is the time it takes for the signal to control the hydraulic pump, to go from zero to
100% if the speed setpoint is 100% and drive start is activated. The stop ramp is the time it takes to go
from 100% to zero when drive stop is activated.
Drive start and stop are ramped commands (as well as fixed forward, fixed reverse and inch reverse).
The start ramp is controlled by the parameters DxC01 in forward direction and DxC03in reverse direction.
The stop ramp is controlled by the parameters DxC02in forward direction and DxC04in reverse direction.
Example: If the ”up ramp” D1C01 is set to 10 sec. and the down ramp D1C02 is set to
5 sec. we will get the following output.
The example is based on 50 and 100% setpoint.
Speed
Drive start Drive stop
100 %
Stop ramp
50%
Start ramp
0 10 20 25 Time in sec.
6.4 Output
6.4.1 PWM frequency
The individual settings for each pump are made in PUMP OUTPUTS ( See AS5.2.2)
The outputs are Pulse Width Modulated and the PWM frequency can be set with parameters POx06.
The normal setting is 200Hz but can be set 100 to 2000Hz in steps of 100Hz. If a 5A stroker is used
(can only be controlled in one direction) the frequency must be set to 2000Hz to avoid damaging of the
stroker.
6.4.2 Coil resistance

The nominal resistance for the stroker must be set with parametr POx05. The system will measure the
current in the stroker coil and compensate for the resistance change due to increased temperature.
A typical resistance value is:
5A2 (Denison) 25ohm
9A2 (Denison) 41ohm
SP (Brueninghaus) 20ohm
KA (Sauer Sundstrand) 25ohm
6.4.3 Current setting

For output current setting it is easy to use speed indication if a speed encoder is connected (See
AS6.11 for setup).
.
D(J)07
Lower frquency then 2000Hz can destroy5A2 pump stroker
• Min current forward, parameter POx01.

Start the drive. Increase the current until the drive starts moving forward, decrease until it stops again.
Stop the drive.
• Max current forward, parameter POx02.
Start the drive. Increase the current until the right forward speed is reached. Stop the drive.
• Min current reverse, parameter POx03.

Start the drive. Increase the current until the drive starts moving reverse, decrease until it stops again.
Stop the drive.
• Max current reverse, parameter POx04.
Start the drive. Increase the current until the right reverse speed is reached. Stop the drive.
POx01-04
High current can destroy
pump stroker
6.5 Speed feedback

6.5.1 General
Speed feedback makes it possible to maintain a constant speed at the hydraulic motor shaft. The
Spider compensates for speed deviations due to load changes. To achieve this, a PID regulator is
implemented in the software. This PID regulator compares the actual speed value with the speed set-
point. Any deviation between the two signals is detected as an Error signal and transferred to the PID
regulator. The PID regulator has three different stages.
The proportional part amplifies the Error signal. The Output is proportional to the Error signal.
The Integral stage integrates the Error signal. A small Error signal will over time create a big Integral
stage output.
Derivative stage derives the Error signal. A rapid change will create a big output from the derivative
stage.
The results from the three different stages are added to the stroker output.
The following Example set-up is based on the following facts:

Analog speed encoder with output signal 4-20mA for 0-25Rpm
connected to Analog input 3.
Drive maximum speed is 22Rpm.
The setup regarding speed feedback is made in the following
parameter menus:
"Drive 1 basic - feedback" (D1E01 - D1E03)
"Analog inputs - Analog in 3" (AIH01 - AIH14)
"Pulse inputs - Drive 1" (P1I01 - PII07)
"Drive 1 basic - regulator" (D1D01 - D1D11)
The setup for Drive 2 is identical but the parameters start with "D2xx"
6.5.2 Speed encoder input signal set-up

The type of speed encoder is determined with parameter D1E02.
The possible settings are:
1. Digital feedback.
2. Analog feedback.
3. No feedback.
In this case this parameter is set to 2 -> Analog feedback.
The maximum hydraulic motor shaft speed is set in parameter
D1E01. In this case the parameter is set to 22rpm.
The speed encoder is hooked up to analog input 3, parameters
AIH01 to AIH14 is valid for the set-up. Parameters not mentioned
below are left with the factory setting.
AIH02 and AIH03 are used when calibrating the input. Zero and
span adjustment are possible to make.
AIH05 is set to 25 rpm as that is the range of the speed encoder.
AIH06 is set to rpm.
AIH07 is set to 1 as we want the signal to be presented with one
decimal
AIH09 is set to AS1 meaning Analog Speed drive 1.
AIH12 is set to AUX 1 which is set as a warning, activated when 4 mA is missing. The warning will
indicate a broken speed encoder.
If a digital speed encoder is to be used, parameters P1I01 to P1I07 must be set.

P1I01 parameter value must be the number of digital pulses that the speed encoder produces during
one rotation.
P1I06 can be set if the rotation of the hydraulic motor/encoder is giving a wrong polarity of the reading.
If 1 is set the polarity will change.
P1I07 determines the type of speed encoder used.
1= Quad. This is the standard type with two pulse trains

2= Single pulse with direction. This speed encoder gives a pulse train and in addition a directional
signal ON/OFF.
3= Single pulse without direction. This speed encoder gives one pulse train as an output.
6.5.3 Regulator set-up

The Regulator parameters are all gathered under “Drive 1 basic - Regulator”, parameters D1D01 –
D1D11. Below is a description of each parameter.
Parameter D1D11 has the following choices:
1. Non-regulated drive (Blank indication in 4’th position on display line 1)
2. Regulated drive (REG indication in 4’th position on display line 1)
3. Switching between regulated and non-regulated drive.
Parameter must be set to 2 or 3 to achieve speed feedback. In this case parameter D1D11 is set to 3.
The PID regulator is then possible to activate/deactivate from the Spider front with the predefined
pushbutton REG/UNREG.
D1D01 Sets the regulator function ON or OFF. In this case ON, the regulator is enabled.
D1D02 Feed forward function is set ON or OFF. In this case ON, the speed set-point is put to the
stroker output as an initial value and the regulator compensates for deviations in speed.
If the parameter is set OFF the regulator output will be the only signal to the
stroker output.
D1D03 Sets the Proportional regulator stage function ON or OFF. In this case select ON. The
proportional stage reacts proportional to the Error input signal. Action of this stage is
determined by parameter D1D06.
D1D04 Sets the Integrator function ON or OFF. In this case select ON. This function gives the
drive a possibility to reach set-point speed over time. Action of this stage is determined
by parameter D1D07.
D1D05 Sets the Derivative function ON or OFF. In this case select OFF. The derivative stage is
used when very quick speed changes are to be expected at the drive. It reacts on the
rate of change at the Error input signal. The D stage is seldom used due to a difficult
tuning procedure. Action of this stage is set by parameters D1D08 and D1D09.
D1D06 Proportional gain parameter sets the gain of the P-stage. In this case set to 0.5 as a start
value. P gain 0.5 means that half the Error signal input value will be transferred to the
stage output. Proportional stage however, will not make the drive reach set-point speed.
There will always be a remaining Error. The remaining Error value is though depending
on the Proportional gain setting. If the Error signal is small, close to zero, P gain will not
produce any output at this stage output. The P stage always needs an Error signal to
modify.
D1D07 Integrator time parameter sets the integration time of the I-stage. In this case set to 10
seconds as a start value. Integrator time 10 seconds means that the output value of this
stage will reach 63% of the Error signal input value in 10 seconds. Introduction of
Integration will eliminate the remaining Error signal. The actual speed will over time
correspond to speed set-point. It can be compared with a Capacitor that is charged with
the Error signal.
D1D08 Derivative time parameter sets the Derivative time of the D stage. In this case it is left at
the default value, 10 seconds. Derivative time 10 seconds means that the derivative
“gain” is a factor 10. The output from this stage is the “gain” factor multiplied with the rate
of change of the Error signal.
D1D09 Derivative decline time parameter sets the Derivative decline time of the D stage. In this
case it is left at default value, 10 seconds. Derivative decline time 10 seconds means that
the output value from this stage will decline 63 % in 10 seconds.
D1D10 Max feedback deviation is the allowed difference between command and actual speed. If
this exceeds for 10sec., the drive will switch over to unregulated drive and give the
warning ERROR TOO LARGE.
6.5.4 Regulator tuning
The above settings give in most cases a good performance of the drive. However to optimise the
parameters the following method can be used.
In short words the method is as follows:
Increase the proportional gain until the drive starts to oscillate. Note the oscillation time. Reduce the
Proportional gain with 50 %. Set the Integrator time minimum to the double oscillation time value.
This is a recommended step by step list of how to tune the PI regulator:

1 Select UNREG mode.
2 Make sure that stroker currents are correctly adjusted.
3 Deselect the Integrator stage, by setting the parameter D1D04 to Off.
4 Reduce the ramp time setting to zero or as much as the drive can tolerate.
5 Start the drive.
6 Give about 50 % speed command.
7 Select REG mode. This enables the regulator. Check performance of the drive. If the drive starts
to oscillate, stop the drive and reduce the Proportional parameter value.
8 Increase the Proportional gain in small steps. Start and stop the drive. Check the drive stability.
When the drive starts to oscillate try to determine cycle time of the oscillation (the time from one
pulse top to the next).
9 Decrease the proportional gain value to half of what set in 8.
10 Activate the Integral part by setting the parameter D1D04 to On.
11 Set the Integrator parameter to minimum the double oscillation time.
6.6 Power limitation

Power limitation function is not possible in the monitor type spider. Power limitation
Basic function or higher is needed to get the power limitation function.
Power limitation is aquired by utilizing an analog input for sensing
the electric motor current. See AS 5.2.6 for setup of the analog input.
First set the function for the analogue input in
AS5.2.6:Analog inputs -Analog in x:AIF09-AIN09 toEC1, EC2 or EC3. Set analog input
Limitation level is set with parameters Analog inputs -Power for limitation
limit:AIR01-AIR03 AIF-AIN09=ECx
Limitation function is set with parameters Drive 1(2) basic - power

limitation: D1(2)F01-D1(2)F02, See AS3.3 for connection and type of
analog input.
Set input type
for limitation
Example for power limitation setting Drive 1, Electric motor 1: AIF-AIN01
Electric motor = 163A (from data sheet or motor rating plate)
Current transformer 200A = 20mA
We are using analog input 3 for this example.
We want to limit electric motor 1 in drive 1. Set max
input current
AIH05, Max input = 200 AIF-AIN05
AIH06, Units for indication = A
AIH09, Function => Power limitation = EC1
AIR01, Level for power limitation (e-motor 1) = 163
Set sort of
D1F01, Delay time = the time the power is allowed to be higher reading
then the level (AIR01) before the limit function starts AIF-AIN06
DIF02, Ramp time = how fast the reaction will be for stroking
down the pump to limitation level
Example for power limitation setting Drive 2, Electric motor 3: Set function
Electric motor = 240A (from data sheet or motor rating plate) for input
Current transformer 400A = 20mA AIF-AIN09
We want to limit electric motor 3 in drive 2.
Set level
AIJ05, Max input = 400 for limitation
AIJ06, Units for indication = A AIR01-03
AIJ09, function => Power limitation = EC3
D2F01, Delay time = the time the power is allowed to be higher
then the level (AIR03) before the limit function starts Set filter time
D2F02, Ramp time = how fast the reaction will be for stroking D1(2)F01
Set downramp
The ramp time setting must be set by test with the drive. A too short time
time can cause oscillation in the system and a too long time will not D1(2)F02
(By test)
regulate the current to the max setting (same function as P regulation,
see AS6.5).
6.7 Monitoring
The monitoring function is available in all setups. The pre-defined digital inputs (for monitoring) must
be set to off if monitoring is not wanted. See setup of digital inputs under AS 5.2.3.
6.7.1 Functions for monitoring

The pre-programmed functions can be used on any of the 43 digital inputs that are avaliable. The pre-
programmed functions have 3 different types of indication:
Warning = indication on the display and by a digital output if this function is set (see AS6.10)
Alarm = indication on the display and by a digital output if this function is set (see AS6.10)
This function will stop the drive without ramp and after a short delay open the electric motor
interlock output to stop the motor.
Interlock = same as alarm but without stopping the electric motor.
The Warning, Alarm and Interlock indications must be reset in the Alarm/Warning list after the reason
for the indication is fixed (see AS 4.3).
The pre-programmed functions are described in AS 6.9.2.
6.7.2 Extra monitoring input

There are 20 pre-programmed auxiliary channels that can be used for different functions. One is the
monitoring function. If any of the digital inputs is configured as AUX x (see AS5.2.3, Digital inputs: 13
AUX x) the function for the input will be monitoring The function Alarm, Warning or Interlock for the
input, time delay, memory for the input and the text to be in the alarm/warning list can be set, see
AS5.2.11, Setup – Aux monitor.
Example: Digital input 25 as warning input for high temp Drive 1.
See AS 3.3 for electrical connection of digital inputs.

Set parameter Setup - Digital inputs- DIN25: AUX1.
Set parameter Setup - Aux monitor - Aux 1: AMA01 to W1 (warning drive 1).
Set AMA03 (memory bypass) to preferred function:
(If memory bypass = off: Warning indication will be activated if input is opened
Warning indication will remain if input is closed.
and must be reset in Alarm / warning menu).
(If memory bypass = on: Warning indication will be activated if input is opened
Warning indication will disappear if input is closed).
Set AMA02 to needed delay time between opened input and warning indication.
Set the text in AMA04 to HIGH OIL TEMP by using ∧, ∨ and ↵ buttons.
NOTE: The line has to be filled with blank characters by pushing ↵ until the line is filled.
Available characters are all possible characters for the display. For Chinese characters a VFD display
must be mounted and switch SW3-1 must be set to off.
Setup of this function can either be done on the spider front or via SpiderCom program.
AS6, Software settings and function, 05-01-21, replaces04-04-02
6.7.3 Elecric motor interlock outputs

There are 3 normally high digital outputs for interlock of the electric motors (shall be connected via a
relay in the electric motor stop circuit). The interlock output will open time-delayed after an Alarm.
The delay time is set in Setup-Drive monitor-Emotor interlock: DMD01-DMD03.
See AS 3.4.2 for electrical connection. The interlock is dependent on how the configuration is done in
Setup-Main settings-Configuration, see AS6.1 for description.
The normal stop sequence at alarm:

1. The output to the pump is set to zero without ramp.
2. After a time delay (settable) the electric motor interlock is opened.
6.7.4 Monitoring outputs

There are 13 digital outputs that can be configured in Setup – Digital outputs.
They can be used for monitoring of Alarm, Warning or Interlock or monitoring of a digital input.
It is possible to use an auxiliary function only for controlling a digital output. AMx01 is then set to OFF
and a digital output must be adressed to the aux function.
See AS6.10 for possible settings and functions for the digital outputs.
6.7.5 Tank temp monitoring

The tank temperature can be monitored with digital or analog signal selected by parameter TMB01.
For digital type input functions must be selected, see AS6.9.
The choice of analog sensor can be of Pt100 type (standard) connected to prepaired inputs or
standard analog signal type connected to a configurable analog input. If a configurable analog input is
used the function is set to TANK A. Configurable input selection will disconnect the Pt100 type input.
By using an analog sensor the switch levels for Alarm, Warning, Filter interlock, Min temp, Cooling
control, Heating control and Flushing control can be set within preset limits. All switches exept filter
interlock can be monitored on digital outputs if needed.
Function Setting [°] Hysteresis [°] On [°] Off [°]

Alarm 60 (TMB03) -- 60 60 (must be reset)
Warning 55 (TMB04) -- 55 55 (must be reset)
Cooling 40 (TMB05) 3 (TMB06) 40 (rising temp) 37
Filter interlock 0 (TMB07) -- 0 0
Heating 15 (TMB08) 3 (TMB09) 15 (falling temp) 18
Min 10 (TMB10) -- 10 10
Flushing 15 (TMB11) 3 (TMB12) 30 (falling temp) 33
6.7.6 Alarm stop

As default, the command output to the pumps will be set to zero without ramp to stop the system as
fast as possible. In some applications it can cause mechanical damage to set the outputs quickly to
zero. An alarm ramp time can be set with parameter MAB10 to allow the system to do a controlled
stop.
6.8 Analog inputs

All analogue inputs can be used for current or voltage signals.
Spider has 9 analogue inputs. 2 is dedicated for speed setpoint drive 1 and drive 2.
The 7 remaining inputs are general and can be used for different purposes (see below).
Analogue input setpoint1, setpoint2 and analog in1-2 is isolated with it's own reference ground.
05-01-21, replaces 04-04-02
Analogue input 3-9 is isolated but with common reference ground with the power supply.
All analogue inputs can be connected to current or voltage signals. The function and the zero - and
maxpoint of the input must be set (see AS5.2.6).
The function settings are described for each function in AS6.5 for Analog speed feedback, AS6.6 for
power limitation AS6.12 for Shredder pressure, AS6.13 for Synchro offset and AS6.14 for
Pressure control.
Example of zero and maxpoint setting:

Speed setpoint with a 0-10V signal for drive 1. 10 V corresponds to 100% speed, parameter AIA01=0-
10V.
Monitor the signal in REG101 (see AS5.2.20).

Connect a 0 V signal to the terminals for analog 1 (+ to terminal AI1:5 and – to terminal AI1:6).
Adjust parameter AIA02 until the reading switches over from 1% to 0%.
Connect a 10V signal to the terminals.
Repeat adjustments for 0 and 10V until the right reading is achieved. As a test, check that the reading
at 5.0V (50%) is 50%.
Analog in 4 with a 4-20mA signal for power limitation drive 1. 20 mA corresponds to 200A, parameter
AII01=4-20mA and AII06=A
For settings of power limitation, see AS6.6.

Connect a 4mA signal to the terminals for analog 3 (+ to terminal AI2:7 and – to terminal AI2:8).
Adjust parameter AII02 until the reading switches over from 1A to 0A.
Connect a 20mA signal to the terminals.
Repeat adjustments for 4 and 20mA until the right reading is achieved. As a test, check that the
reading at 12mA (50%) is 100A.
6.9 Digital inputs

The digital inputs on terminal EI1, DI1, DI2, DI3, DI4, DI5 are all 24VDC functions and are
preconfigured as shown in AS3.7 terminal list.:
-Electric motor started inputs
-Input signals from power unit
-Configurable inputs
-Supply for the inputs
6.9.1 Electric motor started inputs

The electric motor started inputs are to bypass the Charge pressure alarm at electric motor stop and to
prevent against control current to the pump coils at stop. It also controls the cooling control when an
analog temperature transducer is used
6.9.2 Configurable inputs

The configurable digital inputs can be used for control and monitoring.
Function: A=Alarm, W=Warning, C=Control
Abbreviation Description Normal status for Function

input 05-01-21, replaces 04-04-02

01 H APR P1 High pressure A-side monitor function for pump 1 High, low at high W
For monitoring of pump high pressure in forward pressure
direction.
01 H BPR P1 High pressure B-side monitor function for pump 1 High, low at high W
For monitoring of pump high pressure in reverse pressure
direction.
see 01 H APR P1 pressure
see 01 H BPR P1 pressure
02 H APR D1 High pressure A-side monitor function for drive 1 High, low at high W
For monitoring of drive high pressure in forward direction. pressure
02 H BPR D1 High pressure B-side monitor function for drive 1 High, low at high W
For monitoring of drive high pressure in reverse direction. pressure
see 02 H APR D1 pressure
see 02 H BPR D1 pressure
02 H APR 12 High pressure A-side monitor function for drive 1 and 2 High, low at high W
02 H BPR 12 High pressure B-side monitor function for drive 1 and 2 High, low at high W
03 C PRA P1 Low charge pressure A-side monitor function for pump 1 High, low at low A
For monitoring of pump low charge pressure in forward pressure
direction
03 C PRB P1 Low charge pressure B-side monitor function for pump 1 High, low at low A
For monitoring of pump low charge pressure in reverse pressure
direction
see 03 C PRA P1 pressure
03 C PRB P4 Low charge pressure B-side monitor function for pump 4 High, low05-01-21,
at low replacesA04-04-02
04 C PRA D1 Low charge pressure A-side monitor function for drive 1 High, low at low A
For monitoring of drive low charge pressure in reverse pressure
direction
04 C PRB D1 Low charge pressure B-side monitor function for drive 1 High, low at low A
direction
see 04 C PRA D1 pressure
see 04 C PRB D2 pressure
05 SUCTION1 Suction line monitor for pump 1 High, low on closed A

For monitoring of suction line indicator closed oil line

see 05 SUCTION1 oil line


06 RF 75P1 Monitor of return filter for pump 1 clogged to 3/4 High, low on filter W
For monitoring of 3/4 clogged filter. clogged
Only applicable when using two level filter indicators.
06 RF 100P1 Monitor of return filter for pump 1 fully clogged High, low on filter W/(A)
For monitoring of fully clogged filter (must be exchanged) clogged
see 06 RF 75P1 clogged
06 DRF 75 Monitor of drain filter clogged to 3/4 High, low on filter W

06 DRF 100 Monitor of drain filter fully clogged High, low on filter W/(A)
06 F TEMP Interlock of filter warning inputs High, low on temp W

Used when external temp interlock wanted for filter above set value
functions
07 LO LEVEL Low oil level monitor for tank High, low when W
Monitors Low oil level in PU tank below set level
07 MN LEVEL Min oil level monitor for tank High, low when A
05-01-21, replaces 04-04-02
Monitors Min oil level in PU tank below set level
08 MAX TEMP Max oil temp monitor for tank High, low when A
Monitors max set temp. in PU tank above set temp
08 HI TEMP High oil temp monitor for tank High, low when W
Monitors high set temp. in PU tank above set temp l
08 MIN TEMP Low oil temp monitor for tank High, low when A
Monitors low set temp. in PU tank below set temp
09 ALARM R Remote reset of alarms and warnings Low, High=Reset C
09 BUS R Reset of alarms and warnings via bus High=Reset via bus C
09 BUS 1 Switching to Bus command signals, Drive 1 High=Bus drive 1 C
09 BUS 2 Switching to Bus command signals, Drive 2 High =Bus drive 2 C
09 BUS M Switching to Bus command signal, External master High=Bus ext. C

master
10 SHR A D1 Shredder forward stop, Drive 1 High, low at stop C
10 SHR B D1 Shredder reverse stop, Drive 1 High, low at stop C
10 SHR 1+2A Shredder forward stop, Drive 1 and 2 High, low at stop C
10 SHR 1+2B Shredder forward stop, Drive 1 and 2 High, low at stop C
10 INTERV1 Interval control of shredder, Drive 1 High=Interval C
10 SH RES 1 External reset of Shredder blocked function, Drive 1 High=Reset C
10 SH RES12 External reset of Shredder blocked function, Drive 1 and High=Reset C

2
11 PL1 Activate power limitation for Drive 1 High= Power limit C
12 RES EN 1 External enable of counter reset in Synchro mode, Drive1 High=Enable of C

reset input
12 RES EN2 External enable of counter reset in Synchro mode, Drive High=Enable of C
2 reset input
12 FRICTION Friction drive in Synchro counter mode High=Friction drive C
12 INV M Inverting of master speed command in Synchro mode, High=Inverting of C

Drive 1 speed command
13 AUX 1 Connected to Monitor Auxiliary input 1 High, low for A/W/I

indication

indication

indication
05-01-21, replaces 04-04-02

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication
14 START 1 Drive start in Remote mode, Drive 1 High=Start C
14 START 12 Drive start in Remote mode, Drive 1 and 2 High=Start C
14 L START1 Drive start in Local mode, Drive 1 High pulse=Start C
14 L STOP1 Drive stop in Local mode, Drive 1 High, Low C

pulse=stop

pulse=stop
15 FORW 1 Forward drive with fixed speed, Drive 1 High=Forward

05-01-21, replacesC04-04-02
15 REV 1 Reverse drive with fixed speed, Drive 1 High=Reverse C
15 FORW 2 Forward drive with fixed speed, Drive 2 High=Forward C
15 FORW 1+2 Forward drive with fixed speed, Drive 1 and Drive 2 High=Forward C
15 REV 1+2 Reverse drive with fixed speed, Drive 1 and Drive 2 High=Reverse C
15 L REV 1 Local Reverse drive with fixed speed, Drive 1 High=Reverse C
15 L FORW 1 Local Forward drive in manual mode, Shredder Drive 1 High=Forward C
15 INV 1 Inverting of speed command at unidirectional drive, High=Inverting of C

Drive1 speed command

16 SP UP1 Increase set point in Local mode, Drive 1 High pulse = C

increase 1%
16 SP DN1 Decrease set point in Local mode, Drive 1 High pulse = C

decrease 1%

increase 1%

decrease 1%
16 SP RES1 Reset of set point in Local mode, Drive 1 High pulse = reset C
16 REM 1 Remote mode, Drive 1 High=Remote C

Low=Local

Low=Local
16 REM 1+2 Remote mode, Drive 1 and 2 High=Remote C

Low=Local
17 AUTO 1 Shredder Auto mode, Drive 1 High=Auto C

Low=Manual

Low=Manual
17 AUTO 1+2 Shredder Auto mode, Drive 1 and 2 High=Auto C

Low=Manual
18 REG 1 Closed loop speed feedback active, Drive 1 High=Active C

Low=Open loop

Low=Open loop
18 REG 1+2 Closed loop speed feedback active, Drive 1 and 2 High=Active C
Low=Open loop
05-01-21, replaces 04-04-02

18ERR1 RES Reset of error too large function, Drive 1 High pulse = reset C
18ERR1+2R Reset of error too large function, Drive 1 and 2 High pulse = reset C
19 EMOTOR 1 High temp electric motor 1 monitor function High=Temp OK A
20 PR REM 1 Pressure control remote setpoint, drive 1 High=Remote C

Low=Local

Low=Local
20 PR HI 1 Set pressure control output to max speed-up level, Drive High=Max output C
1 Low=Normal control
20 PR LO 1 Set pressure control output to max slow-down level, Drive High=Min output C
20 PR ON 1 Activate pressure control function, Drive 1 High=Active C

Low=Not used

Low=Not used
21 OFF Not used
6.10 Digital outputs

6.10.1 Electric motor interlock outputs
The electric motor interlock outputs must be connected via a 24VDC relay to the starter electric stop
circuit. The output is high when it is allowed to run the electric motor and will open by an alarm, if the
Emergency stop input is opened or by the microprocessor watchdog (controls the program function).
6.10.2 Configurable outputs

The configurable digital outputs can be used for control and monitoring, set with parameterDOx01.
The following functions are common for all outputs
1 Indication only from drive 1
1+2 Indication from drive 1 or drive 2
1*2 Indication that both drive 1 and drive 2 are affected
1...x Same function for all outputs with number 1 to x
Output function
Abbreviation Function Normal status for
output
01 A(1,2, 1+2) Monitoring of common alarm Open, closed at
alarm
01 W(1,2, 1+2) Monitoring of common warning Open, closed at

warning
01 INT(1, 2, 1+2) Monitoring of common interlock Open, closed at

interlock
02 START(1, 2, 1+2, 1*2) Drive started Open, closed at

start
03 READY(1, 2, 1+2, 1*2) Drive ready to use after start delay Open, closed when
ready
04 REMOTE(1, 2) Drive in remote mode Open, closed in
remote mode
05 AUTO(1, 2) Shredder in Auto drive mode. Open, closed in

auto mode
05 REG(1, 2) Drive with regulated speed feedback. Open, closed in

regulated mode
06 PLIM(1, 2, 1+2) Power limit active Open, closed at

active limitation
07 FORW(1, 2) Drive running with forward command Open, closed at

forward run
07REV(1, 2) Drive running with reverse command Open, closed at

reverse run
08 C ZERO Counters in Synchro counter function reset and synchro function Open, closed at
activated activated
synchronisation
08 SYNCHRO Synchronisation within the set limits. Open, closed when

within limits
09 AOUT(1...4) Register for analog output has negative sign Open, closed when
negative
10 EMOTD(1, 2, 1+2, 1*2) Electric motor(s) started Open, closed when

started
11 LOW TEMP Indication for min oil temp active Open, closed when
active
11 HI TEMP Indication for high oil temp active Open, closed when
active
11 MAX TEMP Indication for max oil temp active Open, closed when
active
11 COOL CONI Start cooling interlocked with electric motor started Open, closed for
(with analog temp sensor) cooling
11 COOL COND Start cooling controlled directly from temp sensor Open, closed for
11 HEAT CON Start heating (with analog temp sensor) Open, closed for
heating
11 FLUSHCON Control of flushing circuit (with analog temp sensor) Open for cooling,
closed for heating
12 P(1, 2) C ACT Pressure control of output active Open, closed at

pressure control
12 P(1, 2) HI CA High Pressure control of output active Open, closed at

pressure control
12 P(1, 2) LO CA High Pressure control of output active Open, closed at

pressure control
13 SH BLCK(1, 2) Shredder blocked in auto mode Open, closed when

blocked
14 AUX(1...20) Auxillary function active Open, closed when

active
15 OFF Output not used
6.10.3 Inverted function

An output can get inverted function to normal status by setting parameter DOx02 to yes.
6.10.4 Delayed function

An output can get a time delay by parameter DOx04. The time for the delay is set with parameter
DOx03.
The function can be set to:
ON On delay From the moment when the function for the output is activated , the output will
not be active until the delay time is passed.
OFF Off delay From the moment when the function for the output is deactivated , the output
will not be inactive until the delay time is passed.
PULSE Output pulse From the moment when the function for the output is activated , the output will
be active only during the delay time.
OFF No delay
6.11 Signal monitor

The signal monitor is the reading of the process values (REGxx) indicated with a frame in the block
diagrams, see AS7. It is possible to select and monitor 4 fixed values and a scroll list of up to 9 values
on each display. The possible settings are found in AS5.2.20 and is set in Reading 1(2).
The readings can be used to show process values during drive but can also be used for
troubleshooting. The internal values are normally indicated as a % value
6.11.1 Setpoint indication

The setpoint for the speed can be indicated as a % value with REG102(202). If the setpoint should be
indicated as a rpm value this can be monitored with REG107(207). For this indication parameter
D1(2)E01 must be set to the speed corresponding to 100% command.
6.11.2 Analog input indication

The analog inputs can be indicated with REG 40x where x stands for the input number between 1 to 9,
eg. REG 405 for analog input 5. For each input the units can be set with parameter AIx06 and the
number of decimals with parameter AIx07. The reading can also be scaled to fit eg. a conveyor speed
with parameter AIx08.
6.11.3 Analog bus input indication

The analog inputs from the fieldbus can be indicated with REG 50x where x stands for the input
number between 1 to 4, eg. REG 502 for analog input 2. For each input the units can be set with
parameter BAx03 and the number of decimals with parameter BAx04.
6.11.4 Temperature indication

A PT100 Analog temperature sensor can be indicated with REG 410. Temperature is normally
indicated as °C. If the unit is changed to °F the reading is automatically calculated.
6.11.5 Output indication

For the pump controls the current to the coil can be indicated in mA with REG3x1 where x stands for
the pump number eg. REG 321 for pump 2.
6.11.6 Internal indications

The internal indications can be used for troubleshooting or as indications during setup.
Register Function Reading
REG 101(201) Input command % or actual signal
REG102(202) Speed setpoint %
REG107(207) Speed setpoint rpm
REG103(203) Input command %
REG104(204) Ramped command %
REG108(208) Ramped command rpm
REG105(205) Speed error signal %
REG106(206) Input to output amplifier %
REG110(210) Speed signal %
REG111(211) Pressure command %
REG112(212) Regulated pressure command %
REG113(213) Pressure compensation %
REG114 Master command %
REG115(215) Stop angle °
REG 310 Pump 1 command %
6.11.7 Diagnostic readings

The diagnostic readings can be used for checking the load of the microcontroller.
REG 901 Time for the internal PC task (msec)
REG 902 Max time for the internal PC task (msec)
REG 903 Time for the internal UI task (msec)
REG 904 Max time for the internal UI task (msec)
REG 905 CPU load (%)
REG 906 Max CPU load (%)
REG 907 Stack usage, PC task (%)
REG 908 Stack usage, UI task (%)
REG 909 Stack usage, serial port (%)
REG 911 Calculated resistance, pump 1 (ohm)
6.11.8 Bus readings

The bus readings are used to indicate digital inputs from fieldbus.
REG 511 Digital in 1-8
6.11.9 Scroll menu

For each reading in the scroll list it is possible to set a text and a REG. The text and the REG will be
shown on the same line.
The scroll list is activated by ◄ for left display and by ►for right display and active list is indicated with
two arrows on the scroll list. The scrolling is done with ▲ or ▼ and only the activated indications will
be shown.
The scrolling will be active 10sec after ▲ or ▼ is used and have to be activated again for scrolling
Example:
Tank temp and a pressure transducer on analog in 3 indicated on display 2:
R2A01 - TANK TEMP
R2A02 – REG401
R2A03 – PRESSURE
R2A04 – REG403
Will give:
→ TANK TEMP 37.8ºC ←
PRESSURE 143bar
▲ or ▼ will alter between these two readings.
6.11.10 Emergency stop angle indication

The movement angle of the roll between activated emergency stop and actual stop can be indicated in
° with REG115(215). This function requires digital speed encoder.
6.12 Shredder
The selection of shredder function is made by setting parameter MAA01 to SHREDDER (see AS6.1).
The specific parameters are found in SETUP – SHREDDER 1(2).
In shredder all features described in 6.1.- 6.11 are avaliable except for the possibility to switch
between speed regulated and non-regulated drive. The selection of speed regulation has to be set
with parameter SHA(G)10.
The added functions are for the reversals by an overloaded drive.
The shredder has two drive modes, manual and auto.
In manual drive mode the forward button (or by configurable input set as L FORW1(2)) is used for
running forward and the reverse button (or by configurable input set as L REV1(2)) is used for running
reverse. The drive will run as long as the input is activated and stop when input is opened. The
reversing function is bypassed in manual drive.
In auto drive mode the start button (or by configurable input set as L START1(2)) starts the drive with
the automatic reversing function and is stopped with the stop button(or by configurable input set as L
STOP1(2)). A configurable digital input can be used for start in remote mode.
The switching between manual and auto is made with the MAN/AUT button or with a configurable
digital input (will bypass the button).
A digital output can be used for indication of auto mode.
6.12.1 Speed setpoint

The forward speed setpoint is handled as described in AS6.2 but must be a positive signal. The
reverse speed setpoint can be the inverted forward setpoint scaled with parameter SHB(H)02 (e.g.
reverse always 50% of forward speed) or a fixed command set with parameter SHB(H)01 and SETUP
– DRIVE 1(2) BASIC: D1(2)A05.
6.12.2 Overload detection

The detection of overloaded drive is made with parameter SHA(G)01. The selection can be between:
-Pressure switches that opens at high pressure
-Speed encoder to detect stopped drive
-One pressure transducer in a common pressure port for both directions
6.12.3 Reverse counter

The number of reversals within a limited time window can be set with parameter SHC(I)01 and 02 for
stopping the drive. If the function is not wanted the time window can be set to 1. If the counter setting
is reached the drive will go to manual and the warning text SHREDDER BLOCKED will appear in the
alarm/warning list. The warning must be reset before auto start is possible. The warning can also be
reset by a configurable digital input.
6.12.4 Reverse blocking

The function if the drive blocks during reverse drive can be set with parameter SHA(G)02.
If 1(Stop) is selected the same result will appear as if the counter setting is reached.
If 2(Forward) is set the drive will switch back to forward drive without stopping.
6.12.5 Interval timer

A function for a preset forward/reverse interval can be swiched on by parameter SHA(G)07 or by a
configurable digital input set to INTERV 1(2).
The forward drive time is set by parameter SHA(G)08 and the reverse drive time is set by parameter
SHA(G)09.
6.13 Synchro
The Synchro function set-up is to be found in the following parameter menus
"Synchro - Function"
"Synchro - Drive 1 reset"
"Synchro - Drive 2 setpoint"
"Synchro - Drive 2 indication"
"Synhcro - Drive 2 reset"
"Synchro - External Master"
See also block diagram AS7-7.

The Synchro function is divided in two parts, RATIO and COUNTER. The selection is made with
parameter SYA01.
6.13.1 Ratio drive

The ratio drive function is selected with parameter SYA01 = RATIO. With the parameter SYA02 =1,
the synchro ratio function controls two drives with a friction ratio between the drives. Drive 1 is the
master and Drive 2 is the slave. Drive 1 speed set-point is multiplied with Drive 2 ratio set-point
creating the Drive 2 speed command. The ratio set-point can be a value between -300% and 300%.
SYC01 and SYC02 can be used to limit the span. Setpoints can be hardware signals or signals via the
bus connection. In local mode setpoints are given via the keyboard and display units.
6.13.2 Ratio drive - External master

the synchro ratio function controls two drives with a friction ratio separate for each drive. Drive 1 and
Drive 2 are slaves. An external master speed set-point is multiplied with Drive 1 ratio set-point creating
the Drive 1 speed command. The same is valid for drive 2. The ratio set-point can be a value between
-300% and 300%. SYC01 and SYC02 can be used to limit the span for Drive 2. SYG01 and SYG02
can be used to limit the range for Drive 1. A separate ramp-time, only valid for the External master set-
point, can be adjusted by setting SYF01 - SYF04.
Setpoints can be hardware signals or signals via the bus connection. In local mode setpoints are given
via the keyboard and display units.
6.13.3 Counter drive

The synchro counter function can control the relative position in-between two drives. The counter drive
function is selected with parameter SYA01 = COUNTER. The function requires digital type Speed
encoders. They must have identical number of pulses per turn. Drive 1 is the master and Drive 2 is the
slave. Drive 1 speed set-point is transferred to both drives as a basic speed set-point. Drive 1 is run in
closed loop speed control. Drive 2 is run in closed loop position control. The pulses from each encoder
are counted in two counters and compared. If there is a difference between the two counters, there is
a difference in position of the two drives. The difference signal is processed by Drive 2 regulator and
added to the speed set-point for control of Drive 2 position.
The two counters must initially be reset when the position difference is zero in-between the two rolls.
Parameter SYB02 and SYE02 determines when the counters are enabled to be reset.
1= Enable reset every time electric motor is started
2= Enable reset every time drive start is activated
3= Enable reset by a configurable digital input, set to 12 RES EN 1(2)
Parameter SYB01 and SYE01 determines when/how the counters are to be reset.
1= Reset every time drive start is activated.
2= Reset by activation of the external zero pulse input
The position control of drive 2 is activated when both counters are reset. A ramptime can be adjusted
to achieve a smoth synchronisation; this is done with parameter SYD02. The activation of the
regulator can be indicated by a digital output, set to 08 C ZERO. While operating in counter mode, the
ratio drive can be activated by a configurable digital input, set to 12 FRICTION. The input can be
either a hardware signal, or in bus mode a bus signal.
Offset between the two drives can be set in two ways:

-As a constant value by parameter SYC04.
-With an analog input, the range is maximum 0 to 180°.
-Via the bus connection.
6.14 Pressure control

The Pressure control function set-up is to be found in the following parameter menus
"Pressure 1 - Function"
"Pressure 1 - Pr.function"
"Pressure 1 - Regulator"
See block diagram AS7-8.

Pressure 1 control function is described in this section, Pressure 1 and Pressure 2 control functions
are identical. The Pressure control function is providing a possibility to compensate speed set point
depending on the pressure level in the hydraulic system. It can be used as an overload protection or
as a production improvement function, stable torque can be achieved. Digital outputs can be set -up to
indicate if pressure control is active. There are three choices available, P1 C ACT, P1 HI CA and P1
LO CA. For explanation of the outputs, see chapter Digital outputs. The below diagram describes the
pressure control function, forward action. If pressure is increasing the speed set point is increasing.
By altering a parameter, PRA02 = On, reverse action is selected. The below diagram describes the
pressure control function, reverse action. If pressure is increasing the speed set point is decreasing.
6.14.1 Pressure 1 - function

The pressure control function is selected to be active with parameter PRA01 = On. In addition high
and low control is possible to enable separately. This is done with parameters PRA03 and PRA04.
PRA05 and 06 determines the time delay for pressure control to start. It sets the delay in-between a
pressure change above or below set point and regulation start.
6.14.2 Pressure 1 - Set point

Pressure set point can be local or remote. PRB01 selects if the set point is to be Local, remote or
possible to change via a digital input. The digital input is named PR REM 1. The remote set point can
be via hardware inputs or via bus inputs. The local set point must be entered in parameter PRB02.
PRB03 and 04 defines the dead band of the pressure control. When actual pressure is within Pressure
set point - PRB03 and Pressure set point + PRB04 the speed command is not altered. PRAB05 and
06 defines the maximum influence the pressure control is allowed to have on the speed command.
The unit is % and relates to the full speed range of the drive.
6.14.3 Pressure 1 - Regulator

The PID regulator has a similar parameter set as the standard speed feedback PID control. See
chapter AS6.5 for tuning recommendations.
PRC01 Sets the Proportional regulator stage function ON or OFF. The proportional stage reacts
proportional to the Error input signal. Action of this stage is determined by parameter
PRC04.
PRC02 Sets the Integrator function ON or OFF. This function gives the drive a possibility to reach
set-point pressure over time. Action of this stage is determined by parameter PRC05.
PRC03 Sets the Derivative function ON or OFF. The derivative stage is used when very quick
pressure changes are to be expected at the drive. It reacts on the rate of change at the
Error input signal. The D stage is seldom used due to a difficult tuning procedure. Action
of this stage is set by parameters PRC06 and PRC07.
PRC04 Proportional gain parameter sets the gain of the P-stage. P gain 0.5 means that half the
Error signal input value will be transferred to the stage output. Proportional stage
however, will not make the drive reach set-point pressure. There will always be a
remaining Error. The remaining Error value is though depending on the Proportional gain
setting. If the Error signal is small, close to zero, P gain will not produce any output at this
stage output. The P stage always needs an Error signal to modify.
PRC05 Integrator time parameter sets the integration time of the I-stage. An integrator time 10
seconds means that the output value of this stage will reach 63% of the Error signal input
value in 10 seconds. Introduction of Integration will eliminate the remaining Error signal.
The actual pressure will over time correspond to pressure set-point. It can be compared
with a Capacitor that is charged with the Error signal.
PRC06 Derivative time parameter sets the Derivative time of the D stage. A derivative time 10
seconds means that the derivative “gain” is a factor 10. The output from this stage is the
“gain” factor multiplied with the rate of change of the Error signal.
PRC07 Derivative decline time parameter sets the Derivative decline time of the D stage. A
derivative decline time 10 seconds means that the output value from this stage will
decline 63 % in 10 seconds.
PRC08 Filter time for pressure feedback parameter sets the filter time for the pressure. Useful
when the pressure signal contains a lot of noise, the filter will take away pressure peaks.
6.15 Bus Communication

The bus communication is set up in the following menus
"Bus - Type & Function"
"Bus - Digital Inputs"
"Bus - Analog in 1 - 4"
"Bus - Analog out"
See block diagram AS7.2 and parameter list AS5.2.8 for further details.
6.15.1 General
The Bus function requires that a bus card is installed. The card is a profibus-DP slave following the
standard PROFIBUS-DP EN 50 170. It must be connected to a profibus-DP master. The card will only
respond to incoming commands, working as a slave.
The Bus function is activated when a digital input or a bus input is activated and remote mode is
selected via the keyboard. The digital inputs are BUS 1 and BUS 2, these inputs makes it possible to
select bus control separately for drive 1 and 2. Speed set-points are located at predefined bus
addresses. See chapter AS 6.15.9. The below sketch explains the possible mode changes.
LOC/REM button or digital input

REM 1 (Drive 1)
REM 2 (Drive 2)
Bus card not installed
(BTF01 = Off)
LOC REM BUS Bus card installed
and selected (BTF01 = Profibus)
Digital in
Bus digital in
OFF ON
BUS 1 (Drive 1)
LOC/REM button or digital input BUS 2 (Drive 2)
REM 1 (Drive 1)
REM 2 (Drive 2)
Bus fail
Bus communication fail+timedelay (BTF02)
Alarm/Interlock (selectable via BTF03)
Hardware fail
Alarm/Interlock (selectable via BTF03) Prevents Bus mode
If the bus communication is lost, an alarm or Interlock is trigged. An adjustable timer determines the
filter time for the alarm/interlock. Local mode is activated if the bus is faulty. To be able to start bus
communication again the spider must be restarted by reset or power on.
6.15.2 Bus - Type & Function

The bus communication is activated by setting the parameter BTF01 to "Profibus". BTF02 sets the
Communication drop out time. The timer range is 0 - 10 seconds. BTF03 Function at communication
drop determines if an Alarm or an Interlock is activated at a bus failure.
6.15.3 Bus - Digital inputs

A total of 24 digital input signals can be set-up in the parameters BDI01 to BDI24. The choices are
equal to the choices possible in the hardware digital input setup, see list in chapter AS5.2.3. The
following choices from that list are not valid for the bus inputs:
- START 12
- FORW 1+2
- REV 1+2
- REM 1+2
The digital inputs status is possible to monitor on the spider display. Register REG 511 to REG 513
are representing the status of the inputs. Each register contains 8 digital signals. The value of each
signal can be 0 or 1; the format is binary.
REG/BIT 8 7 6 5 4 3 2 1
REG511 Din 8 Din 7 Din 6 Din 5 Din 4 Din 3 Din 2 Din 1
6.15.4 Bus - Analog in 1 - 4

A total of 4 analog input signals can be set-up in the parameters BAAxx to BADxx. Min and Max
values are defined in BAx01 and BAx02, giving the range of the signal. BAx03 is defining the type of
unit and BAx04 defines the number of decimals for the signal. The signal is then ready to be
displayed. The signals are named REG501 to REG 504. The final step is to define the function. This is
done with the parameter BAx05, the possible settings are:
- BSO = Synchro offset.
- BP1 = Pressure set-point drive 1
- BMS = Master speed set-point
- OFF = Not used (Selected when signal is to be displayed only).
See AS6.15.9 for addresses on the bus.
6.15.5 Bus - Analog out

A total of 8 analog output signals can be set-up in the parameters BAK01 to BAK08. See the
parameter list for a list of selectable registers and AS6.15.10 for addresses on the bus.
6.15.6 Bus - Digital out

A total of 144 digital output signals are available for the Profibus-DP master to read. The signals are
predefined and addresses on the bus are described in chapter AS6.15.11.
6.15.7 Address table - Incoming data

In total 16 bytes are received from the Bus. Analog value data is to be in the data form "signed word"
which should be limited to a value range in-between -10 000 to +10 000. The first two words are
reserved for the set-points for drive 1 and drive 2. The following 4 words are selectable analog inputs,
as earlier described. Digital signals are represented by one bit, in total for 24 inputs, 3 bytes.
Function Bit-> 7 6 5 4 3 2 1 0 Example

Byte
Set point 0 15 8 0001 1101
= 7500
drive 1 1 7 0 0100 1100
Set point 2 1101 1000
= -10000
drive 2 3 1111 0000
4 0010 0111
Analog IN 1 = 10000
5 0001 0000
6
Analog IN 2
7
8
Analog IN 3
9
10
Analog IN 4
11
12 7 0
Digital IN 13 15 8
14 23 16
Reserved 15 0000 0000
The analog values are in "signed word" data format. Negative numbers are the 2's complement of the
positive ones. Below is a table with some examples
Signed word value, binary format Decimal value % signal value

Most significant byte Least significant byte
0010 0111 0001 0000 10000 100
1101 1000 1111 0000 -10000 -100
0001 0011 1000 1000 5000 50
1110 1100 0111 1000 -5000 -50
0000 1001 1100 0100 2500 25
1111 0110 0011 1100 -2500 -25
6.15.8 Address table - Outgoing data

In total 38 bytes are transferred to the Bus. Analog value data is in the data form "signed word", limited
to a value range in-between -10 000 to +10 000. The first word is reserved for the protocol version, the
second for the software version. The following 8 words are the selectable analog outputs, as earlier
described. The last 18 bytes are the digital outputs. Digital signals are represented by one bit, in total
for 144 outputs, 18 bytes. Digital outputs addresses are separately described in chapter 6.15.11.

Byte
Protocol- 0 0000 0000 Reserved
version 1 3 0 3 0 0001 0000 = ver 1.0
Software- 2 3 0 3 0 0011 0001
= ver 3.1.2
version 3 7 0 0000 0010
4 15 8 0000 1001
Analog OUT 1 = 2500
5 7 0 1100 0100
6
Analog OUT 2
7
8
Analog OUT 3
9
10
Analog OUT 4
11
12
Analog OUT 5
13
14
Analog OUT 6
15
16
Analog OUT 7
17
18
Analog OUT 8
19
20 7 0
Digital OUT
21 15 8
…
…
…
37 143 136
6.15.9 Digital output address table
20:0 Start1 21:0 P1HiCa 22:0 Forw2 23:0 ShBlck2 24:0 Ready2 25:0 Dummy
20:1 Remote1 21:1 P1CAct 22:1 Rev2 23:1 A1 24:1 EMot1 25:1 Dummy
20:2 Auto1 21:2 PLim 22:2 Reg2 23:2 A2 24:2 EMot2 25:2 Dummy
20:3 PLim1 21:3 ShBlck1 22:3 CZero 23:3 W1 24:3 CoolConI 25:3 Dummy
20:4 Forw1 21:4 Start2 22:4 Synchro 23:4 W2 24:4 HeatCon 25:4 Dummy
20:5 Rev1 21:5 Remote2 22:5 P2LoCa 23:5 Int1 24:5 CoolConD 25:5 Dummy
20:6 Reg1 21:6 Auto2 22:6 P2HiCa 23:6 Int2 24:6 Flush Con 25:6 Dummy
20:7 P1LoCa 21:7 PLim2 22:7 P2CAct 23:7 Ready1 24:7 Dummy 25:7 Dummy
26:0 AUX1 27:0 AUX9 28:0 AUX17 29:0 HIGH_TEMP

26:1 AUX2 27:1 AUX10 28:1 AUX18 29:1 DRAIN_FILTER75
26:2 AUX3 27:2 AUX11 28:2 AUX19 29:2 DRAIN_FILTER100_WARN
26:3 AUX4 27:3 AUX12 28:3 AUX20 29:3 DRAIN_FILTER100_ALARM
26:4 AUX5 27:4 AUX13 28:4 MIN_OIL_LEVEL 29:4 CHARGE_PR_A_PUMP1
26:5 AUX6 27:5 AUX14 28:5 LOW_OIL_LEVEL 29:5 CHARGE_PR_A_PUMP2
26:6 AUX7 27:6 AUX15 28:6 MAX_TEMP 29:6 CHARGE_PR_A_PUMP3
26:7 AUX8 27:7 AUX16 28:7 MIN_TEMP 29:7 CHARGE_PR_A_PUMP4
30:0 CHARGE_PR_B_PUMP1 31:0 HIGH_PR_B_PUMP1 32:0 RET_FILTER75_PUMP1

30:4 HIGH_PR_A_PUMP1 31:4 SUCTION_LINE_PUMP1 32:4 RET_FILTER100_WARN_PUMP1
33:0 RET_FILTER100_ALARM_PUMP1 34:0 CHARGE_PR_A_D1 35:0 TEMP_ELMOTOR1_D1

33:1 RET_FILTER100_ALARM_PUMP2 34:1 CHARGE_PR_B_D1 35:1 TEMP_ELMOTOR2_D1
33:4 PLAUSIBILITY_ERROR_PUMP1 34:4 HIGH_PR_A_D1 35:4 TEMP_ELMOTOR2_D2
33:5 PLAUSIBILITY_ERROR_PUMP2 34:5 HIGH_PR_B_D1 35:5 TEMP_ELMOTOR3_D2
33:6 PLAUSIBILITY_ERROR_PUMP3 34:6 HIGH_PR_A_D2 25:6 ERROR_TOO_LARGE_D1
33:7 PLAUSIBILITY_ERROR_PUMP4 34:7 HIGH_PR_B_D2 35:7 ERROR_TOO_LARGE_D2
36:0 SHREDDER_BLOCKED_D1 37:0 Dummy

36:2 EMERGENCY_STOP 37:2 Dummy
36:3 ANYBUS_OFF 37:3 Dummy
36:4 ANYBUS_HW_FAIL 37:4 Dummy
36:5 Dummy 37:5 Dummy
DB20 to DB25 are signals to be found in the list of available functions for the digital relay outputs,
described in AS6.10.
DB26 to DB37 are partly signals to be found in the list of available functions for the digital inputs,
described in AS6.9.
6.16 Drive monitoring log

The drive monitoring log consists of three parts, alarm/warning lists, drive time counters and 8
scalable log channels. The alarm/warning lists and drive time counters can be indicated on drive 1
display. The total drive log information must be downloaded to a PC for examination. This requires
a null modem cable 576 00xx-801, a PC with windows XP and SpiderCom software installed.
The alarm lists are found in the menu under LOG READINGS – DRIVE 1 – ALARM and LOG
READINGS – DRIVE 2 – ALARM.
The warning lists are found in the menu under LOG READINGS – DRIVE 1 – WARNING and
LOG READINGS – DRIVE 2 – WARNING.
All four lists are 10 alarms or warnings long. The latest will be at the top and when a new warning
or alarm comes to an already filled list, the oldest will be removed. The alarms and warnings are
marked with date and time for the incident. For setting of actual time see TIME/DATE below.
The drive time counters are found in the menu under LOG READINGS – DRIVE 1 – TIME IN USE
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are DRIVE (the time with drive
started) and PUMPS (the time with started electric motor for each pump). The counters can be
reset , see RESET TIME below.
The settings for the drive monitoring log and clock and the reset of the time counters are made in
SETUP – DRIVE LOG and are protected by a password. The settings can only be done from the
front keypad.
TIME/DATE is the setting of actual date and time. The format is YYMMDD HH:MM and is
selected with > button and changed with ∧ and ∨ buttons. The date/time is used for alarm and
warning list time stamps and the clock is battery backed.
LOG1 to LOG 8 are for setting of the eight one dinensional scalable drive monitoring log channels.
The used analog inputs must be set before the log channels are configured, see AS6.8.
Each channel consists of a measuring area divided in 6 levels. The time the measured reading
has been within each of these levels is stored. The measuring is only active with drive started.
Total measuring time is 100 000 hours.
Parallel to the total time log, 4 shorter log registers with the same setting as the total is stored in
chronological order. The log time is adjustable.
Example: 90-100
- Log channel 2
70-90
50-70
30-50
10-30
- Pressure transducer, 0-400 bar on Ain 4.

0-10
Log Total time

- 200 hours period measuring time data
Period 5
90-100
1.Analog input setting:

70-90
50-70
30-50
Time MT 10-30
AII01=4-20mA for the input signal type.

0-10
AII02,03 for zero and max adjustment of the input Period 1

When full
(see example in AS6.8) 90-100
AII04=0 to set the pressure at 4mA. Time MT 70-90

50-70
30-50
10-30
AII05=400 to set the pressure at 20mA.

0-10
Period 2
AII06=bar for the reading units. 90-100
Time MT 70-90
50-70
30-50
2.Log setting:
10-30
0-10
Period 3
SETUP – DRIVE LOG – LOG 2:
STA=ON will activate the log function Time MT
90-100
70-90
50-70
30-50
MT=200 to set the short time measuring cells Period 4

10-30
0-10
(period 1-4) to 200 hours. Period 1 cell will show

the latest up to 200 hours measurement. When this Erased
cell is full the contents will be moved to period 2 cell
and period 1 cell will start from zero again. Next time period 1 cell is full the contents of period
2 cell will be moved to period 3 cell, the contents of period 1 cell will be moved to period 2 cell
and period 1 cell will start from zero again, and so on. When all cells are full the oldest cell
contents will be erased before the next data movement.
LHI=300 to set where level 6 starts
LLO=100 to set where level 1 stops. The area between LLO and LHI will be divided into 4
equal parts. In this case the levels will be:
300-400bar drivetime
0-100bar drivetime
REG=REG404 to select log reading of analog in 4.
When finished setting the question RESET LOG? comes. Select with > button and push ∧ to
get a Y (yes) and then > button to reset. The questions comes if a change is done in any of
the parameters in the specific log channel setup and doesnot affect the other three channels.
The log can be set on or off with STA=OFF or ON without the need to reset the log channel.
RESET TIME for reset of the drive time counters. When the function is selected with > button
push ∧ to get a Y (yes) and then > button to reset.
6.17 Analog outputs
The spider card has four output channels. Each channel can be selected as 0-10V or 2-10V
voltage output or as 0-20mA or 4-20mA current output. The selection between current and
voltage is made by jumpers on the card and by using different terminals.
The selection between 0-10V and 2-10V or between 0-20mA and 4-20mA is made with
parameters in the setup menu.
The outputs can be zero and maxpoint adjusted.
Example for channel 1, 4-20mA for 0-20rpm speed from digital speed encoder.
1. Set parameter D1E01 to 20.0rpm (the speed that corresponds to 100%).
2. Connect a current meter in series with the output signal.
3. Parameter AOA02 must be ON for 4mA output.
4. Select parameter AOA03. The system gives 0% to the card. Adjust the parameter until
closest to 4mA output.
5. Select parameter AOA04. The system gives 100% to the card. Adjust the parameter
until closest to 20mA output.
6. Repeat 4 and 5 until the best result is achived.
6.18 Language selection

A language selection for the alarm/warning list texts and in some cases indication texts on the
main display can be done in the menu (SETUP – MAIN SETTINGS - LANGUAGE :MAC01).
The selectable languages are: English (Default language)
German
French
Spanish
Italian
Japanese (Requires the standard LCD display type)
Dutch
Finnish
Swedish
Short form (abbreviations)
Chinese (Requires a VFD display type)

The system saves the log on a separate memory card (shared with paramterer memory).
The drive monitoring log consists of four parts, alarm/warning lists, drive time counters, six
scalable log channels and two scalable 3D-log channels. The alarm/warning lists and drive time
counters can be indicated on drive 1 display. The total drive log information must be downloaded
to a PC for examination. This requires null-modem cable 576 3521-003, a PC with windows XP
and SpiderCom2 software installed.
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are PUMP (the time with started
electric motor) and DRIVE (the time with drive started). The counters can be reset , see RESET
TIME below.
SETUP – LOG FUNCTION and are protected by a password.
LOG1 to LOG 8 are for setting of the eight scalable drive monitoring log channels.
RESET TIME will reset the time counters for total drive time.
6.20 Emergency stop

The Emergency stop circuit consist of two parallel systems. The main system is a monitoring channel
configured as Alarm. The time delay between opening of the emergency stop input and the shutdown
of the electric motors is set with parameter DMD01-03.
The backup system is a hardware timer on the board with possibility to set the delay between 2 and 32
sec with SW1 (see AS4.5).
The timer must be set 0 - max 4sec longer then the main system. A time set more then 4 sec longer
will give a warning. If setting is shorter or 5sec longer the system will shutdown at hardware test.
Setting Time delay

0 2 sec
1 4 sec
2 6 sec
3 8 sec
4 10 sec
5 12 sec
6 14 sec
7 16 sec
8 18 sec
9 20 sec
A 22 sec
B 24 sec
C 26 sec
D 28 sec
E 30 sec
F 32 sec
At each power up and each time all electric motors are stopped, the system will check that the relays
for the electric motor interlock outputs not are stucked in closed position.
The emergency stop alarm is as default with memory and must be reset but can be set to automatic
reset with MAB11:ON.
6.21 Program update

The program version can be updated by using the cable used for SpiderCom (576 3521-003) and the
software program Loader.exe (Spider flash loader).
Run Loader.exe. Select the file for download Start the procedure
Reset the Spider board by pushing the reset button or by switching on and off the power to the card to
start the download procedure.
When the download is ready, reset the Spider system and set new parameters.
6.22 Hardware calibration

When the software is updated a hardware calibration is needed. This calibration is needed to
compensate for the offset in the measuring channels for the stroker current feedback. This calibration
must be done without stroker coils connected.
Disconnect contact PO1, PO2, PO3 and PO4.

In the main menu there is a choice for this calibration
HW CALIBRATION
↵ ⇒ PWM OFFSET
↵ ⇒ CAL. OFFSET NO
∧ ⇒ CAL. OFFSET YES
↵ will start the calibration. Calibration OK and the calibration settings will be indicated when the
procedure is ready. This adjustment will be stored in an EEProm on the main board.
AS-7.1
Spider Digital inputs
AS7.1, Digital inputs, Engineering manual 05-01-21
AS-7.2
Spider Analog in- and outputs
AS7.2, Analog in- and outputs, Engineering manual 05-01-21
AS-7.3
Spider Pump outputs
AS-7.4
Spider Monitor
AS7.4, Monitor, Engineering manual 05-01-21
AS-7.5
Spider Basic function
AS7.5, Basic function, Engineering manual 04-04-02
AS-7.6
Spider Shredder function
AS7.6, Shredder function, Engineering manual 04-04-02
AS-7.7
Spider Synchro function
AS7.7, Synchro function, Engineering manual 04-04-02
AS-7.8
Spider Pressure function
AS-7.9
Spider Emergency stop
AS-7.9
PAC MANUAL DE INSTALACIÓN Y MANTENIMIENTO
Manual de Instalación y
Mantenimiento
PAC
Prefacio Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Prefacio
Hagglunds Drives es uno de los fabricantes más importantes en el mundo
de sistemas hidráulicos de baja velocidad, alto torque y de uso pesado.
Ofrecemos un sistema de propulsión duradero que funcionará bajo las
condiciones más difíciles con un mínimo nivel de mantenimiento. Contamos
con clientes industriales y marítimos en todas partes del mundo quienes
saben que, al buscar soluciones, apoyo o servicio, pueden confiar en
Hagglunds Drives. La fábrica y oficinas principales de Hagglunds Drives
están ubicadas en Mellansel, Suecia. Además, contamos con oficinas de
ventas y servicio en 40 países.
Nuestros sistemas de propulsión de alta calidad se basan en motores

hidráulicos de pistones, los cuales son únicos y fueron desarrollados como
resultado de la experiencia acumulada durante 30 años en los sectores
industriales y marítimos. Hoy en día, los avances en el diseño han resultado
en nuestra línea de productos de unidades de potencia PAC. Esta es la
unidad que impulsa nuestros sistemas de transmisión. Nuevas soluciones,
en conjunto con soluciones técnicas bien establecidas, han contribuido a la
creación de este producto. El diseño de la unidad de potencia PAC incorpora
las características más deseables, así como los más altos niveles de
confiabilidad operativa.
El presente manual proporciona los datos necesarios para la instalación y

mantenimiento de la PAC. Para poder encontrar datos específicos, favor
de utilizar el índice. Sin embargo, pueden haber cambios en los equipos y,
por lo tanto, nos reservamos el derecho de incorporar modificaciones en el
manual, según sean necesarias, sin notificación previa u obligación por
nuestra parte.
Antes de iniciar la instalación y el mantenimiento, favor de leer el manual y

cerciorarse de que lo entienda completamente. Todo el personal involucrado
debe leer y tomar en cuenta las precauciones de seguridad que aparecen
en la sección 1.1.
Los contenidos de este manual están sujetos a modificación sin

notificación previa u obligación. Por lo tanto, los datos incluidos en
el presente siempre deben ser confirmados con Hagglunds Drives o
Original AM326-1A-SP 2000
sus representantes.
2
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Contenido
Contenido
1. GENERAL ........................................................................................................................ 4
1.1 Precauciones de seguridad ...........................................................................................................4
1.2 Principio operativo .........................................................................................................................6
2. DATOS TECNICOS ......................................................................................................... 7
2.1 Condiciones operativas .................................................................................................................7
2.2 Agua de enfriamiento ....................................................................................................................8
2.3 Requisitos para la limpieza del fluido hidráulico ............................................................................8
2.4 Selección del fluido hidráulico .......................................................................................................9
2.5 Monitoreo de la unidad de potencia ............................................................................................10
3. MANEJO DE LA UNIDAD DE POTENCIA EMPACADA............................................... 11
3.1 Almacenaje de la unidad de potencia empacada ........................................................................ 11
3.2 Levantamiento de la unidad de potencia empacada ................................................................... 11
4. INSTALACIÓN ............................................................................................................... 12
4.1 Instrucciones de instalación ........................................................................................................12
4.2 Métodos y pesos de levantamiento .............................................................................................14
4.3 Colocación de la unidad de potencia ..........................................................................................15
4.4 Ensamble de las patas del gabinete ...........................................................................................15
4.5 Ensamble del motor eléctrico ......................................................................................................16
4.6 Ensamble del enfriador de aire-aceite y ventilación del gabinete ...............................................18
4.7 Ensamble de la tapa superior......................................................................................................19
4.8 Conexiones hidráulicas ...............................................................................................................19
4.9 Conexiones eléctricas .................................................................................................................20
4.10 Tubería ......................................................................................................................................20
4.11 Filtración adicional antes del arranque ......................................................................................24
4.12 Puesta en servicio .................................................................................................... 25
4.12.1 Antes de la puesta en servicio ................................................................................................25
4.12.2 El llenado del sistema con fluido hidráulico ............................................................................ 25
4.12.3 Procedimiento inicial de arranque ..........................................................................................27
4.13 Ajuste de las bombas ................................................................................................................29
5. MANTENIMIENTO PREVENTIVO ................................................................................. 31
5.1 Registro de mantenimiento .........................................................................................................31
5.2 Tabla de mantenimiento ..............................................................................................................31
5.3 Reposición del filtro .....................................................................................................................32
5.4 Inspección del fluido hidráulico ...................................................................................................33
5.5 Lubricación del motor eléctrico....................................................................................................34
5.7 Limpieza del enfriador de aire-aceite ..........................................................................................35
5.8 Unidad de potencia fuera de servicio ..........................................................................................35
6. MANTENIMIENTO CORRECTIVO ................................................................................ 35
6.1 Mantenimiento común .................................................................................................................35
6.2 Reposición del ensamble de la bomba hidráulica / motor eléctrico.............................................36
6.3 Detección de fallas ......................................................................................................................37
7. DESECHO DE LA UNIDAD DE POTENCIA ................................................................. 38
3
General Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
1. GENERAL
1.1 Precauciones de seguridad
El cumplimiento de las precauciones de seguridad es de suma importancia. En caso de tener cualquier
duda, favor de comunicarse con su representante de Hagglunds Drives para pedir asesoría.
Señales de advertencia
En el presente manual, se incluyen las siguientes señales de advertencia, las cuales indican la existencia
de un peligro potencial que ocasionará o pudiera ocasionar lesiones corporales o daños a la propiedad.
Se han establecido tres categorías en lo que se refiere al nivel del peligro:
!
PELIGRO
Se utiliza el término PELIGRO para indicar la presencia de un riesgo
que ocasionará lesiones corporales severas, muerte o daños
significativos a la propiedad si se hace caso omiso de la advertencia.
!
ADVERTENCIA
Se utiliza el término ADVERTENCIA para indicar la presencia de un
riesgo que pudiera ocasionar lesiones corporales severas, muerte o
daños significativos a la propiedad si se hace caso omiso de la
advertencia.
PRECAUCION
! Se utiliza el término PRECAUCION para indicar la presencia de un
riesgo que ocasionará o pudiera ocasionar lesiones corporales
menores o daños a la propiedad si se hace caso omiso de la
advertencia.
General
Se debe limitar el acceso al equipo únicamente al personal autorizado. Se deben realizar operaciones
en relación con la PAC al estar totalmente familiarizado con las funciones de la unidad de potencia
(incluyendo el sistema de control), así como la transmisión en su totalidad.
El servicio y reparación de los sistemas eléctricos, hidráulicos y mecánicos requieren de los servicios
de personal profesional que entiende los riesgos involucrados.
Se deben utilizar los equipos de seguridad para la prevención de accidentes durante el ensamble y
mantenimiento, de acuerdo con los reglamentos vigentes en el país.
4
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC General
Antes de la detección de fallas

• Utilizar el código del pedido y la demás documentación técnica adjunto para identificar las
características de su unidad de potencia y sistema.
• Leer la documentación técnica adjunta (incluyendo este manual) y familiarizarse con el PAC
(incluyendo el sistema de control), así como la transmisión total.
• Usar equipo de seguridad, tales como cascos, anteojos, zapatos de seguridad y protección para
los oídos.
• Cerciorarse de que no exista energía acumulada en el sistema antes de iniciar el trabajo de
mantenimiento.
• Cerciorarse de que toda la energía eléctrica haya sido apagada.
• Cerciorarse de que no exista presión atrapada dentro del sistema hidráulico.
• Cerciorarse de que no pueda entrar presión en el sistema hidráulico de la unidad de potencia a
través del motor hidráulico, por ejemplo, cargas sobre la flecha o tambor del winche.
• Si se utiliza el sistema hidráulico para levantar dispositivos, tales como elevadores, winches,
etc., estos deben estar amarrados o en la posición de descanso.
• Cerciorarse de que todos los acumuladores estén descargados.
Suministro de energía eléctrica
Los equipos de seguridad, necesarios para la prevención de accidentes, deben ser proporcionados
de acuerdo con los reglamentos vigentes en el país.
Todos los niveles para el suministro de energía eléctrica deben estar dentro de los límites de la
construcción del equipo. Véase la documentación técnica y las placas de capacidad máxima.
Ensamble
Seguir las instrucciones cuidadosamente y favor de tomar en cuenta los pesos y fuerzas de gran
magnitud en el momento de realizar operaciones de levantamiento. El ensamble y ajuste incorrectos
de los componentes eléctricos, hidráulicos y mecánicos pueden ocasionar lesiones corporales o daños
a la propiedad.
Antes del arranque
Antes de arrancar nuevos sistemas de transmisión, o sistemas reconstruidos o que han sido sometidos
a mantenimiento, se deben realizar inspecciones y pruebas de todos los accesorios y sistemas de
seguridad.
Mantenimiento y servicio
Se deben cumplir con los intervalos de mantenimiento que corresponden a su PAC o los máximos
intervalos que aparecen en la tabla de mantenimiento (sección 5.2, Tabla de Mantenimiento) y se
debe mantener una bitácora de mantenimiento. El mantenimiento regular y correcto es necesario
para operación confiable y segura.
Se deben utilizar únicamente refacciones recomendadas y suministradas por Hagglunds Drives.
Fluido hidráulico
Favor de tomar en cuenta que la mayoría de los fluidos hidráulicos pueden ocasionar lesiones corpo-
rales y severos daños al medio ambiente. Revisar las advertencias en el contenedor o consultar con
el proveedor. El fluido hidráulico desgastado puede contener contaminantes nocivos. Recomendamos
el uso de un proveedor profesional en lo que se refiere al suministro y desecho de fluidos desgastados.
El fluido hidráulico, bajo ninguna circunstancia, debe entrar en los drenajes o tuberías de agua.
5
Principio Operativo Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Envoltura de la campana
Favor de tomar nota de que existen componentes rotatorios dentro de la envoltura de la campana
durante operaciones. Favor de tener cuidado al realizar inspecciones a través del registro. Reponer
la tapa del registro después de realizar una inspección.
Superficies calientes
Las temperaturas en el sistema hidráulico por encima de los 158º F (70º C) resultarán en superficies
calientes.
Situaciones de emergencia
Paro de emergencia: debe existir la posibilidad de apagar la energía eléctrica durante una situación
de emergencia. Se deben utilizar extintores de incendio que son aprobados para uso con productos
petroleros y equipos eléctricos.
1.2 Principio operativo

Componentes principales
1. Bomba hidráulica 18
20
2. Válvula de drenaje 19
3. Vidrio de nivel
4. Medidor de presión de carga
5. Medidor de servo-presión
6. Medidor de presión principal –
compuerta “B”
7. Medidor de presión principal –
compuerta “A”
8. Respirador de aire
17
9. Filtro de drenaje 11
7 8
10. Filtro de retorno 5 6
11. Motor eléctrico 4
6
4
5
12. Interruptor del filtro 13
9
7
3
13. Interruptor límite de la válvula de 12 12
15 14
succión 15
10 10
14. Interruptor de presión de carga 1 16
15. Stroker electrohidráulico 13

16. Calentador de aceite
17. Caja de terminales 2
18. Enfriador de aceite
19. Interruptor de temperatura
20. Interruptor de nivel
Nota: Puede haber cambios en el dibujo y la

tabla de componentes principales.
Función
La función de la unidad de potencia es la de suministrar al motor hidráulico (u otros sistemas hidráulicos)
el flujo requerido de aceite y presión en el momento correcto. Todos los componentes están
ensamblados en uno o más gabinetes compactos. El PAC cuenta con una o más bombas, las cuales
son impulsadas por uno o más motores eléctricos. La bomba principal es de pistón axial con
desplazamiento variable para sistemas de circuito cerrado. El motor eléctrico está totalmente encerrado
y cuenta con un ventilador de enfriamiento. Dos sistemas de control están disponibles.
6
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Datos Tecnicos
Sistemas de control disponibles

Spider: Un pequeño sistema de control compacto y sujeto a configuración. Puede monitorear la
unidad de potencia y puede controlar uno o dos bombas a través de tres funciones previamente
programadas:
• Básico, para la mayoría de nuestras transmisiones, puede ser configurado para controlar la
velocidad de retroalimentación y limitar la potencia.
• Desmenuzador, para aplicaciones relacionadas con desmenuzadores.
• Sincro, para transmisiones sincronizadas y de fricción.
MCA: Para funciones especiales de control, normalmente se basan en PLC y tarjetas de control.
Nota: También se puede controlar el PAC a través de los sistemas de control externos proporcionados
por el cliente.
El PAC es un producto muy flexible con una amplia gama de opciones. De esta manera, se puede
seleccionar una unidad de potencia estándar para cumplir con las características que se requieren
para muchas aplicaciones. Este manual de instalación y mantenimiento pretende cubrir las opciones
estándares y puede ser que no abarca todos los detalles en lo que se refiere a unidades de potencia
especiales, las cuales pueden desviarse del concepto estándar del PAC.
Favor de analizar la documentación técnica adjunto

!
PRECAUCION
para identificar las características de su unidad de
potencia.
2. DATOS TECNICOS
2.1 Condiciones operativas
La unidad estándar del PAC está diseñada para las condiciones que se establecen a continuación. Si
los requisitos están fuera de las condiciones que se establecen más adelante, favor de comunicarse
con su representante de Hagglunds Drives para explicar sus requisitos específicos para tomar en
cuenta consideraciones especiales en el diseño.
Temperatura ambiental: Un mínimo de 32º F (0º C) y un máximo de 85º F (30º C).
Altitud: Un máximo de 3,300 pies (1,000 metros).
Ubicación clasificada: La unidad está diseñada para una ubicación estándar. Las unidades
pueden ser construidas para uso en ubicaciones clasificadas como peligrosas. Favor de
comunicarse con su representante de Hagglunds Drives para mayores detalles.
7
Datos Tecnicos Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
2.2 Agua de enfriamiento

El sistema de enfriamiento está diseñado para operar principalmente con agua limpia.
Si existen partículas en el agua con un diámetro en exceso de 0.02” (0.5 mm), se debe utilizar un filtro.
Es importante:
• Mantener el filtro de agua (si lo hay) de la manera correcta, para obtener el flujo de agua
requerido a través del enfriador de agua / aceite.
• Cerciorarse que tenga el flujo, temperatura y presión requeridos en lo que se refiere al agua de
enfriamiento (véase la documentación técnica adjunta).
• Revisar la temperatura en el sistema hidráulico, de acuerdo con los intervalos de mantenimiento
para su unidad de potencia especifica o los máximos intervalos que se establecen en la tabla de
mantenimiento.
• Limpiar el sistema de enfriamiento si la temperatura del sistema hidráulico excede de los límites
especificados.
• Limpiar y vaciar el sistema de enfriamiento (lado de agua) antes de iniciar periodos de
inactividad (especialmente si el agua de enfriamiento no está totalmente limpia).
Si la capacidad de enfriamiento es insuficiente, la vida útil del motor

hidráulico, los componentes principales en la unidad de potencia y el fluido
hidráulico será reducida.
2.3 Requisitos para la limpieza del fluido hidráulico

El PAC cuenta con filtros en las líneas de drenaje y retorno. Para poder alcanzar la vida útil nominal,
es importante cumplir con las recomendaciones relacionadas con los niveles de limpieza y los requisitos
de mantenimiento.
Recomendaciones relacionadas con la limpieza
• Se debe limpiar el sistema antes de arrancar (sección 4.12, “Limpieza del sistema antes de
arrancar”).
• Al llenar el tanque con fluido hidráulico, se debe llenarlo a través de la conexión rápida (sección
4.13.2, “Llenado del sistema con fluido hidráulico”).
• El nivel de contaminación con partículas dentro del sistema no debe exceder de lo establecido
en ISO/DIS 4406 16/13 (NAS 1638, clase 7).
• El contenido de agua debe ser <0.1% y en el caso de aplicaciones individuales de alta demanda
en lo que se refiere a la vida útil <0.05%.
• Siempre se deben utilizar los filtros recomendados y suministrados por Hagglunds Drives.
• Se debe analizar el fluido hidráulico de acuerdo con los intervalos de mantenimiento para su
PAC específico o los máximos intervalos que se establecen en la tabla de mantenimiento
(sección 5.2, “Tabla de mantenimiento”). Debe tener mucho cuidado al sacar equipos para
reparación o mantenimiento para que basura no entre en el sistema. Se deben limpiar los
componentes antes de desensamblarlos.
No se debe volver a utilizar fluido hidráulico que se

derrama del sistema.
8
2.4 Selección del fluido hidráulico

La unidad de potencia está diseñada principalmente para operar con fluidos hidráulicos convencionales
a base de petróleo. Al seleccionar el fluido hidráulico, recomendamos una consulta con su representante
de Hagglunds Drives.
El fluido hidráulico debe cumplir con los siguientes requisitos:
• Debe cumplir con FZG 90, etapa de prueba 11, que se describe en IP 334 (DIN 51354).
• Debe contener inhibidores para evitar oxidación, corrosión y espuma.
• Una viscosidad dentro del intervalo establecido para el PAC (véase más adelante) y el motor
hidráulico a la temperatura de operación (medida dentro de la envoltura del motor)
• El contenido de agua debe ser <0.1% y en el caso de aplicaciones individuales de alta demanda
en lo que se refiere a la vida útil <0.05%.
En el caso de otros fluidos hidráulicos, favor de comunicarse con su representante de Hagglunds
Drives si:
• Requiere de otros sellos dentro de la bomba y otros componentes.
• La vida útil, presión máxima u velocidad máxima de las bombas pueden ser reducidas.
Límites de viscosidad VISCOSIDAD RECOMENDADA a

Recomendada 100 VI temperatura de operación 40-150
Indice de Para operación con cSt (187-720 SSU).
viscosidad VI grandes diferencias de 150 VI
temperatura En lo que se refiere a arranques en
Mínimo continuo 40 cSt (187 SSU) frío, la máxima viscosidad
Mínimo intermitente 20 cSt (98 SSU) permitida es de 1600 cSt (7400
Viscosidad n
Máximo continuo 150 cSt (720 SSU) SSU) al operar a baja presión y
Máximo intermitente 1600 cSt (7400 SSU) bajo flujo.
Temperatura ºF (lectura en la envoltura del motor)

50 100 150 200
1000
Viscosidad n SSU
Viscosidad n cSt
150 720
Viscosidad
100 Recomendada
40 187
VG 100
VG 46 VG 150
VG 68
10
0 10 20 30 40 50 60 70 80 90 100
Temperatura ºC (lectura en la envoltura del motor)
• Revisar las advertencias en el contenedor o consultar con el proveedor.

• Evitar el contacto prolongado del fluido hidráulico con su piel.
• Utilizar los servicios de un proveedor profesional en lo que se refiere al
!
ADVERTENCIA
•
desecho de los fluidos desgastados y filtros.
El fluido hidráulico, bajo ninguna circunstancia, debe entrar en los
drenajes o tuberías de agua.
• Para evitar lesiones, limpiar los derrames de fluido hidráulico de los
pisos, de inmediato.
9
Datos Tecnicos Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
2.5 Monitoreo de la unidad de potencia

Si la función de monitoreo no está incluida en el sistema de control proporcionado con el PAC, el
sistema debe cumplir con la siguiente función:
INTERRUPTERES DE MONITOREO FUNCIONES EXTERNAS
UNIDAD DE POTENCIA
Interruptor máximo de
la temperatura de aceite
1
Interruptor mínimo de
la temperatura de aceite
1
Interruptor mínimo del
1
nivel de aceite
1 PARO DEL MOTOR HIDRÁULICO

Interruptor de cerrada
la línea de succión
1
1s 0s PARO DEL MOTOR ELÉCTRICO
Interruptor de presión
Tiempo de retardo de apagado
de baja
Tiempo de retardo de encendido
0s 0.5s 1
5s 0s
&
Tiempo de retardo de encendido
Motor eléctrico empezado
Interruptor de advertencia
de la temperatura de aceite
1
Interruptor del
nivel bajo de aceite
1
Interruptor del filtro
1
de retorno
0s 5s 1 INDICACIÓN DE ADVERTENCIA
Interruptor del
filtro de drenaje
0s 5s 1
Interruptor de
alta presión
0s 5s 1
El monitoreo de los interruptores de la unidad de potencia está agrupado en dos niveles, de acuerdo
con el diagrama anterior.
La señal de advertencia le informa con respecto a la existencia de un problema en el PAC que no
requiere de atención inmediata.
El alarma indica la necesidad de parar la bomba. En lo que se refiere a la secuencia de paro, primero
se para el motor hidráulico sin rampa, al ajustar el ángulo oscilante de la bomba a cero. Posteriormente,
después de una pequeña demora, se para el motor eléctrico.
El interruptor de presión de baja carga debe estar enclavado durante el paro y arranque del motor
eléctrico para evitar una alarma y darle tiempo a la bomba para incrementar la presión de carga
después de su arranque.
10
3. MANEJO DE LA UNIDAD DE POTENCIA EMPACADA

3.1 Almacenaje de la unidad de potencia empacada
En el momento de su entrega, los componentes hidráulicos están protegidos internamente con una
capa de aceite (con aditivos para evitar oxidación). Esto ofrece suficiente protección para almacenaje
bajo techo en una ubicación con aire acondicionado durante un periodo hasta de 12 meses.
Se deben almacenar el PAC y los componentes incluidos bajo techo en un lugar seco, libre de
vibraciones y polvo. No se deben almacenar el PAC y los componentes durante más de tres meses
en una ubicación sin aire acondicionado. (Esto incluye los componentes que forman parte de la
unidad de potencia que se entregan por separado.)
Para evitar condensación, se debe colocar la unidad de potencia en un lugar en donde no está
directamente expuesta a la luz del sol o a bajas temperaturas.
Si el almacenaje excede los límites antes mencionados, se debe operar la unidad de

potencia de manera que se lubrique el sistema hidráulico con nuevo fluido (sección 5.8
“Unidad de potencia fuera de servicio”)
3.2 Levantamiento de la unidad de potencia empacada

La unidad de potencia empacada cuenta con una etiqueta que indica el
centro de gravedad y el peso. Normalmente, el empaque de la unidad
de potencia está diseñado para manejo con un montacargas.
Etiqueta de centro
de gravedad.
• El centro de gravedad es alto, véase la etiqueta en la unidad de
potencia.
!
PRECAUCION
•
•
Evitar las aceleraciones, desaceleraciones y vueltas rápidas al
trasladar el equipo.
Se debe colocar el montacargas de acuerdo con las instrucciones
que se señalan a continuación.
Levantamiento con montacargas
• La longitud mínima de la plataforma del montacargas es de 51.2” (1300 mm).
• La distancia mínima entre las secciones de la plataforma del montacargas es de 31.5” (800 mm)
en el caso de un PAC de dos puertas y 43.3” (1100 mm) en el caso de una unidad de potencia
de tres puertas.
• Se debe colocar la plataforma de acuerdo con el centro de gravedad.
Componentes que se entregan por separado
• Siempre se indica el peso en el empaque.
• Los bultos empacados sobre patines están diseñados para manejo únicamente con
montacargas.
• Algunos otros bultos pueden ser levantados con una grúa, pero siempre se deben leer las
indicaciones que aparecen en la etiqueta colocada sobre el bulto.
• Nadie debe pararse por debajo del bulto después de subirlo.
!
PELIGRO
• Unicamente se debe utilizar equipo de levantamiento que tiene la
capacidad de manejar el peso que se indica en la etiqueta colocada
sobre el bulto.
11
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
4. INSTALACIÓN
4.1 Instrucciones de instalación
Para que el PAC funcione correctamente, se debe proceder con la instalación de acuerdo con estas
instrucciones. Se deben tomar en cuenta las condiciones bajo las cuales la unidad estará en operación.
La instalación incorrecta, al incumplir con las instrucciones establecidas en este manual y la
documentación técnica adjunta, puede afectar la operación y/o vida útil de la unidad de potencia.
Siempre se deben cumplir con las medidas de seguridad que se establecen en este manual.
Para cumplir con los requisitos en lo que se refiere a la circulación

del aire, nunca se debe colocar la unidad de potencia directamente
en contra de un muro u otra obstrucción similar. De ser así, favor de
comunicarse con su representante de Hagglunds Drives.
PAC 100/200/300/400 PAC 200D/400D/600/800

H1
H1
B2 A2 B2
H2
H2
B1 M A1 B1
A3
Tamaño del Gabinete 1 2 3 4 5

Tipo PAC 100 PAC 300 PAC 400D
PAC 200D PAC 800
Dimensiones PAC 200 PAC 400 PAC 600
H1 89 in. (2261mm) 89 in. (2261mm) 99 in. (2515mm) 99 in. (2515mm) 106 1/2 in. (2705mm)
B2 51 1/8 in. (1299mm) 76 in. (1949mm) 62 in. (1575mm) 100 in. (2540mm) 117 3/4 in. (2991mm)
A1 39 3/8 in. (1000mm) 39 3/8 in. (1000mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm)
12
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
Colocación de la unidad de potencia

Se deben tomar en cuenta los siguientes factores en el momento de colocar la unidad PAC:
• Se debe colocar la unidad sobre un cimiento plano para evitar vibraciones.
• Se debe colocar la unidad de manera se faciliten el mantenimiento y servicio (sección 4.3,
“Colocación de la unidad de potencia”).
• Se debe proteger la unidad contra los elementos, agua en el aire, contaminación y calor.
• Se debe garantizar una ventilación adecuada de la unidad de potencia, el motor eléctrico y el
enfriador de aire-aceite para propósitos de enfriamiento.
• Se debe minimizar la longitud de la tubería.
Se deben colocar abrazaderas en cada tubo por separado y los tubos deben sujetarse a un cimiento
firme para evitar vibraciones. Las conexiones principales de los tubos con el PAC siempre deben
contar con mangueras.
Si se instala el enfriador de aire en un lugar que no sea sobre
PRECAUCION
! la unidad de potencia, favor de tomar en cuenta que el
enfriador se arranca súbitamente y tiene bordos filosos.
OIL OIL OIL OIL
OUT IN OUT IN
QUITAR LOS PANELES LATERALES
Si se instalan las unidades, una junto a la otra, se deben quitar los

páneles laterales. De esta manera, se puede dar mantenimiento a las
unidades de potencia.
13
4.2 Métodos y pesos de levantamiento Motor eléctrico

Potencia HP (kW) Peso* libras (kg)
30 (22) 365 (165)
Se indica el peso total de la unidad de potencia en 40 (30) 490 (222)
la placa de identificación colocada en la puerta de 50 (37) 560 (254)
la caja de terminales dentro del gabinete. 60 (45) 800 (363)
75 (56) 840 (380)
Levantamiento con cuerdas y/o cadenas 100 (75) 1160 (526)
125 (93) 1540 (698)
Levantar el PAC después de haber quitado la tapa superior con un ángulo
150 (112) 1730 (785)
máximo de levantamiento de 90º. 200 (149) 1750 (794)
Levantamiento con montacargas 250 (186) 1925 (873)
300 (224) 2500 (1134)
• La longitud mínima de la plataforma del montacargas es de 51.2”
350 (261) 2650 (1202)
(1300 mm). 400 (298) 3500 (1587)
• La distancia mínima entre las secciones de la plataforma del 450 (336) 4300 (1950)
montacargas es de 31.5” (800 mm) en el caso de un PAC de dos
puertas y 43.3” (1100 mm) en el caso de una unidad de potencia de
tres puertas. * Este es el peso de un
• Se debe colocar la plataforma de acuerdo con el centro de motor eléctrico estándar.
gravedad. Se pueden encontrar
datos más exactos
correspondientes al
motor especifico en la
placa de identificación.
Bombas Denison
Modelo Peso libras (kg)
P6S 335 (152)
P7S 335 (152)
P11S 484 (220)
P14S 484 (220)
P24S 753 (342)
P30S 786 (357)
Enfriador de aire-aceite
Tamaño Peso libras (kg)
B A A B AOVH-30 190 (86)
AOVH-40 350 (159)
AOL-950 221 (100)
AOL-1200 296 (134)
AOL-1600 355 (161)
Siempre se deben utilizar los cuatro puntos de
levantamiento al subir la unidad de potencia

• Unicamente se debe utilizar equipo de levantamiento que tiene la capacidad de
!
PELIGRO •
manejar el peso de la unidad de potencia (según se indica en la placa de
identificación dentro del gabinete).
No se debe levantar la unidad de potencia con fluido hidráulico dentro del tanque
o cuando la barra frontal está desensamblada.
14
4.3 Colocación de la unidad de potencia

Se debe dejar el siguiente espacio mínimo alrededor del PAC para garantizar ventilación adecuada y
espacio para maniobrar al realizar trabajos de mantenimiento. Trabajos de mantenimiento mayor,
tales como la reposición de la bomba o el motor, requieren de más espacio.
No se deben instalar los PACs uno junto al otro sin haber quitado los páneles laterales.
Es importante que todos los tubos de agua y fluido hidráulico estén correctamente montados para
permitir suficiente espacio para maniobrar al realizar trabajos de mantenimiento.
PAC 100/200/300/400 PAC 200D/400D/600/800

CONTORNO DEL PISO CON EL ENFRÍADOR DE AIRE CONTORNO DEL PISO CON EL ENFRÍADOR DE AIRE
8 [203mm] 8 [203mm]
CONTORNO DEL PISO SIN CONTORNO DEL PISO SIN
EL ENFRÍADOR DE AIRE EL ENFRÍADOR DE AIRE
32 [813mm]
36 [914mm]
32 [813mm]
32 [813mm] 32 [813mm]
32 [813mm]
40 [1016mm]
40 [1016mm]
REFERENCIA: CONTORNO DEL PISO

LAS DISTANCIAS MOSTRADAS SON MÍNIMAS REFERENCIA: CONTORNO DEL PISO
LAS DISTANCIAS MOSTRADAS SON MÍNIMAS
4.4 Ensamble de las patas del gabinete

Las patas (opcionales) del gabinete minimizan las vibraciones y facilitan la nivelación del PAC. Se
entregan las patas por separado, dentro del gabinete, y deben ser ensambladas de acuerdo con las
siguientes instrucciones:
1. Ensamblar las patas del gabinete antes de

llenar el tanque con fluido hidráulico.
2. Ensamblar las patas del gabinete antes de
1-1 1 AJUSTABLE
instalar el motor o los motores eléctricos, ya

sea que hayan sido entregados por
separado o proporcionados por el cliente.
2
1
2
3. Levantar la unidad de potencia de acuerdo

con las instrucciones que se establecen en
este manual (sección 3.2, “Levantamiento de
la unidad de potencia empacada”).
Cerciorarse de cumplir con las precauciones
de seguridad.
4. Ensamblar las patas del gabinete de
acuerdo con el dibujo más adelante. Hay que tener mucho cuidado al
instalar las patas del gabinete. Fa-
5. Nivelar el PAC al ajustar los tornillos.
! vor de seguir las instrucciones que
aparecen en la sección “Métodos
ADVERTENCIA de pesos de levantamiento”.
15
4.5 Ensamble del motor eléctrico

En algunos casos, se entregan el motor o los motores eléctricos por separado. Las siguientes
instrucciones son aplicables únicamente en aquellos casos.
1. Quitar la tapa superior de la unidad de potencia
Aflojar los pernos que sujetan la tapa superior al armazón. Instalar los pernos de argolla en las
aperturas en las esquinas de la tapa superior y levantar la tapa. Si el espacio de levantamiento es
insuficiente, se pueden quitar el panel frontal y la viga frontal de la unidad de potencia.
2. Quitar el silenciador de ruido
Quitar el silenciador de ruido y colocarlo en un lugar protegido. Al volver a instalar el silenciador de
ruido, el material de aislamiento debe voltearse hacia arriba.
3. Desempacar el motor o los motores eléctricos
Desempacar el motor eléctrico y realizar una inspección para detectar daño externo. Además, revisar
los datos en la placa de identificación para cerciorarse de que sean los mismos que aparecen en la
documentación técnica.
4. Revisar los acoplamientos de la flecha
Revisar el acoplamiento de la flecha axial para cerciorarse de que el espacio libre cumpla con las
especificaciones del fabricante del acoplamiento.
5. Levantar el motor eléctrico
Primero, se debe utilizar el perno de argolla en la parte superior para levantar el motor eléctrico y
colocar en una posición vertical. Luego, se debe levantarlo con todos los pernos de argolla. El motor
eléctrico nunca debe pararse sobre el acoplamiento de la flecha.
Se pueden necesitar dos diferentes tipos del equipo de levante para levantar el motor eléctrico.
6. Instalar el motor eléctrico en la unidad de potencia
Levantar el motor eléctrico y colocarlo dentro del PAC. Es importante que esté colgándose en forma
perpendicular. Extender el acoplamiento de la flecha a través del registro de inspección adentro del
acoplamiento de nylon en forma de estrella sin hacerle ningún daño. Se debe colocar la caja de
conexiones del motor eléctrico de la manera que se señala en el dibujo que aparece en la sección 1.2
“Principios operativos”. Bajar el motor hasta una posición aproximadamente 0.2” (5 mm) por encima
de la envoltura de la campana. Colocar los pernos engrasados dentro de los hoyos y apretarlos a
mano.
7. Apretar los pernos en la envoltura de la campana
Realizar una inspección para cerciorarse de que exista un espacio libre axial en el acoplamiento de la
flecha a través del registro de inspección en la envoltura de la campana y, después, apretar los pernos
que sujetan la envoltura de la campana.
16
8. Ensamblar la tapa superior y el silenciador de ruido

Ensamblar al proceder al revés de lo señalado en los puntos 1 y 2.
Si la parte superior del motor eléctrico está por debajo del silenciador de ruido, se debe formar una
hoja delgada de aluminio en forma de un cilindro o hexágono para colocarse por encima de la tapa del
ventilador. Se debe sujetar la hoja de aluminio a la pantalla protectora contra calor con remaches,
para permitir que el motor eléctrico obtenga aire de enfriamiento por encima de la pantalla protectora
contra calor (la zona en donde se encuentra la entrada para el aire de enfriamiento).
El hoyo en el silenciador de ruido debe estar directamente por encima del motor eléctrico y debe ser
ligeramente más pequeño que la sección transversal de la tapa del ventilador.
En lo que se refiere a la conexión del motor eléctrico, véase la (sección 4.9 “Conexiones eléctricas”).

• Utilizar todos los pernos de argolla al levantar el motor eléctrico.
!
PELIGRO •
• Unicamente se debe utilizar equipo de levantamiento que tiene la capacidad
de manejar el peso, según se indica en la placa de identificación.
No se deben meter manos o dedos entre el motor eléctrico y la envoltura de
la campana durante el proceso de ensamble.
17
4.6 Ensamble del enfriador de aire-aceite y ventilación del gabinete

Normalmente, se entrega el enfriador de aire-aceite por separado y, por lo tanto, debe ser instalado en
la unidad de potencia. Las siguientes instrucciones son aplicables únicamente a estos casos. (Puede
haber cambios en los dibujos y la documentación técnica.)
• Instalar los montantes con los tornillos (en los hoyos perforados) en el PAC, de acuerdo con el
dibujo de instalación en la documentación técnica adjunta.
• Levantar el enfriador de aire-aceite. Nunca se debe levantar junto con el motor eléctrico.
• Instalar el enfriador de aire-aceite sobre los montantes con los tornillos.
• Verificar que los tornillos estén correctamente apretados.
• Conectar las mangueras hidráulicas. Favor de tomar nota de que “Oil In” en la unidad de
potencia debe conectarse con “Oil Out” del enfriador de aire-aceite y viceversa. Se deben
mantener en posición las protecciones de los acoplamientos hasta no completar el proceso de
ensamble, ya que, de esta manera, se evita la entrada de basura.
• En lo que se refiere a las conexiones eléctricas, acoplamientos y mangueras, véase las
secciones correspondientes.
• El enfriador de aire-aceite siempre debe estar conectado con mangueras flexibles.
1 1/4" JIC 37˚ FLARE 1 1/4" JIC 37˚ FLARE
PENETRACIÓN ELÉCTRICA PENETRACIÓN ELÉCTRICA
RECOMENDADA RECOMENDADA
OIL OIL OIL OIL
OUT IN OUT IN
FLUJO
DE AIRE FLUJO
DE AIRE
C C
CORTINA DE HULE CORTINA DE HULE
A
1 1/4" SAE A B A B 1 1/4" SAE
B
E E
D D
B B
A A
Nota: Debe haber una apertura en la orilla • Hay que tener cuidado con las
inferior de la hoja de hule para permitir la
salida del aire de enfriamiento del ventilador
del motor eléctrico.
PELIGRO
! •
partículas en el aire de salida.
Si el enfriador de aire se afloja,
puede ocasionar graves lesiones
corporales.
Dimensiones pulgadas (mm)

Tamaño del Unidad de Compuerta de drenaje Conexiones del Enfriador
Compuertas del enfriador
gabinete potencia del motor
A B C D E OIL IN & OIL OUT
1 PAC 100/200
48 5/8" (1235) 43 7/8" (1114) 71 1/2" (1816) 15 1/4" (387) 5" (127)
2 PAC 200D
1 1/4" JIC 37° male flare
3 PAC 300/400 59 3/8" (1508) 54 5/8" (1387)
75 1/2" (1918) 19 3/8" (492) 6" (152)
4 PAC 400D/600 62 5/8" (1591) 57 7/8" (1470)
5 PAC 800 74 3/8" (1889) 69 3/8" (1762) 82 3/4" (2102) 17 5/8" (448) 10 1/2" (267) 1 1/2" JIC 37° male flare
18
4.7 Ensamble de la tapa superior

Si se instala la unidad de potencia a la intemperie, se debe sellar la tapa superior con una tira selladora.
No se debe usar pegamento para sellar la tapa superior. Se recomienda la colocación de la unidad de
manera que la entrada para el aire no se dirija hacia un lugar polvoriento.
¡NINGÚN
PEGAMENTO!
4.8 Conexiones hidráulicas

Durante el ensamble de las conexiones hidráulicas, se debe tomar en cuenta lo siguiente:
• Se deben mantener en posición las protecciones de los acoplamientos hasta no completar el
proceso de ensamble, ya que, de esta manera, se evita la entrada de basura.
• Todos los tubos deben estar correctamente montados para permitir suficiente espacio para
maniobrar al realizar trabajos de mantenimiento.
• Siempre se deben utilizar mangueras para conectar la bomba con los tubos.
Personal profesional que entiende todos los riesgos involucrados debe realizar todas las mediciones
del sistema hidráulico. Hay que tener mucho cuidado al conectar las conexiones A y B (de alta presión).
Tamaño de la Conexiones Hoyos con rosca ** * SAE brida J 518, código 62,
bomba principales A y 414 bar (6000 psi) conexiones
Denison B* Rosca Profundidad de 90º deben ser utilizadas.
P6/P7 ** Se requieren de 4 pernos /
1 1/2" 5/8-11 UNC
P11/P14 1.06 in. (27 mm) conexión, de preferencia,
tornillos prisioneros de Grado 8.
P24/P30 2" 3/4-10 UNC
Tamaño Dimensión de la conexión

Unidad de
del Línea de
No se deben realizar gabinete
potencia Flushing
drenaje
mediciones o trabajo
!
PELIGRO
de mantenimiento si
el sistema hidráulico
1
2
3
PAC 100/200
PAC 200D
PAC 300/400
1 1/4" SAE
1" SAE female
esta presurizado. code 61 flange
4 PAC 400D/600
5 PAC 800
19
4.9 Conexiones eléctricas

Precauciones de seguridad
• Todo el equipo eléctrico debe ser instalado y utilizado por personal calificado que está
familiarizado con los requisitos de seguridad.
• Se deben utilizar los equipos de seguridad para la prevención de accidentes durante el
ensamble y mantenimiento, de acuerdo con los reglamentos vigentes en el país.
• Se deben aterrizar los equipos eléctricos, de acuerdo con los reglamentos locales, antes de
conectarlos al suministro de energía eléctrica.
• Los niveles para el suministro de energía eléctrica deben estar dentro de los límites aplicables a
los equipos; véase la documentación técnica y la información en las placas de identificación.
Caja de terminales
Conectar los cables a bornes de tornillo dentro de las cajas de conexión. Realizar las conexiones de
acuerdo con el diagrama eléctrico que forma parte de la documentación técnica adjunta.
Enfriador de aire-aceite
El voltaje y conexión aparecen en la placa de identificación. Conectar el motor eléctrico al suministro
de energía eléctrica. Verificar la orientación de la rotación; véase la flecha que indica la orientación
del flujo de aire en la sección 4.6.
Motor eléctrico
Conexión del voltaje de acuerdo con la designación en la placa de identificación.
En la mayoría de los países la instalación de

!
PELIGRO
equipo eléctrico debe ser realizada por
electricistas calificados.
4.10 Tubería
Al calcular el tamaño de las mangueras y la tubería hidráulica, entre el motor y la unidad de potencia,
se debe utilizar un factor de seguridad de, por lo menos, 4 veces la presión máxima del sistema en lo
que se refiere a la resistencia a la tensión. Favor de tomar en cuenta que el equipo puede volver a
ajustarse a una mayor presión al estar en operación. En términos generales, las pérdidas de presión
en el sistema de tubería deben mantenerse a un mínimo, pero existen excepciones en el caso de
ciertas aplicaciones. Favor de comunicarse con un representante de servicio de Hagglunds Drives
para mayores datos.
Tubería hidráulica
Las tuberías hidráulicas deben ser de acero de alta calidad, de acuerdo con ISO 3304, DIN 2391/C o
ANSI/B93.4
Mangueras
Para evitar daño a consecuencia de vibración, es importante que el PAC y el motor estén conectados
a las tuberías a través de mangueras.
Las mangueras deben ser cortas y del menor diámetro posible para obtener un pequeño volumen de
compresión. Sin embargo, se debe tomar en cuenta el radio mínimo de dobladura permitido, de
acuerdo con los datos proporcionados por el fabricante de la manguera. Además, se deben tomar en
cuenta las velocidades de flujo que se especifican en “Tamaño de los tubos”.
20
Prueba de presión
Se debe realizar una prueba de presión a 1.5 veces la presión máxima de trabajo en las líneas principales
para detectar posibles fugas.
Se recomienda la realización de las pruebas de presión con una bomba hidráulica manual.
Lavado de los tubos (flushing)
Antes de arrancar la unidad de potencia, se debe limpiar el sistema de tubería con una bomba de
lavado de un tamaño adecuado para eliminar los contaminantes que pueden haber entrado durante el
proceso de ensamble y/o soldadura. Favor de comunicarse con un representante de servicio de
Hagglunds Drives para determinar los procedimientos correctos de limpieza y lavado.
Tamaño de los tubos
Es importante que las líneas entre las conexiones principales el motor y el PAC sean lo más corto
posible.
Esto ofrece las siguientes ventajas:
1. Un pequeño volumen de compresión dentro del sistema hidráulico.
Esto es especialmente importante en el caso de sistemas hidráulicos con variaciones
grandes y rápidas en la carga y en el caso de transmisiones en donde la exactitud de la
velocidad es esencial.
2. Pequeñas pérdidas de pontentia en el sistema hidráulico.
3. Menores costos de instalación, puesto que tubos de menor diámetro y más cortos pueden
ser utilizados. En el caso de un sistema hidráulico normal, la caída total en la línea de presión y
de retorno no debe exceder del 5% de la presión normal de trabajo.
Se recomiendan los siguientes valores en lo que se refiere al flujo, los cuales no se
deben exceder:
Líneas principales: 15 pies/seg (4.5 m/s) Líneas de drenaje: 5 pies/seg (1.0 m/s)
4. Un menor nivel de ruido.
En el caso de ciertos sistemas, en donde se requieren de pequeños volúmenes de
compresión, flujos más altos son aceptables. Favor de comunicarse con un representante
de servicio de Hagglunds Drives para analizar estos casos específicos.
Al calcular el tamaño de las mangueras y la longitud de los tubos entre las conexiones de drenaje del
motor y el PAC, favor de tomar en cuenta que la caída total en la presión a las conexiones de drenaje
del motor no debe exceder de 14.5 psi (1 bar). La caída en la presión a través del PAC es de 7.25 psi
(0.5 bar).
Acoplamientos de los tubos
Es esencial que se seleccione un acoplamiento apretado y a prueba de presión.
Se recomiendan los siguientes tipos de acoplamientos:
Acoplamientos no soldados son preferibles
Los acoplamientos no soldados permiten la mayor limpieza durante la instalación del sistema de
tubería (en comparación con un sistema soldado).
Acoplamientos soldados (soldadura de boquilla y/o a tope)
Si se utilizan acoplamientos soldados, las tuberías deben ser maquinadas, estandarizadas, limpiadas
en un baño químico. Posteriormente, deben ser cepilladas, lavadas internamente y sopladas antes
del flushing.
Acoplamiento de tubos
Acoplamientos de collarín, de acuerdo con SAE J 514.
21
Abrazaderas para tubos

Se deben sujetar los tubos con abrazaderas colocadas a intervalos uniformes.
La distancia entre las abrazaderas no debe exceder de 6 pies (2 m) en el caso de tubos con diámetros
externos de entre ½” (15 mm) y 1 ½” (38 mm). La distancia entre las abrazaderas no debe exceder de
9 pies (3 m) en el caso de tubos con diámetros externos en exceso de 1 ½” (38 mm).
Además, se deben instalar abrazaderas inmediatamente antes y después de una dobladura en los
tubos. Adicionalmente, se deben instalar abrazaderas inmediatamente antes de la transición a la
manguera.
Las abrazaderas deben sujetarse a una superficie estable, sin vibraciones, tal como una estructura de
concreto.
Las abrazaderas deben ser del tipo que permite cierto movimiento axial y radial en la unión sujetada y
debe contar con buenas características en lo que se refiere a la absorción de vibraciones.
Almacenaje de los componentes incluidos
Se deben almacenar los componentes incluidos de la misma manera que la unidad de potencia (sección
3.1, “Almacenaje de la unidad de potencia empacada”). No se deben quitar los materiales de empaque
durante el periodo de almacenaje.
No se debe realizar ningún trabajo en relación con el sistema de tubería si
!
PELIGRO
el sistema hidráulico esta presurizado. Se debe utilizar el equipo de
seguridad necesario durante la instalación del sistema de tubería. Se
debe cumplir con los requisitos de seguridad normales durante cada etapa.
Manejo de los accesorios

Se debe realizar una inspección visual de las superficies de los sellos antes de proceder con la
instalación. Las superficies de los sellos no deben tener mostrar indicios de daño o agrietamiento. Si
se cae el acoplamiento o si tiene muescas, se debe realizar una inspección visual. Verificar que los
sellos (si los hay) se encuentran en la posición correcta, libre de cualquier agrietamiento y saturados
de aceite.
La protección y empaque que vienen con los accesorios deben permanecer, sin quitarse, hasta no
proceder con el ensamble final.
22
Accesorios para bridas Abrazaderas

Se deben apretar los pernos en forma de cruz. Distancia normal entre las abrazaderas:
Accesorios JIC (SAE J514, ISO 8434) • En el caso de tubos con un diámetro menor
Se deben apretar los accesorios en forma manual a 1” (25.4 mm): la distancia entra las
y, posteriormente, con una vuelta de ¼ o ½ con abrazaderas debe ser de 60-80” (1524-2032
una llave apropiada. No se deben apretar los mm).
accesorios excesivamente. • En el caso de tubos con un diámetro mayor
a 1” (25.4 mm): la distancia entra las
Se deben utilizar las herramientas correctas, ya abrazaderas debe ser de 80-100” (2032-
que se puede ocasionar daño a los accesorios y 2540 mm).
pueden ser difíciles de quitar. Se deben limpiar los tubos inmediatamente antes
Favor de tomar en cuenta que los accesorios y después de la dobladura e inmediatamente an-
pueden expandirse debido al calor y las tes de una manguera.
vibraciones. Se deben revisar todos los accesorios Accesorios soldados
posteriormente y, según el caso, volver a
Favor de comunicarse con su representante de
apretarlos.
Hagglunds Drives.
Correcto Instalación de mangueras
En el momento de su instalación y con el propósito
de evitar fallas prematuras, debe cerciorarse de
que las mangueras no estén torcidas o sujetas a
esfuerzos anormales. El radio de la dobladura
debe cumplir con las recomendaciones del
fabricante.
Pruebas de presión
Se deben realizar pruebas de presión antes del
lavado para poder eliminar contaminación por
Incorrecto esfuerzos producidos por presión. En el caso de
las líneas principales, se deben realizar pruebas
de presión y fugas a una presión estática de 1.5
Limpieza veces la presión máxima del sistema (pero sin
El proveedor debe limpiar, inspeccionar y sellar exceder de la presión de rotura). Al realizar las
todos los tubos y mangueras. Si se doblan los pruebas de presión, se deben desconectar o
tubos en el campo en el momento de su proteger el motor hidráulico y la unidad de potencia
instalación, se debe limpiar el sistema a la mediante el cierre de las válvulas.
conclusión del proceso de instalación.
23
Ejemplo de la instalación de la
tubería que es conveniente y en
donde fácilmente se puede instalar
en aislamiento contra ruido
4.11 Filtración adicional antes del

arranque MOTOR HIDRAULICO
Se deben conectar un filtro de presión y válvula

de retención en la línea principal de la unidad de Mangueras
potencia. Se conecta el filtro de presión en el lado Interconectadas
de retorno de la bomba.
Se recomienda un nivel de filtración de Beta 10 = Dirección el flujo
75 o mejor.
El tamaño del filtro debe concordar con el de la
bomba, de manera que la caída en la presión al
Filtro
pasar por el filtro no sea excesiva y, a la vez, sin
exceder de las especificaciones máximas de
Válvula de retención
presión/flujo del filtro.
Las líneas principales deben conectarse en el
motor, de manera que se permite la filtración del
sistema total. Véase el dibujo más adelante.
El flujo máximo de la unidad de potencia debe
filtrarse a través del circuito principal durante un UNIDAD DE POTENCIA
periodo de, por lo menos, dos horas en el caso de
instalaciones pequeñas y durante un periodo de
tiempo significativamente mayor en el caso de Se debe utilizar una válvula de retención
instalaciones más grandes. de un tamaño correcto para el flujo del
aceite. Al utilizar la bomba principal, se
Se debe tener mucho cuidado para cerciorarse debe reducir la presión máxima.
de que la carrera de la bomba esté sincronizada
con la dirección del flujo libre de la válvula de
retención.
24
4.12 Puesta en servicio

4.12.1 Antes de la puesta en servicio
• Favor de leer y entender el manual completo, así como la documentación técnica adjunta.
• Realizar una inspección visual del sistema completo para detectar indicios de daño, circuitos
incorrectos, la seguridad de los cimientos y para cerciorarse de que el nivel de filtración de los
filtros cumpla con los requisitos establecidos en la documentación técnica.
• Cerciorarse de que el acoplamiento entre el motor eléctrico y la bomba esté correctamente
instalado.
• Cerciorarse de que la presión previa a la carga en el acumulador (opcional) cumpla con los
requisitos establecidos en la documentación técnica.
Limpieza
• Se debe lavar y limpiar la parte interna del sistema hidráulico.
• En caso de tener cualquier duda con respecto a la limpieza del sistema, se debe realizar una
inspección completa antes de llenarlo con aceite.
Tubería
• ¿Todos los acoplamientos están correctamente apretados?
• ¿Toda la tubería está limpia?
• ¿Toda la tubería está instalada, libre de esfuerzos?
• ¿Todas las líneas cumplen con el dibujo de instalación / diagrama de tubería?
Sistema eléctrico
• Cerciorarse de que el motor eléctrico o los motores eléctricos, sistema de control así como los
demás componentes eléctricos, estén conectados al voltaje correcto.
• Realizar una verificación manual de la función de los componentes eléctricos y el sistema de
monitoreo. Los instrumentos que no pueden ser activados pueden ser inspeccionados para
verificar que los cables estén correctamente instalados y, posiblemente, puedan ser operados
en forma manual. En el momento de llenar el tanque, se debe revisar el interruptor y medidor
de nivel.
4.12.2 El llenado del sistema con fluido hidráulico

Antes de llenar el sistema
• Cerciorarse de que se estén utilizando el tipo y calidad correctos de fluido hidráulico. No se
deben mezclar distintos tipos de fluido hidráulico sin antes consultar con los fabricantes.
• Cerciorarse de que el tambo que contiene el fluido
hidráulico y el tanque / las mangueras no estén
contaminados con agua o cualquier otra substancia.
• Cumplir con las instrucciones en lo que se refiere al
manejo de los acoplamientos y mangueras (sección
4.10 “Tubería”).
• Colocar un tapón en la conexión “D” de drenaje
(motor) para evitar que fluido que no ha sido filtrado
entre en el motor hidráulico en el momento de llenar
el sistema por primera vez.
• Llenar la bomba con fluido hidráulico filtrado a través 'D1' PUERTO
de la puerto “D1” de la bomba. Al completar el DE DRENAJE
proceso de llenado, volver a colocar el tapón/
manguera que se conecta a la puerto “D1”.
25
En el momento de llenar el sistema

Utilizar una unidad de bombeo de llenado, equipada con filtro, en donde la capacidad de filtración sea
de 10 micrones o mejor.
Normalmente, el nuevo fluido no ha sido filtrado y, por lo tanto, basura

entrará en el sistema. Por consiguiente, al llenar el sistema, el fluido
siempre debe pasar por un filtro. Nunca se debe vaciar el fluido hidráulico
dentro del tanque a través del filtro del respirador de aire.
Siempre se debe bombear el fluido a través de la conexión rápida. La conexión rápida es un

acoplamiento inoxidable de desconexión rápida; véase el dibujo más adelante. Para mejores resultados,
el fluido que entra en el sistema será filtrado a través del filtro de drenaje.
Se debe llenar el tanque con aceite hasta una altura de 0.79” (20 mm) por debajo del nivel máximo del
vidrio de nivel en el tanque antes de arrancar por primera vez.
Verificar la operación correcta del vidrio de nivel y el indicador en el momento de llenar el tanque.
El sistema está lleno

ENTRADA DE LA ENTRADA DE LA cuando el fluido
MANGUERA EN UNIDAD DE
DE ILENADO LA POTENCIA hidráulico está a 5/8 del
vidrio de nivel
FILTRO DE RETORNO
CONEXIÓN DE
ILENADO DE ACEITE
FILTRO DE DRENAJE DE
LA CARCAZA DE LA
BOMBA/MOTOR
CALENTADOR
DEL ACEITE
Después de llenar el sistema con fluido, se debe abrir la línea de drenaje y volver a conectar la línea de
drenaje del motor hidráulico.
• Revisar las advertencias en el contenedor o consultar con el proveedor
!
ADVERTENCIA
•
•
(sección 2.4 “Selección del fluido hidráulico”).
Evitar el contacto prolongado del fluido hidráulico con su piel.
Para evitar lesiones, limpiar los derrames de fluido hidráulico de los
pisos, de inmediato.
26
4.12.3 Procedimiento inicial de arranque

Nota Importante:
• Cerciorarse de que el sistema y la máquina están listos para entrar en operación. Advertir a
todo el personal en el área de que el arranque esté en proceso.
• Cumplir con todas las precauciones de seguridad que se establecen en este manual (sección
1.1 “Precauciones de seguridad”).
• Nunca se debe operar la unidad de potencia con instrumentos o elementos de control
defectuosos.
• Alejar materiales inflamables de la unidad de potencia.
• Durante el periodo de arranque, se realizará la filtración del sistema hidráulico para eliminar las
partículas de basura. Por lo tanto, se debe verificar el indicador del filtro durante todo el
procedimiento de arranque.
Al realizar un arranque en frío, los filtros pueden indicar desviación (by-pass). Después de unos
minutos de estar en operación, oprimir el indicador visual para restablecerse. Si los indicadores no se
restablecen después de que el sistema haya alcanzado la temperatura de operación, se debe
inspeccionar y reponer el filtro.
ETAPA 1. Inmediatamente antes de arrancar
• Verificar el nivel del fluido en el tanque y volver a llenarlo hasta una altura de 0.79” (20 mm) por
debajo del nivel máximo del vidrio de nivel en el tanque (sección 4.12.2, “Llenado del sistema
con fluido hidráulico”).
• Verificar si algunos de los componentes requieren de llenado con fluido hidráulico limpio, tales
como la carcaza de la bomba y la carcaza del motor.
• Realizar una inspección del equipo de seguridad.
• Cerciorarse del cumplimiento de todas las etapas especificadas (sección 4.12.1 “Antes de la
puesta en servicio”).
• Cerciorarse de que todas las válvulas en el lado de succión, presión y entrada de la bomba, así
como cualesquiera válvulas en las líneas de drenaje, están abiertas.
• Cerciorarse de que el agua de enfriamiento esté conectada y abierta en caso de utilizar un
enfriador de agua-aceite.
En lo que se refiere a los puntos de ajuste del sistema de control (si hay), véase las instrucciones por
separado en la documentación técnica adjunta.
ETAPA 2. Arrancar la bomba, sin carga, durante intervalos cortos
Se debe arrancar el PAC con la bomba, sin carga, durante intervalos cortos.
• Si el fluido hidráulico está frío, pueden ser necesarios varios arranques para elevar la presión
de carga.
• Cerciorarse de que la presión de carga corresponda a los datos y puntos de ajuste que se
establecen en la documentación técnica adjunta.
• Si todo está en orden, se puede permitir la operación de la bomba y la introducción del flujo
dentro del sistema hidráulico sin carga.
• Se deben limitar el flujo y presión hasta que todo el aire haya sido purgado de las líneas.
Cerciorarse de que la presión de carga siga bien.
27
De inmediato, cerciorarse de
que la dirección de rotación de ROTACIÓN
la bomba sea la correcta, ya

que, de otra manera, la bomba
será dañada. La dirección de
rotación correcta de la bomba
aparece en la etiqueta colocada
por debajo del motor eléctrico.
Véase el dibujo a continuación.
ETAPA 3. Operación de la bomba, sin carga, durante intervalos más largos

Seguir con la operación durante un periodo de tiempo, sin carga, hasta que el sistema esté estable y
se establezcan los controles. Verificar el nivel del aceite, ya que algunas partes del sistema se llenarán
de aceite.
Revisar el nivel del fluido en el
• Verificar el nivel del fluido en el tanque tanque
• Verificar todos los entrecierres.
• Cerciorarse de que no existan ruidos o vibraciones anormales.
• Cerciorarse de que el nivel de presión especificado para la presión de carga en el PAC se
mantenga de acuerdo con los valores establecidos en el diagrama hidráulico en la
documentación técnica adjunta. Dichos niveles de presión son previamente establecidos en la
fábrica y, normalmente, no hay ninguna necesidad de ajustarlos.
• Cerciorarse de que no haya fugas.
• Detener la operación del motor eléctrico.
• Corregir cualesquiera fallas que se hayan detectado.
• Realizar una inspección de todas las conexiones, pernos, etc., y apretarlos en caso de ser
necesario.
• Volver a arrancar.
ETAPA 4. Operación del sistema hidráulico, con carga
Se puede operar el sistema hidráulico con carga después de que la operación del mismo, sin carga,
sea satisfactoria.
• Gradualmente, incrementar la presión de carga hasta que se logre la operación correcta.
• A estas alturas, puede ser necesario el ajuste del flujo, las curvas de transición, etc.
• Mantener el sistema en operación hasta que se alcance la temperatura de operación normal.
28
ETAPA 5. Inspecciones
• Cerciorarse de que no existan ruidos o vibraciones anormales.
• Revisar la operación del equipo de seguridad.
• Verificar la temperatura dentro del tanque y el circuito cerrado. Cerciorarse de que el control del
enfriador sea estable. De ser que no, realizar una inspección del suministro de agua, los
controles, el enfriador de aire, etc.
• Cerciorarse de que no haya fugas.
• Cerciorarse de que los controles e interruptores (opcionales) del compensador de la bomba
estén ajustados a los niveles que corresponden a la transmisión especifica. En el momento de
su entrega, dichos niveles de presión están ajustados a los niveles especificados por el cliente
y, normalmente, no es necesario volver a ajustarlos. Dichos niveles están especificados en la
documentación técnica. Se puede revisar fácilmente el compensador del sistema al cerrar una
válvula de bola en la sección de alta presión y al permitir la operación de la bomba hasta que se
registre la presión en el medidor.
• Se debe verificar la presión de trabajo para cerciorarse de que corresponda a los valores
especificados.
ETAPA 6. Detener la operación del motor eléctrico
• Corregir cualesquiera fallas detectadas en los puntos anteriores.
• Revisar el indicador del filtro. No es inusual que se requiere su reposición durante la puesta en
servicio del sistema, ya que el sistema está eliminando las partículas de basura. Al reponer los
elementos del filtro, hay que seguir las instrucciones (sección 5.3 “Reposición del filtro”) para
evitar que basura entre en el sistema. Si aún permanece basura dentro del sistema, será
necesario un lavado adicional para evitar la falla prematura de los componentes del sistema.
• Realizar una inspección de todas las conexiones, pernos, etc., y apretarlos en caso de ser
necesario.
• Quitar todos los fluidos de desecho, pedazos de cable, etc., para mantener limpia la zona
alrededor de la unidad.
4.13 Ajuste de las bombas En caso de fallas imprevistas, el

Bomba Denison Gold Cup !
PELIGRO
hecho de estar trabajando en zonas
de alta presión puede ser peligroso.
P6S, P7S, P11S y P14S P24S y P30S
AJUSTE DE LA
PRESIÓN DE CARGA
VÁLVULA DE
AJUSTE DE LA COMPENSACIÓN
PRESIÓN DE CARGA
Vista desde atrás Vista desde atrás Vista frontal
29
Se ajustan la presión de carga y el nivel de presión del compensador de la bomba antes de que el PAC
salga de la fábrica y, por lo tanto, normalmente no existe la necesidad de volver a ajustarlos. Siempre
se deben verificar los niveles de presión en la documentación técnica. Personal profesional que
entiende los riesgos y funciones relacionados con la bomba debe realizar el ajuste de la presión
de la(s) bomba(s). Se deben ajustar las presiones durante operación y con el sistema a la temperatura
de operación. Favor de tomar nota de que las presiones pueden cambiar con distintos niveles de
viscosidad.
1. Ajuste de la presión de carga: Quitar la tuerca con cabeza de botón, aflojar la tuerca
prisionera y ajustar la presión con una llave Allen de 5/32”. Se incrementa la presión a dar la
vuelta en sentido de las manecillas del reloj. La presión de carga (en el medidor de la presión
de carga) debe estar dentro de los siguientes límites: 218 psi (15 bar) en el caso de P6S/P7S y
P11S/P14S y P24S y 261 psi (18 bar) en el caso de P30S.
Si se pretende utilizar otras cargas de presión, favor de consultar con su representante de Hagglunds Drives.
2. Después de ajustar la presión de carga: Apretar la tuerca prisionera y volver a colocar la
tuerca con cabeza de botón. Registrar el ajuste en la bitácora u otra documentación técnica.
3. En caso de incrementar los niveles de presión principales: Cerciorarse de que la tubería y
estructura de la máquina pueden aguantar la mayor presión/mayor torque que proviene del
motor hidráulico.
4. Ajuste de la presión del compensador: Aislar la bomba y, después, activar o mover la señal
de entrada al control de manera que se incremente la presión en el circuito cerrado de alta
presión al punto de ajuste en el limitador de presión. Se alcanza el ajuste en el limitador de
presión cuando la presión deja de incrementarse y permanece estable en un nivel de presión
(según se indica en los medidores).
Se establece el ajuste en el limitador de presión en el lado A- y B- en la válvula del compensador.
Quitar la tuerca con cabeza de botón, aflojar la tuerca prisionera y ajustar la presión con una llave
Allen de 5/32”. Se incrementa la presión a dar la vuelta en sentido de las manecillas del reloj.
5. Después de ajustar las presiones principales: Apretar la tuerca prisionera y volver a colocar
la tuerca con cabeza de botón. Registrar el ajuste en la bitácora u otra documentación técnica.
30
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Mantenimiento
5. MANTENIMIENTO PREVENTIVO
5.1 Registro de mantenimiento
Recomendamos se mantenga una bitácora de mantenimiento para registrar servicio / mantenimiento
/ reparaciones, adiciones y modificaciones de los equipos. Cada nota, observación o comentario
debe ser fechado.
5.2 Tabla de mantenimiento

El mantenimiento de los sistemas hidráulicos tiene el propósito de evitar fallas en el sistema y de
mantener el sistema en operación de una manera eficiente, de acuerdo con las especificaciones. Los
procedimientos específicos dependen de las características del equipo, el entorno de operación y el
ciclo de trabajo, tomando en cuenta las consecuencias de una falla. Para optimizar los intervalos
entre el mantenimiento, recomendamos un análisis de Costo de Ciclo Util. Al realizar cualquier trabajo
de mantenimiento, se deben cumplir con las precauciones de seguridad (sección 1.1 “Precauciones
de seguridad”).
Inspecciones diarias, la primera semana después de la puesta en servicio
• Fugas de fluidos
• Nivel de fluido en el tanque
• Temperatura de operación
• Presión del sistema
• Actuación del sistema
• Condiciones generales
• Ruidos inusuales
• Indicadores de contaminación en los filtros
Inspecciones antes del arranque (hasta diario)
• ¿La válvula de succión está abierta?
Inspecciones frecuentes
• Vibraciones inusuales
• Ruidos inusuales
• ¿La unidad está relativamente limpia? ¿Los ductos de aire no tienen obstáculos?
• ¿Los niveles de presión son normales y estables?
• ¿Las velocidades del actuador son normales y estables?
• Temperatura de operación
• ¿La transmisión está operando sin contratiempos?
31
Mantenimiento Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Mantenimiento programado
Se debe realizar mantenimiento programado, a intervalos específicos, el cual debe incluir las siguientes
inspecciones y medidas:
• Todos los puntos mencionados en inspecciones frecuentes
• Verificar todos los niveles de presión
• Verificar la estabilidad de los niveles de la temperatura en todo el sistema
• Quitar el agua y lodo del tanque a través del tapón de drenaje
• Realizar una inspección del motor eléctrico
• Verificar la operación del equipo de monitoreo / interruptores, etc.
• Limpiar las áreas en donde existe una acumulación de suciedad
Nota: Nunca se debe usar un sistema de lavado de alta presión para limpiar la parte interna de
la unidad de potencia.
• Realizar una inspección de los cables
• Realizar una inspección de los acumuladores (opcionales) en lo que se refiere a la carga previa
• Realizar una inspección del flujo en las líneas de drenaje y la condición del aceite en la línea de
drenaje
• Realizar una inspección de las mangueras, acoplamientos y bomba(s) para detectar
agrietamientos, fugas y condiciones en general
• Realizar una inspección del acoplamiento de la flecha a través del registro de inspección.
Advertencia: existen componentes rotatorios dentro del registro de inspección
• Realizar una inspección del flujo del agua de enfriamiento
• Verificar que el aislamiento dentro del gabinete (especialmente en la campana) esté bien
sujetado
• Verificar que las puertas y la tapa de la unidad de potencia no han sufrido daño
Intervalos máximos entre inspecciones mayores y reposiciones

Filtros Respirador
Entrada Fluido Acumulador(es)
de de aire en el
de aire hidráulico (opcionales)
aceite tanque
Después de las primeras 100 horas en ý *
Después de 3 meses o 500 horas en
operación
ý *
Una vez cada 6 meses þ ý * þ þ
Una vez cada 24 meses ý
þ=Examen ý=Reemplazo * Si el indicador de contaminación está disparado, se
deben cambiar los filtros, de inmediato, y se debe
5.3 Reposición del filtro realizar una inspección del aceite.
Filtro simple
1. Detener las operaciones y parar el motor eléctrico.
2. Quitar el tazón del filtro y cambiar el cartucho del filtro.
Es muy importante que, durante el proceso de instalación, no se exponga el nuevo cartucho a
suciedad y, por lo tanto, debe mantenerse dentro de contenedor de plástico lo más que se
puede.
Realizar una inspección del anillo “O” y el anillo de respaldo para detectar cualquier daño. De ser
necesario, reponer las piezas.
3. Volver a instalar el tazón del filtro y apretarlo en forma manual hasta que se detenga y, luego,
regresar 1/8 de vuelta.
Nota: En el momento de quitar un cartucho, se debe realizar una inspección para detectar
contaminación inusual dentro de los pliegues. Favor de comunicarse con su oficina de Hagglunds
Drives para asesoría.
32
Filtro doble (duplex)

1. Oprimir la palanca de igualación de presión en la parte inferior de la palanca de interrupción y
mantenerla así; véase el dibujo más adelante.
2. Retirar la perilla (catch knob), voltearlo y embragar la palanca de interrupción del otro lado.
3. Aflojar los tornillos de venteo, únicamente en el lado en donde se pretende reponer el filtro
(véase el dibujo más adelante), unas 2 ó 3 vueltas.
4. Quitar el tazón del filtro y cambiar el cartucho.
Es muy importante que, durante el proceso de instalación, no se exponga el nuevo cartucho a
suciedad y, por lo tanto, debe mantenerse dentro de contenedor de plástico lo más que se
puede.
Realizar una inspección del anillo “O” y el anillo de respaldo para detectar cualquier daño. De ser
necesario, reponer las piezas.
5. Volver a instalar el tazón del filtro y apretarlo en forma manual hasta que se detenga y, luego,
regresar 1/8 de vuelta.
6. Volver a llenar el filtro al oprimir la palanca de igualación de presión y mantenerla allí hasta no
ser que el hoyo para el tornillo de venteo no tiene ninguna burbuja.
7. Apretar el tornillo de venteo. Realizar una inspección del filtro para detectar fugas al oprimir
nuevamente la palanca de igualación de presión.
5.4 Inspección del fluido hidráulico

Recomendamos se realice un análisis del fluido hidráulico una vez cada 6 meses. El análisis debe
abarcar viscosidad, oxidación, contenido de agua, aditivos y suciedad. En la gran mayoría de los
casos, el proveedor del aceite realizará un análisis para determinar la condición del fluido hidráulico y
puede recomendar las medidas apropiadas. Si los resultados del análisis indican que el fluido hidráulico
no cumplen con los requisitos (sección 2.3 “Requisitos en lo que se refiere a la limpieza del fluido
hidráulico”), ya no se debe usarlo y, por lo tanto, debe ser cambiado o limpiado de inmediato. Volver
a llenar el fluido de acuerdo con las instrucciones (sección 4.12.2 “Llenado del sistema con fluido
hidráulico”).
Tornillos de
venteo
• Los riesgos relacionados con

fluido hidráulico. Palanca de
• Almacenar el fluido hidráulico igualación
de presión
!
PRECAUCION
desgastado y los cartuchos
contaminados y deshacerse de
ellos en una forma apropiada.
En esta
posición,
se puede Palanca de
• El fluido puede ser caliente si el cambiar interrupción
enfriamiento es insuficiente. este
elemento.
Diferentes tipos de fluidos hidráulicos son

afectados en formas distintas. Favor de
consultar con el fabricante.
33
Mantenimiento Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
5.5 Lubricación del motor eléctrico

La lubricación de motores eléctricos mayores de 30 HP
1. Limpiar las boquillas de grasa.
2. Engrasar el motor eléctrico con una pistola de grasa.
Grasa
En el momento de volver a engrasar, únicamente se debe utilizar grasa especial para rodamientos
con las siguientes características:
• Grasa de buena calidad a base de litio o complejo de litio.
• Viscosidad del aceite base 476-667 SSU a 104ºF (110-140 cSt a 40ºC).
• Consistencia NLGI grado 2 ó 3.
• Rango de temperatura –22ºF a +248ºF (-30ºC a +120ºC) constantemente.
Grasas con las características correctas están disponibles a través de todos los fabricantes principales
de lubricantes. Si se cambia el tipo de grasa y usted no está seguro de la compatibilidad, se debe
realizar el proceso de lubricación varias veces, a cortos intervalos, para desplazar la grasa vieja.
Entrada de aire para el motor eléctrico
Verificar que las entradas de aire en la campana del gabinete del motor eléctrico no estén tapadas con
basura y que el aire pueda pasar fácilmente.
!
PRECAUCION
Leer la etiqueta de
advertencia en el
cartucho de grasa.
Programa de lubricación del motor eléctrico (60 Hz)
Tamaño
Motor eléctrico Intervalos de Volumen de
del
HP (kW) lubricación grasa
armazón
1.0 pulgada
286 30 (22)
cubica
40 (30)
6 to 12 meses
50 (37) 1.5 pulgada
324-365
60 (45) cubica
75 (56)
100 (75)
125 (93)
150 (112)
2.5 pulgada
404-449 200 (149) 6 meses
cubica
ENTRERROSCAS 509
DE LA GRASA 250 (186)
300 (224)
350 (261)
400 (298)
3 meses Revisar datos
5011 450 (336)
5.6 Reposición del respirador de aire

Véase la tabla de mantenimiento (sección 5.2 “Tabla de mantenimiento”) en donde se establecen los
intervalos recomendados de reposición.
1. Limpiar el área en donde se encuentra el respirador de aire.
2. Desatornillar el respirador de aire y cerciorarse de que ninguna materia extraña haya entrado
dentro del tanque.
3. Atornillar un nuevo respirador de aire.
34
5.7 Limpieza del enfriador de aire-aceite

Limpieza de las aletas de aire
• La forma más fácil de limpiar las aletas de aire es mediante el uso de aire comprimido o lavado
con agua.
• Se puede eliminar la suciedad con un material para quitar grasa y un sistema de agua de alta
presión. Si se utiliza un sistema de agua de alta presión, se debe dirigir el chorro de agua en
forma paralela a las aletas.
Seguir las precauciones de seguridad que aparecen en el contenedor de

material de limpieza. Desconectar la unidad de potencia antes de
! desconectar el enfriador de agua-aceite/aire. Cerciorarse de que el

suministro de energía eléctrica haya sido cortado antes de limpiar. No se
ADVERTENCIA deben tirar el material de limpieza o el agua que se utiliza para el lavado
en el ambiente.
5.8 Unidad de potencia fuera de servicio

Periodos fuera de servicio
Limpiar y vaciar el sistema de enfriamiento (lado de agua) antes de iniciar periodos de inactividad
(especialmente si el agua de enfriamiento no está totalmente limpia). Si el PAC estará fuera de
servicio durante más de tres meses, se debe proteger el sistema hidráulico internamente contra
oxidación.
Se puede hacer esto de la siguiente manera:
• Utilizar fluido hidráulico que es congruente con los tipos de fluidos que se utilizan en su
ubicación, el cual cuenta con aditivos para impedir la oxidación.
• Utilizar aditivos que ofrecen protección contra la oxidación hasta por un periodo de un año.
Posteriormente, se debe arrancar el equipo a intervalos para mantener una capa protectora
sobre las superficies internas de los componentes y líneas de aceite y, de esta manera, se los
protege contra la corrosión.
• Si algunas partes del sistema están desconectadas, las conexiones abiertas deben ser
protegidas con tapones tapas para evitar la entrada de partículas de basura.
Entrada en servicio nuevamente
Antes de volver a arrancar el sistema, después de un largo periodo de inactividad, se debe realizar
una inspección para determinar si las instrucciones correspondientes a la puesta en servicio original
siguen siendo aplicables. Además, se deben cumplir con las siguientes medidas:
• Remover la solución de conservación y cualesquiera indicios de contaminación.
• Seguir los procedimientos para el arranque inicial (sección 4.12.3 “Procedimientos para el
arranque inicial”).
6. MANTENIMIENTO CORRECTIVO
6.1 Mantenimiento común
Antes de quitar cualquier componente hidráulico/eléctrico, se debe desconectar la unidad de potencia.
Cerciorarse que ninguna energía se haya acumulado en el sistema y que el suministro de energía
eléctrica está desconectado del motor eléctrico. Seguir las precauciones de seguridad recomendadas.
35
Mantenimiento Correctivo Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Antes del desensamble

• Realizar la detección de fallas.
• Limpiar todos los ensambles y componentes. Adoptar todas las precauciones necesarias para
evitar que basura entre dentro del sistema.
• Unicamente personal profesional de servicio debe realizar el desensamble.
Desensamble
• Etiquetar todas las piezas y proteger las superficies de precisión.
• Realizar una inspección de todas las partes durante el proceso de desensamble para detectar
desgaste o daño.
• Si se drena el fluido hidráulico y se pretende volver a usarlo, cerciorarse de que todos los
contenedores estén limpios y tapados cuando no estén en uso.
• Limpiar todos los componentes metálicos con un solvente apropiado antes de su reensamble y
apartarlos en una tela limpia, sin pelusa.
Reensamble
• Lubricar con el fluido hidráulico del sistema.
• Reponer todos los sellos, empaques y anillos “o” con nuevos del tamaño correcto.
• Cerciorarse de que todas las conexiones de las tuberías estén totalmente selladas.
• Volver a llenar con fluido hidráulico de acuerdo con las recomendaciones (sección 4.12.2
“Lllenado del sistema con fluido hidráulico”).
6.2 Reposición del ensamble de la bomba hidráulica / motor eléctrico

El método más común de cambiar la bomba es el de levantar la unidad completa del motor eléctrico /
bomba para después sacar la bomba.
El motor eléctrico y la bomba están ensamblados en una unidad y montados sobre la placa de soporte
del motor que está sujetada al armazón con montantes amortiguadores.
1. Quitar la tapa superior y el silenciador de ruido: Puntos 1 y 2 (sección 4.5 “Ensamble del motor
eléctrico”).
2. Separar la placa de soporte del motor: Separar la placa de soporte del motor del armazón.
3. Colocar el equipo de levantamiento: Colocar el equipo de levantamiento en los cuatro hoyos en
las esquinas de la placa de soporte del motor.
4. Levantar el motor eléctrico / bomba: Favor de tomar en cuenta el peso y el centro de gravedad.
5. Ensamblar: Ensamblar al revés de los puntos 1 a 4.
• Siempre se deben utilizar los cuatro puntos de levantamiento al subir la

unidad del motor eléctrico / bomba.
• Nunca se deben utilizar los pernos de argolla del motor eléctrico para
!
PELIGRO
•
subir la unidad completa del motor eléctrico / bomba.
Unicamente se debe utilizar equipo de levantamiento con la capacidad
de sostener el peso (sección 4.2 “Métodos de levantamiento y pesos”).
• Nadie debe pararse por debajo de la unidad después de subirla.
• Tomar en cuenta el centro de gravedad al realizar las maniobras de
levantamiento.
36
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Detección de Fallas
6.3 Detección de fallas

Falla Probable Causa Medida
Falta de voltaje principal al Buscar la causa en la red para el
motor eléctrico suministro de energía eléctrica.
Está cerrada la válvula de Abrir la válvula en la línea de succión;
succión verificar la operación del interruptor.
Falta de aceite en el Verificar el nivel de aceite en el depósito y
depósito la operación del interruptor.
Temperatura del depósito
La unidad de potencia no Verificar la operación del interruptor de
por encima del límite de
arranca temperatura en el depósito.
ajuste
Buscar la causa en la red para el
suministro de energía eléctrica.
Realizar una inspección del sistema de
Falta de voltaje de control
control en la unidad de potencia. Si el
sistema de control se ha disparado,
determinar la razón.
Ninguna corriente de control al control
electrohidráulico. Realizar una inspección
Ninguna presión en el servo
de la función de control o la tarjeta de
control electrónico.
Defecto en el acoplamiento Realizar una inspección a través del
entre la bomba y el motor registro de inspección en la envoltura de
La unidad de potencia no
eléctrico la campana.
tiene flujo de aceite
Orientación incorrecta en la
rotación de la bomba Verificar la orientación de la rotación.
hidráulica
Verificar que la presión no sea excesiva,
La carga es demasiado
de manera que se reduzca el suministro
grande
proveniente de la bomba.
La línea de succión no está
Abrir la válvula en la línea de succión.
abierta
La presión de carga está
Verificar que la presión de carga sea la
excesivamente baja o no
correcta.
existe
Los pernos de embarque en
la placa de la bomba/motor Quitar los pernos de embarque.
todavía están instalados
Realizar una inspección de la línea de
succión para detectar fugas. Realizar una
Ruido indeseable Fugas de aire y cavitación
prueba al vaciar aceite sobre las juntas en
de la bomba
los tubos y escuchar cambios en el ruido
de la bomba.
Un obstáculo en el filtro de
Cambiar el filtro.
aire dentro del tanque
Desgaste del elemento de
elastómero en el Cambiar el elemento de elastómero.
acoplamiento de la flecha
Orientación incorrecta de la
Cambiar la orientación de la rotación.
rotación
Alta temperatura del aceite Ningún intercambio de Verificar la presión de carga y el punto de
en el circuito cerrado aceite del circuito cerrado ajuste de la válvula reversible.
37
Detección de Fallas Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Falla Probable Causa Medida

La unidad de potencia no
Realizar las medidas antes mencionadas.
suministra aceite
Verificar la señal de entrada a la tarjeta
Ninguna señal de mando a
amplificadora y la señal de salida al
la bomba
control de la bomba electrohidráulica.
Ninguna presión en el
El acoplamiento de la Verificar que el acoplamiento e inserto de
sistema
bomba / motor no está la bomba y el motor eléctrico estén
instalado correctamente correctamente instalados y apretados.
La válvula compensadora
Reponer la válvula compensadora de la
de la bomba no está
bomba.
cerrada
Véase nuestras recomendaciones con
respecto al aceite.
Bajo nivel de viscosidad
Verificar la temperatura del aceite y la del
circuito de enfriamiento.
Realizar una inspección de los filtros y
Material abrasivo está cambiarlos en caso de ser necesario.
circulando por la bomba con Cerciorarse de la reposición de los filtros
Desgaste excesivo
el fluido hidráulico de acuerdo con los intervalos
establecidos.
Aire en el sistema hidráulico Encontrar y reparar la fuga en el sistema
y cavitación de la bomba de aire y purgar el aire del sistema.
Alto contenido de agua en Realizar una inspección del fluido

el fluido hidráulico hidráulico y cambiar el aceite.
Realizar una inspección del flujo del agua
de enfríamiento, temperatura del agua,
enfriador, válvula de agua y filtro de agua
Deficiencia en la capacidad
o enfriador de aire (opcional).
de enfriamiento
Si el enfríador de aire está limpio,
inspeccione las aletas de enfríamiento y
remueva cualquier obstrucción.
Alta temperatura del aceite
Fugas internas en la bomba Reponer o reparar la bomba.
Cantidad insuficiente de
Verificar que la bomba de carga esté
aceite de reposición en el
suministrando suficiente aceite de lavado.
sistema hidráulico
Realizar los ajustes de acuerdo con los
La presión de carga está
valores en el diagrama del circuito
fuera de los límites
hidráulico.
7. DESECHO DE LA UNIDAD DE POTENCIA

Cuando el PAC o algún componente está desgastado, debe deshacerse del mismo lo más pronto
posible. El fluido hidráulico desgastado, los materiales expuestos al fluido hidráulico y grasas pueden
ocasionar daños al medio ambiente y debe deshacerse de los mismos de acuerdo con los reglamentos
locales.
• Cerciorarse de que la unidad de potencia esté totalmente desconectada.
• Los componentes pueden contener energía acumulada.
! • Tomar en cuenta el riesgo de incendio durante el proceso de
desensamble.
PELIGRO • El acumulador (opcional) debe estar vacío y descargado.
38
AM326-1A-SP 2000 Printer : Precision Printing 2000
HÄGGLUNDS DRIVES INC.

2275 INTERNATIONAL STREET
COLUMBUS, OHIO 43228 USA
Phone: (614) 527-7400 Fax: (614) 527-7401
www.hagglunds.com
COMPACT CB MANUAL
Manual de instalacíon y mantenimiento
COMPACT CB
SP683-1h 2003
Prólogo Manual de instalacíon y mantenimiento, Compact CB
Prólogo
Hägglunds Drives es uno de los primeros fabricantes del mundo de grandes
sistemas de accionamiento hidráulico, un primer puesto que ha sido posible
gracias a un imbatible espíritu de servicio y a un desarrollo continuo, tanto
de productos como de mercados, en el mundo entero. Nuestras unidades se
encuentran en casi todos los sectores industriales y marinos, en los que existen
altísimas exigencias de eficacia y fiabilidad. Nuestra oficina principal y nuestra
planta de fabricación se encuentran en Mellansel, Suecia, y contamos con
nuestras propias oficinas de ventas y representación en unos 40 países.
Nuestros sistemas de accionamiento de alta calidad están basados en

nuestros exclusivos motores de pistones hidráulicos, desarrollados gracias a
una amplia experiencia acumulada a lo largo de 30 años en las áreas industrial
y marina. En la actualidad, el resultado de este trabajo de desarrollo progresivo
es el potente motor industrial COMPACT CB. Las soluciones técnicas, bien
sean nuevas o ya establecidas, contribuyen a la creación de este producto.
Este motor hidráulico se ha diseñado con las características más adecuadas
y comporta una máxima fiabilidad operativa.
Este manual contiene la información necesaria para la instalación y el

mantenimiento del motor. Si desea alguna información específica, busque la
sección que desee en el índice. Sin embargo, dado que pueden producirse
cambios en el equipo, nos reservamos el derecho de rectificar este manual,
según proceda, sin previo aviso ni obligación alguna.
El presente Manual de instalación y mantenimiento es válido para

los motores fabricados a partir del 1.01.02.
Original EN683-2h 2002
2
Manual de instalacíon y mantenimiento, Compact CB Índice
Índice
1. INFORMACIÓN GENERAL....................................................................................................4
1.1 Instrucciones de seguridad ....................................................................................................4
1.2 Datos sobre el motor .............................................................................................................5
1.3 Descripción de funcionamiento ..............................................................................................6
2. DATOS TÉCNICOS.................................................................................................................7
2.1 Presión de carga recomendada..............................................................................................7
2.2 Ruido de una instalación completa .........................................................................................8
2.3 Elección de fluido hidráulico ...................................................................................................9
Fluidos ecologicos adecuados para el medio ambiente .......................................................10
3. INSTALACIÓN......................................................................................................................11
3.1 Instrucciones de montaje......................................................................................................11
Rosca de la herramienta de montaje ....................................................................................12
Ejes estriados .......................................................................................................................12
3.1.1 Métodos de elevación ...........................................................................................................13
Colocación del motor en una superficie plana ......................................................................14
3.1.2 Montage del acoplamiento sobre el eje del motor ................................................................15
3.1.3 Montaje del brazo de par sobre el motor .............................................................................17
3.1.4a Montaje del motor sobre el eje conducido - eje de acoplamiento.........................................18
3.1.4b Montaje del motor sobre el eje conducido - estriado ...........................................................21
3.1.5 Desmontaje del motor del eje conducido .............................................................................22
3.1.6 Montaje del punto de reacción .............................................................................................22
3.2 Conexiones de aceite ..........................................................................................................24
3.2.1 Dirección de rotacíón del eje del motor ...............................................................................26
3.2.2 Drenaje y purga del motor ...................................................................................................26
3.2.3 Recirculacion de aceite en el motor......................................................................................27
4. INSTRUCCIONES DE FUNCIONAMIENTO ........................................................................28

4.1 Almacenamiento ..................................................................................................................28
4.2 Antes de la puesta en servicio..............................................................................................28
4.3 Puesta en servicio ...............................................................................................................29
4.4 Mantenimiento periódico ......................................................................................................29
Tabla de mantenimiento ........................................................................................................29
Motor.....................................................................................................................................30
Filtros ...................................................................................................................................31
Aceite ...................................................................................................................................31
4.5 Revisión del aceite................................................................................................................31
5. LOCALIZACIÓN DE AVERÍAS ...........................................................................................32

DECLARACIÓN DE CONFORMIDAD ................................................................................33
3
Información general Manual de instalacíon y mantenimiento, Compact CB
1. INFORMACIÓN GENERAL
1.1 INSTRUCCIONES DE SEGURIDAD
Es de la máxima importancia seguir en todo momento las instrucciones de seguridad;
si tiene alguna duda al respecto, póngase en contacto con la oficina de HD más
cercana.
Señales de aviso
En este manual encontrará las siguientes señales de aviso, que indican un peligro potencial
que puede derivar en lesiones personales o importantes daños materiales. Dependiendo de
la probabilidad de peligro y de lo graves que pudieran ser las lesiones personales o los daños
materiales, existen tres niveles de clasificación:
PELIGRO se utiliza para indicar la existencia de un peligro

cuyas consecuencias serían graves lesiones personales,
fallecimiento, o importantes daños materiales, si se hiciera
caso omiso de la señal.
AVISO se utiliza para indicar la existencia de un peligro

que puede dar lugar a graves lesiones personales,
fallecimiento, o importantes daños materiales, si se hiciera
caso omiso de la señal.
PRECAUCIÓN se utiliza para indicar la existencia de

un peligro que podría o puede ser causa de lesiones
personales o daños materiales menores, si se hiciera caso
omiso de la señal.
Área de aplicación
El personal de Hägglunds siempre debe aprobar y supervisar todas las aplicaciones, ya sean
nuevas o reconstruidas.
Montaje
Siga atentamente las instrucciones y preste atención a los grandes pesos y fuerzas implicados
durante la elevación.
Antes del comienzo

Antes de arrancar aplicaciones nuevas, reconstruidas o reparadas, deben ser revisados, todos
los accesorios y funcionamiento, de los dispositivos de seguridad.
Mantenimiento periódico
Observe los intervalos del gráfico de mantenimiento (4.4) y lleve un registro de los mismos.
Desmontaje
Siga atentamente las instrucciones y preste atención a los grandes pesos y fuerzas durante la
elevación.
4
Manual de instalacíon y mantenimiento, Compact CB Información general
1.2 Datos del motor

Tabla 1.1
Tipo de motor Cilindrada Par nominal *Velocidad Velocidad **Presión Par máximo Potencia máxima
nominal 1) máxima máxima 2) 3)
Sistema intermitente
métrico Vi Ts n n p kNm kW
CB 280-240 15 100 240 53 68 350 79 530
CB 280 17 600 280 44 58 350 92 530
CB 400-240 15 100 240 94 125 350 79 970
CB 400-280 17 600 280 73 105 350 92 950
CB 400-320 20 100 320 71 94 350 110 970
CB 400-360 22 600 360 59 82 350 120 960
CB 400 25 100 400 58 75 350 130 970
CB 560-440 27 600 440 49 65 350 140 930
CB 560-480 30 200 480 48 62 350 160 970
CB 560-520 32 700 520 41 57 350 170 960
CB 560 35 200 560 40 53 350 180 970
CB 840-600 37 700 600 30 45 350 200 880
CB 840-640 40 200 640 28 41 350 210 850
CB 840-680 42 700 680 27 40 350 220 890
CB 840-720 45 200 720 25 37 350 240 870
CB 840-760 47 800 760 23 34 350 250 840
CB 840-800 50 300 800 23 34 350 260 890
CB 840 52 800 840 21 32 350 280 870
Tipo de motor Cilindrada Par nominal *Velocidad Velocidad **Presión Par máximo Potencia máxima
nominal 1) máxima máxima 2) 3)
EE.UU. intermitente
Vi Ts n n p lbf·ft hp
in3/rev lbf·ft/1000 psi rev/min rev/min psi
CB 280-240 920 12 200 53 68 5000 57 000 710
CB 280 1070 14 200 44 58 5000 67 000 710
CB 400-240 920 12 200 94 125 5000 57 000 1300
CB 400-280 1070 14 200 73 105 5000 67 000 1300
CB 400-320 1230 16 300 71 94 5000 76 000 1300
CB 400-360 1380 18 300 59 82 5000 86 000 1300
CB 400 1530 20 300 58 75 5000 95 000 1300
CB 560-440 1690 22 400 49 65 5000 100 000 1300
CB 560-480 1840 24 400 48 62 5000 110 000 1300
CB 560-520 1990 26 400 41 57 5000 120 000 1300
CB 560 2150 28 500 40 53 5000 130 000 1300
CB 840-600 2300 30 500 30 45 5000 140 000 1200
CB 840-640 2450 32 500 28 41 5000 150 000 1100
CB 840-680 2610 34 600 27 40 5000 160 000 1200
CB 840-720 2760 36 600 25 37 5000 170 000 1200
CB 840-760 2910 38 700 23 34 5000 180 000 1100
CB 840-800 3070 40 700 23 34 5000 190 000 1200
CB 840 3220 42 700 21 32 5000 200 000 1200
* Se requiere una presión de carga de 12 bares/175 psi para motores en modo de frenando. (Especiales consideraciones deben
ser tomadas, respecto a presión de carga, refrigeración y selección del sistema hidráulico, para velocidades superiores a las
nominales, las 4 vias deben ser utilizadas).
** Los motores han sido diseñados de acuerdo con las normas DNV. Se permite una presión de comprobación y una presión
máxima de 420 bares/psi.
1
) Consideraciones especiales con respecto a la presión de carga, refrigeración y elección de sistema hidráulico para la velocidad
anteriormente indicada.
2
) Calculado en: Métrico= Ts·(350-15)·0,98 EE.UU= Ts·(5000-218)·0,98.
3
) Válido para la mínima viscosidad del aceite permitida 20 cST en la carcasa del motor.
5
Información general
1.3 Descripción de funcionamiento

El motor hidráulico industrial de Hägglunds Los líneas principales de aceite están
COMPACT CB es del tipo de pistones radiales conectados a las bocas A y C del bloque
con un eje hueco/bloque de cilindros giratorio de conexiones y los conductos de drenaje a
y una carcasa fija. El bloque de cilindros está las bocas D1, D2, D3 ó D4 de la carcasa del
montado en cojinetes a rodillos fijos en la motor.
carcasa. Los pistones, cuyo número es par, El motor se conecta al eje de la máquina
están colocados radialmente en taladros en el accionada a través del eje hueco del bloque
interior del bloque de cilindros, y la placa de de cilindros. El par se transmite utilizando
distribución dirige el aceite de entrada y salida un acoplamiento del eje mecánico o,
hacia y desde los pistones en funcionamiento. alternativamente, mediante estriado.
Cada pistón funciona contra un rodillo de
leva. Patentes vigentes
Cuando la presión hidráulica actua sobre US 4522110, US 005979295A, SE 456517,
los pistones, empuja a los rodillos de leva EP 0102915, JP 83162704, GB 1385693,
contra la inclinación del anillo de leva, que EP 0524437
está rígidamente conectado a la carcasa,
produciendo así un par. Los rodillos de leva Calidad
transmiten la fuerza de reacción a los pistones, A efectos de garantizar la calidad, mantenemos
los cuales están guiados en el el bloque de un sistema de Garantía de calidad, certificado
cilindros giratorio. Así pues, tiene lugar la con la norma ISO 9001, EN 29001 y BS 5750,
rotación y el par disponible es proporcional a parte 1.
la presión del sistema.
Figura 1. Motor COMPACT
1 1. Anillo de leva
2. Podillo de leva
2 A, C 3. Pistón
3 4. Acoplamiento del eje
D
4 8 5. Bloque de cilindros /
eje hueco
6. Bloque de cilindros /
5 Estriado
7. Tapa delantera
8. Cilíndrico cojinete a
rodillos
11
9. Bloque de conexiones
6 10. Placa de distribución
11. Cojinete axial
7 9 A = Boca »A« entrada o
salida
10
C = Boca »C« entrada o
salida
D = Boca de purga
Datos técnicos
2. DATOS TÉCNICOS
2.1 Presión de carga Hay dos casos bien determinados:
recomendada
Caso 1:
El sistema hidráulico debe estar concebido de El motor funciona en modo de frenado. La
manera que el motor reciba suficiente presión presión de carga requerida en la boca de
de carga en la boca de baja presión. Esto se entrada es la que se indica en el diagrama
aplica a todo tipo de instalaciones. que vemos a continuación.
Caso 2:
El motor sólo funciona en modo de accio-
namiento. La contrapresión necesaria en la
boca de salida corresponde al 30% del valor
indicado en el diagrama que vemos a continua-
ción, pero puede no ser inferior a 2 bares (29
En aplicaciones con cargas sus-
psi).
pendidas, la presión de carga en las
conexiones de los motores, deben
ser las indicadas en el grafico de
abajo, en todas las condiciones.
Tabla 2.1a Presión de carga

PRESIÓN DE CARGA RECOMENDADA - MOTORES COMPACT
Conexión de bocas sencillo, viscosidad del aceite 40 cSt/187 SSU
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 400 / CB 400-360
CB 560 / CB 560-520
CB 280-240
CB 400-320
CB 840-720
CB 840-600
CB 840
CB 280
20
18
250
16
14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80
Recommended charge pressure - CB 280-840 2-portt connection
Velocidad [r pm](rpm)
Speed [rpm]
Nota:
El diagrama es válido para una presión en la carcasa de 1 bar (15 psi). Al incrementar la presión
en la carcasa, la presión de carga debe aumentar en consecuencia. El gráfico es válido para los
casos en los que se utilizan 4 bocas. La presión máxima en la carcasa es de 3 bares (43,5 psi)
(durante un 1% del tiempo de operación uniformemente dividido, se admiten puntas de presión
de 5 segundos máximo hasta 8 bares (116 psi)).
Datos técnicos Manual de instalacíon y mantenimiento, Compact CB
PRESIÓN DE CARGA RECOMENDADA - MOTORES COMPACT

Conexión de bocas doble, viscosidad del aceite 40 cSt/187 SSU
Tabla 2.1 Presión de carga
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 560 / CB 560-520
CB 400 / CB 400-360
CB 840-720
CB 840-600
CB 280-240
CB 400-320
CB 840
CB 280
20
18
250
16

14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
2.2 Ruido de una instalación completa

Sonido ambiental
Motor de Sonido en Motor Sonido procedente de la

bomba tuberías hidráulico unidad conducida
Sonido de Cimentación y estructura
Observaciones:
Ruido de fondo Motor hidráulico

Normalmente no se puede influir en el ruido El motor hidráulico es una fuente de ruido
de fondo, pero suele conocerse y es fácil de conocida. (Tablas de datos de sowido - ver
medir. arpartado 4.9 del Engineering manual)
Unidad de la bomba Unidad accionada
La unidad de la bomba es una conocida fuente La unidad accionada es una fuente de
de ruidos. ruidos desconocida (para nosotros), pero
pro bablemente podamos conseguir dicha
Ruido de los tubos información del proveedor. Al fijar el brazo
El ruido de los tubos probablemente sea el de par de un motor hidráulico a la base del
origen de la mayoría de los errores en las insta- revestimiento de una máquina accionada, es
laciones: todas las abrazaderas de los tubos muy importante estudiar la construcción de
deben ser del tipo antivibratorio y fijarse al la cimentación o estructura. Éste puede ser
techo, la pared o el suelo de hormigón. Debe el factor más importante a tener en cuenta,
evitarse fijarlas en estructuras metálicas no pues muchas estructuras pueden producir
rígidas o en estructuras que produzcan reso- resonancia, causando graves problemas de
nancia. ruido.
8
Manual de instalacíon y mantenimiento, Compact CB Datos técnicos
2.3 Elección del fluido hidráulico

Los motores hidráulicos de Hägglunds están diseñados primordialmente para trabajar con aceites
hidráulicos convencionales basados en petróleo. El aceite hidráulico puede elegirse consultando
con el suministrador del aceite o con la oficina local de ventas, teniendo presente los siguientes
requisitos:
GENERALIDADES
El aceite debe ser conforme con FZG (90) fase de ensayo grado 11 descrito en IP 334 (DIN 51354).
El aceite debe contener también inhibidores para evitar la oxidación, corrosión y formación de
espuma. La viscosidad del aceite mineral depende en gran parte de la temperatura. La elección
definitiva del aceite debe depender de la temperatura de trabajo que se espera, o se conoce, en
el circuito y no en el depósito del aceite.
Las altas temperaturas del circuito reducen considerable-
VISCOSIDAD RECOMENDADA
mente la vida de servicio del aceite y de las juntas de A LA TEMPERATURA DE TRABAJO
goma.Asimismo dan como resultado una baja viscosidad 40-150 cSt/187-720 SSU.
que a su vez proporciona lubricación deficiente.
El contenido de agua deberá ser inferior al 0,1%. En aplica-
ciones industriales que exigen una larga vida de funciona-
Límites de temperature
miento, el contenido de agua será inferior al 0,05 %.
La temperatura normal de trabajo debe ser
Límites de viscosidad inferior a +50°C (122°F)
Indice de viscosidad =100 recomendada Juntas de nitrilo
=150* para funcionamiento (motor estándar) -35°C a +70°C
con grandes diferencias de Juntas de Viton -20°C a +100°C
temperatura Juntas de nitrilo
Mín. permitido en trabajo continuo 40 cSt/187 SSU (motor estándar) -31°F a +158°F
Mín. permitido en trabajo intermitente 20 cSt/98 SSU** Juntas de Viton -4°F a +212°F
Máx. permitido 10000 cSt/48000 SSU
* Muchos fluidos hidráulicos con mejoradores VI están sujetos temporal o permanentemente a reducciones de la viscosidad.
** Las viscosidades bajas reducen la vida de servicio de los motores “COMPACT CB”.
Fluidos resistentes al fuego

FUNCIONAMIENTO CON FLUIDOS RESISTENTES AL FUEGO
Los siguientes fluidos han sido probados para los motores de Hägglunds : (ISO/DP 6071)
Fluido Aprobado Juntas Pinture interna
HFA: Aceite (3-5%) en emulsión de agua No - -
HFB: 40-45% de agua de emulsión invertida en Sí Nitrilo (motor Sin pintura*
aceite estándar)
HFC: Agua-glicol Sí Nitrilo (motor Sin pintura*
estándar)
HFD: Líquidos sintéticos
HFD:R Ésteres fosfáticos Sí Vitón Sin pintura*
HFD:S Hidrocarburos clorados Sí Vitón Sin pintura*
HFD:T Mezcla de los anteriores Sí Vitón Sin pintura*
HFD:U Otras composiciones Sí Vitón Sin pintura*
*Debe ser especificado no se recomienda.
¡IMPORTANTE! Cuando se usan fluidos resistentes al fuego debe considerarse una

reducción de los valores de presión y de la vida de servicio. Consultar siempre a la
compañía Hägglunds o a su representante autorizado para que den su aprobación en
el caso de utilizar estos tipos de fluidos.
9
Datos técnicos Manual de instalacíon y mantenimiento, Compact CB
Fluidos ecológicos
Fluido Aprobado Juntas Pintura interna
Líquido vegetal HTG */** Sí Nitrilo (motor estándar) -
Ésteres sintéticos HE ** Sí Nitrilo (motor estándar) -

* Los fluido vegetales presentan una buena lubricación y un pequeño cambio de viscosidad a distintas temperaturas.
Si desea que los fluido vegetales tengan una vida de servicio adecuada, debe controlarlos cada 3 meses y
tenerlos a una temperatura inferior a +45 °C (113°F).
** Fluidos ecologicos dan la misma vida de servico, que el aceite mineral.
Filtración Eplicación del

El aciete de un sistema hidraulico debe filtarse
«GRADO DE FILTRACIÓN»
siempre, asi como el aceite recibido de su El grado de filtración β10=75 indica lo
provedoor debe filtarse cuando se añada al siguiente:
sistema. El grado de filtración de un sistema β10 significa el tamaño de la partícula ≥10 µm
hidráulico es una cuestión en la que están que se eliminará mediante la filtración.
implicados la vida de servicio frente al dinero
empleado en la filtración. =75 significa el grado de filtración del tamaño
de la partícula arriba mencionada. El grado
Para conseguir una vida de servicio adecuada, de filtración se define como el número de
es importante que siga nuestras recomen- partículas en el aceite antes de la filtración
daciones sobre el nivel de contaminación. en relación con el número de partículas en el
A la hora de elegir el filtro, es importante aceite después de la filtración.
con si de rar la cantidad de partículas de Antes de la filtración, el aceite contiene un
suciedad que puede absorber para seguir número N de partículas ≥10 µm, y después
funcionando satisfactoriamente. Por dicha razón, de pasar el filtro una vez, el aceite contiene
reco-mendamos un filtro con un indicador que
un número de partículas ≥10µm.
emita una señal cuando haya que cambiar el
cartucho del filtro. Esto significa que se ha filtrado un número
de
Recomendaciones de filtrado partículas (=98,6%).
Antes de arrancar, compruebe que el sistema
se ha limpiado a fondo.
1. En general, el nivel de contaminación de
nuestros motores no debe superar el de
ISO 4406 19/15 (NAS 10).
2. Para aplicaciones industriales de gran ren-
dimiento, el nivel de contaminación no debe
superar el de ISO 4406 16/13 (NAS 7).
3. Al llenar el depósito y la carcasa del motor,
recomendamos el uso de un filtro con un
grado de filtración ß10=75.
10
Manual de instalacíon y mantenimiento, Compact CB Instalación
3. INSTALACIÓN
3.1 Instrucciones de montaje Diseño del extremo del eje conducido
de un eje sobrecargado
Para que el motor funcione correctamente,
Cuando el eje conducido está sobrecargado
debe instalarlo con la máxima precisión
y sujeto a grandes esfuerzos, por ejemplo, en
posible. Si conecta los elementos del motor
los cambios de la dirección de rotación, se
de forma que no cumplan los requisitos de las
recomienda que el eje tenga una ranura para
instrucciones que se indican a continuación,
eliminar los esfuerzos; consulte la figura 3.1 y
la vida de servicio del motor puede resultar
las tablas 3.1 y 3.4.
gravemente afectada.
Normalmente el motor debe estar totalmente
lleno de aceite. Cuando se instala el motor con Figura 3.1
el eje en el plano horizontal, las conexiones de G
drenaje se colocarán en sentido vertical. Debe F

Máx. R 3,2
utilizar la más alta de las dos conexiones de a
drenaje, consulte figura 3.25.

Cuando el motor está montado con el eje en el
plano vertical; consulte 3.2.2 «Drenaje y purga
C
A
D
del motor».
Debe dimensionar la tubería de drenaje de ma-
E
30°
nera que la presión de la carcasa del motor no
sea superior a 3 bares (43,5 psi). 6±0,5
(0,24±0,02)
R 50
(R 1,97)
La presión máxima de la carcasa es de 3 bares B±0,5
(B±0,02)
(43,5 psi). Se permiten breves picos de hasta
8 bares (116 psi) durante el trabajo. La presión Eje con carga normal
de la carcasa permitida cuando el motor está En aplicaciones con un solo sentido de
parado es de 8 bares (116 psi). rotación en las que los esfuerzos del eje son
El motor debe estar siempre conectado de moderados, éste puede ser liso, consulte la
tal manera que tenga suficiente presión de figura 3.2 y las tablas 3.1 y 3.5.
carga, en la conexión de baja presión. Esto
es especialmente im port an te a grandes
Figura 3.2
velo-cidades y con inversión de marcha
rápida, consulte 2.1 «Presión de carga Máx.
recomendada».
Tabla 3.1 Válido para acoplamientos
Dim CB 280 CB 400 CB 560/840

A
-0,014 -0,017
mm 180 -0,054 200 -0,015
-0,061 260 -0,069
in
-0,00055 -0,00059
7.0866-0,00213 7.8740 -0,00240 10.2362 -0,00272
-0,00067 Tabla 3.2
B Accionamientos unidireccionales
mm 106 117 153
in 4.17 4.61 6.02
Acero con resistencia Relmin= 300 N/mm2
C
mm 174 194 254
in 6.85 7.64 10 Accionamientos bidireccionales
Nota: Las dimensiones son válidas para +20 °C (68 °F).

11
Instalación Manual de instalacíon y mantenimiento, Compact CB
Eje estriado Rosca de la herramienta de

montaje
Las estrias se han de lubricar con aceite
hidráulico, o llenado con aceite de la
transmision de la caja reductora, a la que este Para facilitar el montaje del motor en el eje
unido. Para evitar desgastes en el estriado, el conducido o para extraer el motor del eje, se
montaje debe estar dentro de las tolerancias recomienda taladrar y roscar un agujero (tabla
de la figura 3.3. 3.5) en el centro del eje para una herramienta
de montaje; consulte 3.1.4 «Montaje del motor
Consulte 278 5023, 278 5024, 278 5025, en el eje conducido», y «3.1.5» «Extracción del
ó 278 5026 si desea información sobre la motor del eje conducido».
construcción del eje y la tabla 3.4 sobre el
control de del estriado. La herramienta tiene una rosca UNC y
una rosca métrica asi el agujero puede ser
Tabla 3.3 taladrado y roscado con una de las dos
alternativas de la tabla 3.5.
Accionamientos unidireccionales
Accionamientos bidireccionales
Acero con resistencia Relmin= 700 N/mm2 Tabla 3.5 Rosca alternativa
(figuras 3.1 y 3.2)
CB 280 - 840
D M20 UNC 5/8"
Tabla 3.4 E >17 (0,67) >13,5 (0,53)
Motor CB 280/400 CB 560/840 F 25 (0,98) 22 (0,87)
G 50 (1,97) 30 (1,18)
Perfil del diente y DIN 5480 DIN 5480
forma del fondo
Tolerancia 8f 8f
Guía Trasera Trasera
Ángulo de presión 30 ° 30°
Módulo 5 5
Número de 38 50
dientes Figura 3.3
Diámetro primitivo ø190 ø250
Diámetro menor ø188 0 ø248 0
A
-1,201 -1,201
Diámetro mayor ø199 0 ø259 0
-0,290 -0,320
ø
ø
Medida sobre los -0,088 -0,103

calibres de contol 210,158 270,307
-0,157 -0,181
Diámetro de los ø10 ø10

calibres
Modificación del +2,25 +2,25 0,15 A
addendun XM
0,4 A
12
3.1.1 Métodos de elevación

Antes de empezar la elevación, asegúrese Antes de empezar la
siempre dónde está el centro de gravedad. ele vación, asegúrese
siempre dónde está el
Figura 3.4a centro de gravedad. Nunca
se sitúe debajo del brazo
del par o de un motor en
suspensión.
Figura 3.5
Figura 3.4b Figura 3.4c
13
Colocación del motor en una

superficie plana
Tabla 3.6
Cuando se coloca el motor sobre una superficie
Motor Motor con
plana, como el suelo, debe reposar sobre el
acoplamineto
diámetro exterior o sobre la superficie protegida
kg lb del eje hueco (consulte las figuras 3.6 y 3.7).
CB 280 928 2042
CB 400 1288 2834
CB 560 1514 3331
Figura 3.6
CB 840 1844 4057
Tabla 3.7
Brazo de par Peso
kg lb
TCA 40 128 282
Soporte
TCA 84 224 493
Figura 3.7
Debe elegir los aparejos de

elevación con un margen de
seguridad fiable en cuanto al
peso total del objeto que se
va a elevar.
Soporte
NOTA:
El motor no debe apoyarse sobre el eje hueco,
cuando el acoplamiento está montado, ya que
este podría dañarse.
Al almacenar el motor, siempre debe colocarlo
sobre la superficie del eje hueco. También es
aconsejable instalar soportes en la superficie
de montaje del motor, consulte la figura 3.7.
14
3.1.2 Montaje del acoplamiento en el eje del motor

Antes del montaje del motor, hay una serie de condiciones previas que deben cumplirse:
- Obsérverse que los acoplamientos, están engrasados de fabrica con MoS2 (Molycote) en las
superficies cónicas y tornillos, consulte la figura 3.8. Dicho lubricante permanecerá en estas
superficies pero:
Bajo ninguna circunstancia el

Molycote debe pasar a las super-
ficies de contacto, entre el eje
conducido y el motor.
Por lo tanto, es importante que en las manos no quede ningún resto de Molycote. Una vez
cumplidas dichas condiciones, puede empezar el montaje.
- Limpie el eje conducido y la parte externa e interna del eje hueco del motor Compact.
- Quite los separadores entre los dos anillos de fijación del acoplamiento.
- Monte el acoplamiento sobre el eje hueco del motor. Debe empujar el acoplamiento hacia
arriba hasta el tope del eje. Utilice un destornillador para abrir el anillo de acoplamiento y
lograr así un montaje más fácil.
Nunca apriete los tornillos de

acoplamiento hasta que el motor
esté montado en el eje condu-
cido.
- Monte el motor en el eje conducido siguiendo las instrucciones de la sección 3.1.4 "Montaje
del motor sobre el eje conducido" (utilizando o sin utilizar la herramienta de montaje).
Recuerde:
- La superficie cónica entre el anillo de acoplamiento y los bridas de fijación + los tornillos debe
estar engrasados MoS2 (Molycote), consulte la figura 3.8. Esto se hace en fábrica a la entrega.
Cuando haya desmontado un motor para efectuar una revisión general o realizar un servicio,
y tenga que volver a montarlo, tal vez necesite lubricar de nuevo estas superficies con Molycote
pero, recuerde: sólo las superficies especificadas.
cadas
- Absolutamente nada de Molycote en las superficies de contacto entre el eje y el motor. Limpiar
el eje accionado y el interior del eje hueco del motor.
- La alineación del motor en el eje (comprobación dimensional).
- Una variación mínima en la separación entre los bridas de fijación (comprobación
dimensional).
- El par correcto en los tornillos (utilice una llave dinamométrica).
Antes de poner en marcha el motor,

comprobar que el acoplamiento
giratorio no causa daños.
15
Figura 3.8
Anillos de fijación
Labio
Anillo de acoplamiento
Arandela - - - - -= Superficie
engrasada
Superfície limpa
16
3.1.3 Ajuste del brazo de par en el motor

El brazo de par se ajusta en el motor antes de Figura 3.9 CA 50/70
instalar éste en el eje conducido.
- Limpie la superficie de contacto del brazo
de par y el motor con tricloretileno o un dis-
olvente similar.
- Engrase los tornillos.
- Asegúrese de que el brazo de par está
montado en la dirección correcta cuando
el motor esté instalado en su sitio en la
máquina. Para conseguir el máximo nivel
de aceite posible en la carcasa del motor,
éste debe ser girado hasta que las salidas
de purga estén colocadas de acuerdo con la
figura 3.12.
- Alinear el brazo de par sobre el mo tor
utilizando los tornillos com anilhas. Par de
apriete, consulte la tabla 3.8.
Figura 3.9a CA 100/140/210
No suelde, taladre, rectifique, ni

realice ningún trabajo similar en
el brazo de par sin la aprobación
de Hägglunds.
Tabla 3.8
Motor Dimensión de los tornillos Número de Par de apriete
tornillos Nm lbf·ft

Nota: Utilice una llave dinamométrica y tornillos engrasados.
17
3.1.4a Montaje del motor en el eje conducido

El motor puede montarse en el eje coducido con o sin herramienta de montaje, pero se recomienda
el uso de dicha herramienta porque facilita el trabajo.
Es importante conseguir la longitud de fijación correcta, entre el eje conducido y el eje hueco del
motor.
Asegúrese de utilizar la longitud de acoplamiento completa, por ejemplo, midiendo y marcando el
eje conducido. Esto tiene especial importancia si el trabajo es tan duro que se ha practicado una
ranura alivio de esfuerzos en el eje conducido. Consulte las figuras 3.11, 3.11a y la tabla 3.9.
Montaje del motor con una herramienta de montaje (Figura 3.10a)

- Quite la tapa del extremo junto con los tornillos y arandelas.
- Alinee el motor con el eje conducido.
- Colocar la arandela de plástico existente, entre la tuerca de la herramienta de montaje y el
soporte de fijación. Introducir la herra-mienta por el eje central del motor, roscándola en el eje
conducido usando las muesca para llave en el extremo de la herramienta.
- Lleve el motor hasta el eje girando la tuerca de la herramienta de montaje hasta conseguir la
longitud indicada en la tabla 3.9; consulte la figura 3.11 y 3.11a. Presione y tire del extremo del
brazo de par para lograr un montaje más fácil.
- Consulte la tabla 3.10 para saber cuál es el apriete del acoplamiento del eje.
- Quite la herramienta de montaje.
- Instale de nuevo el tapón.
- Instale de nuevo la tapa del extremo y apriete los tornillos y las arandelas. El par es 80 Nm (59
lbf·ft).
Fig.3.10b
Limpiar el eje accionado y

el interior del eje hueco del
motor
Fig. 3.10a Montaje de la CB 280...840
2 1; Soporte de fijación
2; Arandela de plástico
3; Tuerca
4; Herramienta de montaje
3
4
18
Figura 3.11 Sin ranura para eliminar los esfuerzos Figura 3.12
Montaje del motor sin herramienta

Figura 3.11a Con ranura para eliminar los esfuerzos
de montaje
Puede montar el motor en el eje conducido
sin utilizar herramienta de montaje, aunque es
más difícil y lleva más tiempo. Sin embargo, es
más sencillo montar el motor si se purga el aire
atrapado en el eje hueco durante el montaje.
Para hacerlo, quite la tapa del extremo como se
describe en “Montaje del motor con herramienta
de montaje”.
Ponga en línea el motor con el eje conducido
utilizando una grúa móvil o una carretilla
elevadora y presione con cuidado en el eje
para conseguir la longitud indicada en la
tabla contigua, consulte la figura 3.11.
Para alcanzar el máximo nivel de aceite posible
en la carcasa del motor, debe girarlo hasta
que las salidas de drenaje estén situadas de
acuerdo con la figura 3.12.
Tabla 3.9
Motor Longitud
B mm B in
CB 280 106 4.17
CB 400 117 4.61
CB 560/800 153 6.02
19
Apriete del acoplamiento del eje

Sin embargo, para apretar los tornillos de Marque las cabezas de los tornillos (a las 12 en
acoplamiento debe observar lo siguiente: punto) con un lápiz o con pintura para poder
seguir la secuencia de giro de los tornillos.
Mantener la tensión en los cables, para
evitar que el motor se incline sobre el Ajuste la llave dinamométrica al par
eje, durante el apriete de los tornillos. máximo especificado. Consulte la señal
El balanceo causado por la inclinación del aco-plamiento, o la tabla 3.10, si desea
del motor origina fuerzas extras sobre el conocer el par de apriete de los tornillos de
rodamiento principal. acoplamiento.
Para evitar la desalineación de los dos bridas A continuación, apriete los tornillos siguiendo
de fijación mientras aprieta los tornillos, la secuencia que se muestra en la figura
debe medir la separación entre los bridas 3.14a.
en distintos lugares durante el proceso, Continúe haciéndolo hasta llegar al par
consulte la figura 3.14. La diferencia entre las indicado. Varias pasadas son necesaries
separaciones medidas nunca debe variar más antes de que los tornillos queden apretados
de 1 mm (0,04") en ninguna fase del proceso de acuerdo con el par especificado. Siga
de apriete. comprobando la alineación del acoplamiento
Preajuste los tornillos de acoplamiento en pares (serán necesarios 15-20 giros).
opuestos (12-6-3-9 en punto) hasta alcanzar Cuando alcance el par especificado, es impor-
un máximo del 50% del par especificado para tante que todos los tornillos estén apretados
los tornillos. Es muy importante que, al llegar según dicho par y que no se observe ningún
a esta fase, la desalineación esté controlada otro movimiento.
como se describe arriba.
Tabla 3.10
Tipo de Nº de Dimesiónes Calidad Par de apriete Tipo de

motor tornillos de los Nm lbf·ft cabeza
tornillos
CB 280 12 M20 x 80 10.9 490 362 Hexagon
CB 400 15 M20 x 90 10.9 490 362 Hexagon
CB 560 20 M20 x 100 10.9 490 362 Hexagon
CB 840 20 M20 x 100 10.9 490 362 Hexagon
Nota 1 Tornillos no revestidos lubricados con MoS2 .

Nota 2 Hay una placa metálica en cada acoplamiento con un par de apriete grabado.
Siempre debe utilizar dicho par.
Nota 3 El valor del par de apriete es crítico. Utilice una llave dinamométrica calibrada.
20
Figura 3.14 Figura 3.14a
3.1.4b Montaje del motor en las estrías del eje impulsado
Motores montados en brida.

Para motores montados en brida, el estriado
o-ring
normalmente no esta sujeto a cargas radiales. Sin
carga radial, el eje acanalado se puede engrasar
antes de montar el motor. Si el motor está sujeto
a carga radial, las estrías se han de llenar con
aceite.
- Montar el motor sobre el eje.
Llenar de aceite antes
de apretar el tapón G1. - Atornillar el motor a la brida. Apriete del par
Huelgo axial mín. 5 (0,2) motor, ver tabla 3.10.
Si hay aceite aquí, puede - Llenar de acetie hidráulico por el tapon G1.
ser usado para el estriado,
entonces quitar la junta - Apretar el tapón G1. MV=125 Nm/90 lbf.ft.
torica.
- Montar la tapa. MV=81 Nm/59 lbf.ft.
10 (0,4) durante el Motores montados con brazo de par.

llenado de aceite.
Motores que tienen carga radial, deben tener el
o-ring estirado aceitado.
Separador
- Monte el separador en el eje. MV=450 Nm/300
lbf.ft.
- Montar el motor sobre el eje.
- Llenar de aceite por el tapon G1.
- Monte el tornillo de diseño especial.
- Apriete el tornillo. MV=385 Nm/280 lbf.ft.
Llenar de aceite antes
de apretar el tornillo - Montar la tapa. MV=81 Nm/59 lbt.ft.
M20 L=100 mm
21
3.1.5 Desmontaje del motor del eje conducido

Antes de desmontar el motor del eje conducido, Desmontaje utilizando la herramienta
debe vaciar el aceite de la carcasa del motor a de montaje
través del orificio de drenaje inferior.
- Afloje gradualmente los tornillos del aco-
El motor puede desmontarse del eje con o sin plamiento del eje; consulte las figuras 3.14
herramienta de montaje, pero resulta más fácil y 3.14a. Debe aflojar cada tornillo sólo un
con la herramienta. cuarto de vuelta cada vez.
De esta manera evitará que las bridas se
inclinen y se agarroten. Debe aflojar los
tornillos hasta que el anillo del acoplamiento
quede totalmente libre.
No permanezca nunca de- - Quite la tapa del extremo y el soporte de
bajo del motor durante el fijación con los tornillos y arandelas; consulte
desmontaje. la figura 3.15.
- Coloque la arandela de plástico existente en
Asegúrese siempre de el exterior de la tuerca de la herramienta de
que el equipo de elevación montaje. Entonces pase la herramienta por
el eje central y atorníllela en el eje secundario
tiene fuerza suficiente
hasta la profundidad indicada.
para soportar el peso del
motor. - Atornille la tuerca de la herramienta hasta
que pueda instalar de nuevo el soporte de
fijación.
- Retire el motor del eje conducido desen-
roscando la tuerca de la herramienta de
montaje.
Fig. 3.15 Desmontaje del Compact CB 280...840
- Quite el soporte de fijación y la herramienta
de montaje. Finalmente, instale de nuevo el
soporte de fijación (par 136 Nm /100 lbf·ft)
y la tapa del extremo (par 81 Nm / 59 lbf·ft)
1 como antes.
2
Desmontaje del motor sin utilizar la
herramienta de montaje
- Afloje los tornillos del acoplamiento del eje,
consulte “Desmontaje de motores utilizando
la herramienta de montaje”.
3
4 - Desmonte la tapa del extremo e conete para
que entre aire en el eje hueco del motor;
consulte “Montaje del motor sin herramienta
de montaje”. Despuesde desmontar el motor,
coloque de nuevo los componentes que haya
quitado.
1 - Soporte de fijación
2 - Arandela de plástico - Desmonte con cuidado el motor del eje
3 - Tuerca conducido sujetándolo con una grúa móvil
4 - Herramienta de montaje o una carretilla elevadora.
22
3.1.6 Montaje del punto de reacción

Figura 3.16 Montaje por unión articulada
x = ±2 mm (0,079) de desalineación en la instalación
x ≤ ±15 mm (0,59) de movimiento en uso
Posición
alternativa
La totula debe ser
desmontada durante la
soldadura.
Acero:
EN 10113S355N
DIN St E39
BS 4360 Grade 50C
Protegido contra corrosión tras la soldadura.
Figura 3.17 Figura 3.18
ZONA DE PELIGRO
En caso de fallo de la instalación
del brazo de par
Asegúrese de que la base

puede soportar la fuerza
del brazo de par.
23
3.2 Conexiones de aceite

Cuando se usan tuberías de gran espesor Figura 3.25a
y en accionamiento con inversiones de giro
frecuentes, recomendamos instalar mangu-
eras flexibles entre el motor y los tubería para
evitar daños causados por las vibraciones y
para simplificar la instalación del motor. Las
mangueras deben ser cortas.
Figura 3.25
T4
Tabla 3.11
Conexión Descripción Observaciones
C1, C2 Conexión principal Si se utiliza C como entrada, el eje del motor gira en el
sentido de las agujas del reloj, mirando desde el lado
del eje del motor*.
A1, A2 Conexión principal Si se utiliza A como entrada, el eje del motor gira en el
sentido contrario a las agujas del reloj, mirando desde
el lado del eje del motor*.
D1 Salida de drenaje Normalmente tapada a la entrega.
D2, D3, D4 Salidas de drenaje Normalmente tapada a la entrega.
alternativas
F1, F2 Conexión de recirculación aceite Para recircular el reten del eje. Normalmente tapado.
F3 Conexión de recirculación aceite Para purga de cojinete axial y de la carcasa del motor.
T1 Tomas de presión Se utilizan para medir la presión y la temperatura en
las conexiones principales.
T2, T3 Tomas de presión Utilizado para medir la presión y/o la temperatura del
aceite de drenaje.
T4 Conexión de presión Conexión para brazo de par de dos extremos.
Tabla 3.12
Motor A** C** D1, D2, D4 F1, F3 T1, T3 T4 y y x x
CB 280...840 1 1/4" 1 1/4" G G G G G1/4" G G 223 8.78 99 3,90
1 1/2" 1 1/2" 1 1/4" 1 1/4" 1/4" 1/2" M16 1/4" 1/2" 223 8.78 101 3.98
** Bridas SAE J518C, código 64, 414 bares (6000 psi). Se puede utilizar 1 1/4” o 1 1/2”.
*** La conexión A2 y la conexión C2 están bloqueadas a la entrega. Pueden soportar la máxima presión.
24
Conexiones principales A, C
Tabla 3.13
Motor Conexión a b c
mm (in) mm (in)
CB 280 - 840 1 1/4" 31 (1,22) UNC 1/2" 27 (1.06)
1 1/4" UNC 5/8" 35 (1.38)
Conexión de drenaje D1, D2, D4 Conexión T de prueba
Figura 3.25c Figura 3.25d
G
G1 1/4"
25
3.2.1 Dirección de rotación del

eje del motor Figura 3.26
Con la alta presión conectada a la boca A, el A1
eje del motor gira en la dirección indicada por la C1
flecha, en el sentido contrario a las agujas del
reloj mirando desde el lado del eje del motor.
Con la alta presión conectada a la boca C, el
eje del motor gira en el sentido de las agujas
del reloj mirando desde el lado del eje del
motor.
3.2.2 Drenaje y purga del motor

Montaje horizontal
Cuando se instala el motor con el eje en el plano horizontal. Siempre debe utilizar la más alta de
las cuatro salidas de drenaje D1, D2, D3 ó D4; consulte la figura 3.28.
Debe conectar la tubería de drenaje directamente al depósito, con las mínimas restricciones, a
fin de garantizar que no se sobrepasa la presión máxima de la carcasa.
Montaje vertical
Cuando el motor está montado verticalmente, se debe utilizar la salida de drenaje más alta D1,
D2, D3 o D4. Es necesaria la recirculación del retén radial de baja presión.
El eje del motor apunta hacia abajo

Se debe conectar el motor a una de las conexiones de drenaje del bloque de conexión, ver
figura 3.29. La conexión de recirculación F2 se conectará a una conexión de baja presión. El
orificio debe estar instalado.
El eje del motor apunta hacia arriba

Se debe conectar el motor a las conexiones de las tuberías de drenaje en el alojamiento del
extremo del eje, ver figura 3.30.
La conexión de recirculación de aceite F1 en el alojamiento del extremo del eje se debe conectar
a una conexión de baja presión. Con accionamientos bidireccionales, utilice la conexión con el
promedio menor de presión. (Una conexión de alta presión incrementaría el flujo de drenaje del
motor). Esto permite la recirculación del retén del labio radial. Se aconseja acoplar el manguito y
la unión roscada al motor antes de montar el brazo del par.
Asegúrese de que esta válvula

de retención está conectada en
la dirección correcta.
26
Manual de instalacíon y mantenimiento, Compact CB Mantenimiento
Figura 3.28 Figura 3.30
Orificio ∅1,0 (0,04)
Conexiones
de la tubería
de drenaje Baja presión
Conexiones de la
tubería de drenaje
G 1/4", Conexión de
Figura 3.30 recirculacíon F1 Fig. 3.31
Conexiones de Orificio ∅1,0

1,0 (0,04)
la tubería de
drenaje
G 1/2", Conexión de
recirculacíon F3
Baja presión
3.2.3 Recirculación de aceite

Recirculación de aceite en la carcasa del motor Potencia máxima sin descarga de agua
Para evitar altas temperaturas en la carcasa de CB 280 120 kW (160 hp)
motor, se debe eliminar el calor, porque con altas CB 400/560/840 170 kW (227 hp)
tem pe ra tu ras la viscosidad es menor y la vida Para calcular la recirculación requerida, póngase
de servicio queda reducida. Asimismo, una baja en contacto con su representante de Hägglunds.
viscosidad reduce la potencia del motor. El aceite de recirculación ser drena por la drenaje
- En aplicaciones en servicio continuo, con una normal. Consulte 3.2.2.
tem pe ra tu ra ambiente de +20°C (68°F), y si Conecte la tubería de entrada de recirculación, por la
la potencia de salida excede de los valores a boca de drenaje mas baja, consulte figura 3.31.
continuación indicados, se debe realizar una
recirculaciónde aceite a través de la carcasa.
27
4. INSTRUCCIONES DE FUNCIONAMIENTO
4.1 Almacenamiento
El motor se entrega con una protección interna en forma de película de aceite y una protección externa en
forma de película anticorrosiva, lo que ofrece suficiente protección para su almacenamiento en interiores,
a temperaturas normales, durante unos 12 meses.
Nota: La protección anticorrosión debe retocarse después del transporte y la manipulación.
Si el motor permanece almacenado durante más de 3 meses en locales sin calefacción, o más de 12 meses
en locales con calefacción, debe llenarlo de aceite y colocarlo como se indica en la figura 3.7.
Coloque el motor como se indica en la figura 4.1, llénelo de aceite filtrado en el orden siguiente: D1, A1, C1.
Consulte 2.3, “Filtración” y tabla 4.1.
Tenga mucho cuidado para que no se introduzca ningún elemento contaminante en el motor con el aceite.
Cierre las conexiones A y C con la tapa protectora instalada en la superficie de conexión a la entrega.
Compruebe que todas las juntas tóricas o las juntas de caucho estén es su sitio en la tapa protectora. Ponga
el tapón en D1. En la tabla siguiente vemos la cantidad de aceite necesario para rellenar los distintos tipos
de motores.
4.2 Antes de la puesta en servicio

Compruebe los puntos siguiente antes de poner en servicio el motor, es decir, antes de arrancarlo por vez
primera:
- Compruebe que el motor está conectado en la dirección de rotación correcta (consulte 3.2, “Conexiones
de aceite”, y 3.2.1, “Dirección de rotación del eje del motor”).
- Seleccione el fluido hidráulico de acuerdo con las recomendaciones (consulte 2.3 “Selección del fluido
hidráulico”).
- Llene la carcasa del motor con fluido hidráulico a través de un filtro en las salidas de drenaje D1, D2 o el
orificio de purga (dependiendo de cómo esté montado el motor), consulte tabla 4.1 .
- Compruebe la tubería de drenaje para asegurarse de que no hay una presión excesiva en la carcasa del
motor; consulte 3.1 “Instrucciones de montaje”, y 3.2.2 “Drenaje y purga del motor”.
- Compruebe que el motor está protegido contra las sobrecargas (consulte 1.1. “Datos del motor”).
- Compruebe que la presión de carga se ajusta a la curva de presión de carga (consulte 2.1 “Presión de
carga recomendada”).
- Compruebe que todos los racores y tapones hidráulicos
están bien apretados para que no se produzcan fugas.
- Asegúrese de que el brazo de par está bien sujeto,
Figura 4.1 consulte 3.1.3 y 3.1.6.
Tabla 4.1
Motor Volumen de aceite aprox.
Litros Galones EE.UU
CB 280 15 4.0
CB 400 21 5.6
CB 560 19 5.0
CB 840 25 6.6
28
Manual de instalacíon y mantenimiento, Compact CB Mantenimiento
4.3 Puesta en servicio 4.4 Mantenimiento periódico
- Durante el arranque inicial y el período Cuando un sistema hidráulico lleva cierto

inmediatamente posterior, debe comprobar tiempo en servicio, debe recibir un manteni-
con regularidad y a intervalos frecuentes miento periódico a intervalos que dependerán
toda la instalación hidráulica. del equipo y del tipo de trabajo.
- Debe supervisar la presión de funcionamiento Este mantenimiento periódico debe incluir lo
y la presión de carga para comprobar que siguiente:
corresponden a los valores contratados.
- Compruebe si el sistema hidráulico presenta
- La presión de la tubería de drenaje medida
fugas. Apriete los tornillos, cambie las juntas
en el motor debe ser inferior a 3 bares (43,5
defectuosas y mantenga limpio el acciona-
psi). Este límite de presión es importante
miento.
para la duración de las juntas del motor.
- Inspeccione y limpie todos los filtros de
- Si se producen fugas, solucione la avería y
aire, de aceite y magnéticos; cambie todos
realice nuevas mediciones.
los cartuchos de filtro en los que haya
- Compruebe todas las tuberías, conexiones,
habido alguna indicación de filtro obstruido;
tornillos, etc., y corríjalos en caso
inspeccione el depósito, la bomba, los filtros,
necesario.
etc., y límpielos en caso necesario.
- Compruebe otros posibles puntos de fugas
- Compruebe la presión y la temperatura del
y cambie las piezas defectuosas.
fluido hidráulico y realice las operaciones
- Durante el período de arranque, las partículas
rutinarias. Ajuste las válvulas, etc., si es
de polvo del sistema se eliminan mediante
necesario.
filtros. Los cartuchos del filtro tienen que
- Compruebe el fluido hidráulico; consulte la
cambiarse transcurridas 100 horas de
sección titulada “Aceite”.
funcionamiento y después de este tiempo,
- Compruebe que durante la inspección no
de acuerdo con la tabla de mantenimiento.
se introduzca polvo u otros elementos con-
Consulte los indicadores de “filtros obstruido”
taminantes en el sistema. Compruebe que
en 4.4.
no hay suciedad, sobre el motor hidraulico
Las partículas de suciedad, en el aceite y la instalación; de este modo se detectarán
pueden causar dãnos en las superficies de antes las fugas y averías.
deslizamiento del motor, sobre todo si este - Recomendamos llevar un registro de fun-
aún está en periodo de rodaje. Este punto cionamiento y que todas las inspecciones
es válido durante las 100 primeras horas de planificadas se efectúen a intervalos
funcionamiento. establecidos.
- Las comprobaciones y trabajos de manteni-
miento son las siguientes:
Tabla de mantenimiento
En Filtros Aceite Brazo
funcionamiento de de par
aceite
Después de las Camb. Inspec.
100 primeras
horas
Después de 3 Camp.
meses o 500
horas
Una vez cada 6 Camp. Inspec. Inspec.
meses
Una vez cada
12 meses
Camb. = Cambiar Inspec. = Inspeccionar
29
Mantenimiento Manual de instalacíon y mantenimiento, Compact CB
Motor Filtros
Si el motor va a permanecer almacenado du- Debe cambiar los filtros una vez transcurridas
rante más de 1 mes, debe protegerlo de la las 100 primeras horas de funcionamiento, y
corrosión interna, lo cual puede hacerse de la efectuar el segundo cambio tras 3 meses o
manera siguiente: 500 horas de funcionamiento, lo que primero
1. Mezcle un aditivo anticorrosivo con el ocurra. Después, debe cambiarlos a intervalos
líquido hidráulico del sistema. Utilice un 5% regulares de 6 meses o 4.000 horas de
de Rust Veto Concentrate (fabricado por funcionamiento.
EF Houghton & Co, Philadelfia, EEUU). Este
aditivo ofrece una protección anti-corrosión
durante aproximadamente un año, después Aceite (Consulte también 2.3)
de este tiempo, el motor debe ser girado una
pocas revoluciones
Análisis
2. Si no se utilizan aditivos, el motor debe ser
regularmiente girado unas, pocas revolu- Recomendamos analizar el aceite cada 6
ciones. meses. Dicho análisis debe incluir viscosidad,
oxidación, contenido de agua, aditivos y
3. Si no es posible girar el motor, tape todas contaminación.
las conexiones, abrir la boca de drenaje D1
o D2 en el extremo de la carcasa (o si el La mayoría de los distribuidores de aceite tienen
motor está montado verticalmiente, la boca un equipo que analiza el estado del aceite y
de purga F1 en la carcasa en el lado del recomienda las medidas oportunas a tomar.
eje) y llenar el motor con liquido hidráulico. Hay que cambiar el aceite inmediatamente si
(Consulte las figuras 4.3 y 4.3a). el análisis indica que se ha agotado.
Viscosidad
Muchos aceites hidráulicos se vuelven más
Figura 4.3
fluidos con el uso, lo que se traduce en una
lubricación más deficiente. La viscosidad del
aceite en servicio nunca debe ser inferior a la
viscosidad mínima recomendada.
Oxidación
El aceite hidráulico se oxida con el uso y la
temperatura, lo cual se hace patente por los
cambios de color y olor, una mayor acidez o
la formación de lodo en el depósito. El índice
de oxidación aumenta rápidamente a una
Figura 4.3a temperatura en la superficie superior a 60 °C
(140 °F); entonces debe comprobar el aceite
más a menudo.
El proceso de oxidación incrementa la acidez
del fluido. La acidez se indica en términos
del “número de neutralización”. La oxidación
típica es lenta al principio y después aumenta
rápidamente.
Un rápido incremento (en un factor de 2 y
3) del número de neutralización entre las
inspecciones es señal de que el aceite se ha
oxidado demasiado y hay que cambiarlo de
inmediato.
30
Manual de instalacíon y mantenimiento, Compact CB Localiczación de averías
Contenido de agua
La contaminación del aceite con agua puede El método más común de realizar el análisis es
detectarse haciendo un muestreo de la parte recoger una muestra de aceite en una botella
inferior del depósito. La mayoría de los aceites especial y enviarla a un laboratorio para que
hidráulicos repelen el agua, que se acumula en éste le remita el informe, que se atiene a las
la parte inferior del depósito. Este agua debe normas internacionales al respecto.
purgarse a intervalos regulares. Hay determi- Usted ha de decidir qué análisis debe realizar
nados tipos de aceites para transmisión y el laboratorio. El más común es un recuento
aceites para motor que emulsionan el agua, de partículas, contenido de agua, oxidación y
lo cual puede detectarse por la formación de viscosidad.
revestimientos en los cartuchos de filtro o
cambios del color del aceite. En dichos casos También puede instalar un contador de
deberá asesorarle su distribuidor de aceite. par tículas directamente en el sistema
hidráulico, que le informará de los niveles de
Grado de contaminación contaminación del aceite siguiendo las normas
internacionales. La única desventaja de ese
Una fuerte contaminación del aceite incrementa sistema es que sólo obtiene los niveles de
el desgaste de los componentes del sistema contaminación del aceite.
hidráulico. Debe investigar y solucionar in-
mediatamente la causa de la contaminación.
General
El objetivo es la verificación del estado del
aceite durante el funcionamiento del motor.
Los motores deben estar funcionando a un
régimen normal de trabajo cuando se tome
la muestra. Tenga en cuenta que es muy
importante operar con pulcritud a la hora
Todos los fluidos hidráulicos resultan de tomar la muestra.Utilice siempre botellas
afectados de manera distinta. Consulte especialmente preparadas para la recogida
de muestras de aceite, que puede adquirir en
con su dis-tribuidor de aceite o con el
cualquier laboratorio de análisis de fluidos.No
respresentante de Hägglunds Drives intente nunca depositar las muestras en una
más cercano. botella que haya limpiado previamente si desea
que el análisis sea preciso.La muestra se ha de
4.5 Revisión del aceite recoger con un latiguillo Minimess conectado
a un acoplador Minimess.Limpie con cuidado
todos los puntos de conexión antes de unir el
Finalidad latiguillo Minimess al acoplador.
La finalidad de la recogida de muestras de Tenga cuidado al conectar el latiguillo
aceite es comprobar su estado.Si se llevan a Minimess, ya que el chorro de aceite es
cabo análisis periódicos del aceite, se pueden peligroso. No lo dirija nunca hacia una persona
detectar los productos de desgaste y tomar las u objeto delicado.Compruebe la presión de la
medidas oportunas antes de que se produzca conexión antes de conectarla.
una avería. El análisis del aceite le ayuda a
establecer cuándo es necesario cambiarlo, le
Como efectuar
indica las deficiencias en el mantenimiento y
reduce al mínimo los gastos en reparaciones. Toma de muestras
Además, le brinda la oportunidad de programar Las muestras se han de tomar del acoplador
los reajustes o revisiones, los trabajos de Minimess situado en la parte de presión de
mantenimiento o reparaciones, y de este modo carga del motor en el circuito cerradoNo las
le permite ahorrar dinero y evitar períodos de tome nunca del depósito utilizando las válvulas
inactividad. esféricas.
Limpie con cuidado el acoplador y el
latiguillo.
31
Mantenimiento Manual de instalacíon y mantenimiento, Compact CB
Conecte el latiguillo Minimess al acoplador y Llene únicamente 3⁄4 de la botella, ya que su

controle la dirección del chorro de aceite. contenido se agita en el laboratorio durante
Deje caer como mínimo 2 litros (0,6 gallones el análisis para obtener una mezcla fluida.Se
EE.UU) de aceite en un cubo antes de llenar necesitan como mínimo 200 ml para poder
la botella. realizar un análisis satisfactorio..
Quite el tapón en el último momento y procure Una vez llenada la botella, coloque el tapón
que ninguna sustancia contaminante entre en rápidamente para evitar que el aire entre y
contacto con el tapón, la botella o el latiguillo contamine el contenido, lo que podría dar lugar
Minimess cuando tome la muestra. a un error en el resultado del análisis.
En zonas con aire contaminado, utilice una
lámina de plástico suave (ésta es la protección
Mediciones Internas
usual entre la botella y el tapón en las botellas
Las muestras se han de tomar del acoplador
de laboratorio).
Minimess situado en la parte de presión de
No quite el plástico, coja el extremo del latiguillo
carga del motor en el circuito cerrado.Limpie
con él, introdúzcalo en la botella y llénela.
con cuidado el acoplador y el latiguillo.
Para obtener un resultado fiable, el sistema
Conecte los latiguillos según se indica en el
debe funcionar sin que se mueva ninguna
manual del contador de partículas.
válvula y sin que el latiguillo Minimess toque
Para que la medición sea válida, las lecturas de
la botella.
contaminación deben ser estables alrededor de
10 minutos antes de su finalización.
5. LOCALIZACIÓN DE AVERÍAS
Motor hidráulico
Averiá Causa probable Acción
El motor no funciona. Parada mecánica del acciona- Compruebe la presión del sistema. Si ésta se ha
miento. elevado hasta el ajuste de la válvula limitadora de
presión, retire la carga del
accionamiento.
El motor no proporciona el par Compruebe el nivel de la presión del sistema y cor-

calculado, proque la diferencia rija el ajuste de la válvula limitadora de la presión si
de presión a través del motor es necesario.
no es suficientemente elevada,
con relación a la carga.
No llega aceite al motor o el

que llega es insuficiente. Compruebe el sistema hidráulico. Compruebe las
fugas externas del motor (la conexión D).
El motor gira en la direc- Las conexiones de entrada Conecte bien la entrada de aceite.
ción incorrecta. del aceite al motor están mal
conectadas.
El motor gira Fluctuaciones de la presión o Busque la causa en el sistema o en la unidad
irregularmente. del caudal del sistema hidráu- motriz.
lico.
Ruido en el motor. El motor funciona con una pre- Ajuste la presión de carga al nivel correcto. Con-
sión de carga demasiado baja. sulte 2.1 "Presión de carga recomendada".
Fallos internas en el motor. Comprobar el drenaje si es necesario. Ponga un

tapón magnético y observe el material que se
adhiere al imán. Las partículas de acero indican
daños. Observe que puede depositarse material
procendente de las piezas de fundición, el cual no
indica que exista daño interno en el motor.
Fugas externas de axeite El retén de labio radial está Cambie el retén de labio radial.
en el motor. desgastado.
32
Manual de instalacíon y mantenimiento, Compact CB Declaración de conformidad
DECLARACIÓN DE CONFORMIDAD
Ejemplo de declaración de conformidad de Hägglunds Drives AB
178 5040-601 CB 280 XXXX 02166
La presente DECLARACIÓN DE CONFORMIDAD está disponible previa solicitud para las

entregas en Hägglunds Drives AB. También hay traducciones en otros idiomas.
33
SPIDER CONTOL SYSTEM
Manual para usuarios
SPIDER 2
Publicación del programa v 4.0

Versión de software 4.1.2
AS
Spider Prólogo
Manual de ingeniería 04-04-02, Nuevo
Prólogo
Hägglunds es uno de los principales fabricantes de sistemas de control hidráulico de gran
tamaño del mundo. Ocupa una posición de liderazgo gracias a su inigualable espíritu de servicio
y al permanente desarrollo de productos y mercados en todo el mundo. Nuestros sistemas de
control se encuentran en la mayoría de los segmentos de la industria y la marina, donde las
demandas de eficiencia y confiabilidad son extremadamente altas. Nuestra oficina principal y
nuestra planta de producción se encuentran en Mellansel, Suecia, y tenemos nuestras propias
oficinas de ventas y representación en 40 países distintos.
Este manual de ingeniería proporciona información necesaria para operar el sistema de control
Spider. Para encontrar algún tipo de información en particular, simplemente busque la sección
deseada como figura en el índice. Sin embargo, es posible que haya cambios en los equipos.
Por consiguiente, nos reservamos el derecho de introducir modificaciones en el manual según
consideremos necesario sin aviso previo ni obligación alguna.
Símbolos de advertencia
En este manual encontrará los siguientes símbolos que indican un posible peligro que puede
provocar o provocará lesiones personales o daños materiales significativos. Dependiendo de la
probabilidad de peligro, y de la gravedad que puede tener la lesión personal o daño material, los
símbolos se clasifican en tres niveles.
PELIGRO Se usa para indicar la presencia de un peligro

que provocará lesiones personales graves, muerte o
PELIGRO daños materiales significativos si se ignora esta advertencia.
ADVERTENCIA Se usa para indicar la presencia de un peligro

que puede provocar lesiones personales graves, muerte o
daños materiales significativos si se ignora esta advertencia.
ADVERTENCIA
PRECAUCIÓN Se usa para indicar la presencia de un peligro

que provocará o puede provocar lesiones personales o daños
materiales leves si se ignora esta advertencia.
PRECAUCIÓN
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(1)
AS-1
Spider Introducción
Manual de ingeniería 04-04-02
1.1 Descripción
La unidad Spider es un sistema basado en un microcontrolador, configurable para ajustarse a
diferentes necesidades de aplicación. Está diseñado para adaptarse a la unidad de potencia de
dos o de tres puertas, e incluso a una unidad de una puerta adicional. El sistema de control
puede controlar bombas con doble bobina (Denison 9A, Brueninghaus EP, Sauer Sundstrand
KA o bombas similares) o con bobina simple en una dirección (Denison 5A).
La unidad puede estar montada adentro de la unidad de potencia, en la puerta de la unidad de

potencia, en la parte exterior de la unidad de potencia o puede entregarse por separado con
soportes de pared o bridas para paneles, para que el cliente realice el cableado
correspondiente. En forma opcional, se pueden suministrar los juegos de cables.
La configuración de las funciones preprogramadas del sistema se lleva a cabo usando el panel
delantero, con ayuda de las indicaciones que aparecen en la pantalla o mediante una conexión
en serie con una computadora portátil. Se puede proteger el modo de configuración con una
contraseña.
La unidad Spider puede controlar el sistema con diferentes opciones de configuraciones de

motores eléctricos/bombas.
• De una a cuatro bombas para un sistema de control:
• De dos a cuatro bombas para dos sistemas de control con función independiente:
EM EM
P P
P P
EM EM
P P
EM EM EM
P P P
-------
AS1, Introducción, Manual de ingeniería 04-04-02
• De dos a cuatro bombas para dos sistemas de control con función común. Si uno se para por
una falla, el otro también se para:
EM EM EM
P P
P P
EM EM EM
P P
EM EM EM
P P P
La función Monitor (Monitoreo) puede monitorear el estado de los interruptores de la unidad de

potencia y proporcionar información sobre advertencias o alarmas en la pantalla de texto. Una
alarma hará que el motor o los motores eléctricos paren si la salida del enclavamiento digital
está conectada mediante un relé al circuito del enclavamiento del arrancador. Se pueden
controlar hasta 4 bombas en paralelo para un mismo sistema de control.
La función Basic (Básica) tiene funciones adicionales de limitación de potencia y realimentación

de velocidad en bucle cerrado a través de un regulador PID. Hay entradas disponibles para
codificadores de velocidad analógicos o digitales.
La unidad también puede monitorear señales analógicas en la pantalla, tales como velocidad,
corriente de motores E, presión, etc.
La función Shredder (Triturador) tiene las mismas características que la función Basic (Básica) y
además cuenta con funciones adicionales de reversa a causa de un sistema de control parado
por sobrecarga. Es posible maximizar la cantidad de reversas dentro de un límite de tiempo y
parar el sistema de control cuando está excedido. El sistema de control puede configurarse para
cambiar de dirección, después de un intervalo de tiempo ajustable.
La función Friction (Fricción) tiene las mismas características que la función Basic (Básica) y
funciones adicionales para controlar dos sistemas de control hidráulicos accionados
conjuntamente, con una relación entre los motores.
La función subordinada Friction (Fricción) tiene las mismas características que la función Basic
(Básica) y funciones adicionales para controlar dos sistemas de control hidráulicos accionados
conjuntamente, con una relación respecto del valor de consigna maestro.
La función Synchro (Sincronizar) tiene las mismas características que la función Basic (Básica)
y funciones adicionales para controlar la posición entre dos sistemas de control hidráulicos. Se
puede establecer el ángulo entre los cilindros mediante una señal externa. También es posible
el control en función de una relación. Este modo requiere codificadores de velocidad digitales.
Se agrega la salida de la función de control de presión al comando de flujo de rampa. La función

compara la presión real con una presión de consigna y proporciona una salida positiva o
negativa en función del signo de la diferencia y la dirección de acción de la regulación.
El frente de la unidad Spider tiene botones pulsadores para arrancar y parar el sistema de
control, para configurar el modo local/remoto, para configurar el valor de consigna de velocidad
mediante los botones de aumento y reducción en el modo local, para configurar la reversa por
retrocesos sucesivos, para configurar el sistema de control regulado/no regulado y el sistema de
control automático/manual en el modo Shredder (Triturador). Estas funciones que se activan
mediante los botones pulsadores se pueden puentear en la configuración de las funciones del
sistema.
Todas las entradas y salidas son configurables y pueden conectarse con funciones
preprogramadas en la configuración del sistema. Todas las señales están cableadas en forma
estándar a los terminales de contacto o a través del puerto fieldbus (opcional).
Las entradas digitales pueden configurarse para funciones como arrancar/parar, reversa,
reiniciar, monitoreo de la unidad de potencia y monitor auxiliar, donde es posible configurar la
función y exhibir el texto del monitor.
Las salidas digitales pueden configurarse para funciones como alarmas/advertencias comunes,
listo para usar, sistema de control arrancado, triturador bloqueado, control del enfriador y del
calefactor. Las salidas son del tipo contacto seco de relé.
Las entradas analógicas pueden configurarse para funciones como temperatura del tanque,
velocidad, presión, potencia para monitoreo y control. También pueden configurarse para bucle
de corriente o voltaje.
Las salidas analógicas pueden configurarse para monitorear la velocidad, la presión y
temperatura. También pueden configurarse para bucle de corriente o voltaje.
El sistema incluye una función de monitoreo del sistema de control con contadores de tiempo
del sistema de control, lista de alarmas/advertencias y 8 canales de registro escalables, con
descarga de datos a través de una interfaz en serie. Como opción, se puede agregar un sistema
de monitoreo remoto para el sistema de control con acceso a través de GSM.
1.5 Código para órdenes
AS-2
Spider Datos técnicos
2.1 Sistema mecánico

2.1.1 Datos mecánicos
Dimensiones del cubículo A = 400 mm H = 300 mm P = 145 mm

Clase de encapsulado IP 65
Temperatura ambiente -20..+70°C *
Material del gabinete Acero inoxidable
Material del frente Película de poliéster
Montaje Soportes de pared o brida
Peso 8 kg
(10 kg con soportes o brida)
Tamaño del cable Máx 2.5mm²
* Calefactor provisto en forma opcional
2.1.2 Montaje con soportes de pared
AS2, Datos técnicos, Manual de ingeniería 04-04-02
2.1.3 Montaje con brida
2.1.4 Frente de poliéster

Resistencia química a:
- Alcoholes
- Ácidos diluidos
- Álcalis diluidos
- Ésteres
- Hidrocarburos
- Cetonas
- Agentes de limpieza domésticos
AS2, Datos técnicos, Manual de ingeniería 04-04-02
2.2 Voltaje de alimentación y de salida

2.2.1 Voltaje de alimentación
Voltaje de alimentación principal Autoajustable 90-132, 180-264 VCA

47-63Hz (No necesita configuración)
Consumo de energía 175VA (unidad de alimentación de
150W 376 0071-802 )
300VA (unidad de alimentación de
250W 376 0071-801)
(+50VA con calefactor)*
Corriente de irrupción Máx. 30A
Fusible principal 6A
Alimentación de tarjeta 24VCC±10% , Máx. 8A
Consumo de tarjeta (sin carga) 320mA
* Calefactor provisto en forma opcional
2.2.2 Voltaje de salida
Voltaje de referencia analógica +10VCC 35mA

(aislado) -10VCC 35mA
Alimentación de entrada digital 1 +24VCC 0.3A
Alimentación de entrada digital 2 +24VCC 0.3A
Alimentación de codificador digital +24VCC 0.3A
Alimentación de codificador digital +12VCC 0.1A
Alimentación de entrada analógica +24VCC 0.3A
Alimentación de parada de emergencia +24VCC 0.3A
Alimentación de salida digital +24VCC 0.8A
Alimentación del enclavamiento del +24VCC 0.3A
motor E
2.3 Entradas
2.3.1 Entradas analógicas
N° Descripción Tipo Impedancia

1 Valor de consigna de velocidad, ±0-5VCC 100kΩ
Sistema de control 1 ±0-10VCC 100kΩ
o valor de consigna de fricción, ±4-20mA 250Ω
Sistema de control 1 ±0-20mA 250Ω
(aislado)
1 Valor de consigna de velocidad, ±0-5VCC 100kΩ
Sistema de control 2 ±0-10VCC 100kΩ
o valor de consigna de fricción, ±4-20mA 250Ω
Sistema de control 2 ±0-20mA 250Ω
(aislado)
2 Entradas analógicas configurables +0-5VCC 100kΩ
(aisladas) +0-10VCC 100kΩ
+4-20mA 250Ω
+0-20mA 250Ω
7 Entradas analógicas configurables +0-5VCC 100kΩ
(diferenciales) +0-10VCC 100kΩ
+4-20mA 250Ω
+0-20mA 250Ω
1 Entrada de temp. del tanque, - PT100
29...+107ºC
AS2, Datos técnicos, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
2.3.2 Entradas digitales
N° Descripción Tipo Impedancia Entrada

máx.
1 Realimentación de velocidad lógica 0=0-3,9VCC
digital, Sistema de control 1 lógica 1=6,6-32VCC
Diferencial o simple con señal de
dirección
1 Entrada posición cero, Sistema de lógica 0=0-3,9VCC
control 1 lógica 1=6,6-32VCC
1 Realimentación de velocidad lógica 0=0-3,9VCC
digital, Sistema de control 2 lógica 1=6,6-32VCC
Diferencial o simple con señal de
dirección
1 Entrada posición cero, Sistema de lógica 0=0-3,9VCC
control 2 lógica 1=6,6-32VCC
1 Motor eléctrico 1 arrancado lógica 0=0-3,9VCC 1kΩ
desde el arrancador lógica 1=6,6-32VCC
43 Entradas configurables lógica 0=0-3,9VCC 3kΩ
lógica 1=6,6-32VCC
1 Entrada de parada de emergencia lógica 0=0-4,7VCC 3kΩ
lógica 1=8,0-32VCC
2.4 Salidas
2.4.1 Control de la bomba
N° Descripción Tipo Impedancia Salida máx.

4 Salida del pistón, doble bobina PWM (Modulada en 5-100Ω** 2A*
Anchura de Impulsos)
*Corriente total para todas las salidas 5A
**Salida máx. reducida por encima de 10Ω a 20/Impedancia (A)
2.4.2 Salidas digitales
N° Descripción Tipo Carga máx.

1 Enclavamiento del arrancador, Contacto de relé 3A, 30VCC, 250VCA
motor E 1
motor E 2
motor E 3
13 Salidas configurables Contacto de relé 3A, 30VCC, 250VCA
2.4.3 Salidas analógicas
N° Descripción Tipo Carga máx.

4 Salidas analógicas configurables +0-10VCC 1kΩ
(aisladas, requieren alimentación +2-10VCC 1kΩ
externa, mín. 21,0VCC) +0-20mA 500Ω
+4-20mA 500Ω
AS2, Datos técnicos, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
2.5 Comunicación
2.5.1 Conexión a PC
N° Descripción Tipo Conexión a PC

1 Conexión RS-232 para Sub-D macho de 9 Cable módem nulo
configuración y descarga de polos
registro del sistema de control
2.5.2 Conexión de fieldbus
N° Descripción Tipo Conexión

1 Conexión para módulo fieldbus Profibus
(módulo opcional) Modbus
AS-3
Spider Conexión
Manual de ingeniería
04-04-02
3.1 Cableado
Se prefieren cables blindados para la instalación.
El cableado debe tener como mínimo 0,5mm2 para las señales de entrada y como mínimo 1mm2 para los
cables de alimentación y salida.
La distancia máx. entre el sistema de control y la unidad de potencia es de 50m.
3.2 Alimentación
AS-3 Conexión, Manual de ingeniería 04-04-02
3.3 Señales de entrada

3.3.1. Valor de consigna de velocidad remoto.
La entrada para el valor de consigna de velocidad remoto está aislada y puede ser
bidireccional (valor de consigna de velocidad de avance y de reversa) o unidireccional (valor
de consigna de velocidad de avance y velocidad de reversa fija si es necesario). El valor de
consigna puede ser una señal de voltaje o corriente. La selección se realiza con un puente en
el tablero (vea también AS4.3) y en el menú de configuración (vea AS5.2.6).
3.3.2.1 Entradas analógicas aisladas configurables.

La señal para las entradas analógicas configurables debe ser positiva. La entrada puede ser
una señal de voltaje o corriente. La selección se realiza con un puente en el tablero (vea
también AS4.3) y en el menú de configuración (vea AS5.2.6).
3.3.2.2 Entradas analógicas configurables.

La señal para las entradas analógicas configurables debe ser positiva. La entrada puede ser
una señal de voltaje o corriente. La selección se realiza con un puente en el tablero (vea
también AS4.5.2) y en el menú de configuración (vea AS5.2.6).
3.3.2.3 Entrada analógica de temperatura del tanque.

La temperatura del tanque puede medirse con un sensor PT100.
3.3.3. Codificador digital de velocidad.

Si se utiliza un codificador diferencial y el impulso de la entrada 2 llega antes que el impulso
de la entrada 1, la señal de Rpm será positiva.
Si se usa un codificador de impulso único, un nivel bajo en la señal de dirección hará que la
señal de Rpm tenga signo positivo. Si la señal tiene el signo incorrecto, se puede cambiar la
polaridad con el parámetro P1I06 para el sistema de control 1 y el parámetro P2I06 para el
sistema de control 2.
3.3.4. Entradas del motor eléctrico arrancado.

Las entradas deben estar altas (interruptor cerrado) cuando el motor está parado y abiertas
en el momento del arranque.
Las entradas se utilizan para puentear la alarma de presión de cebado y retardar el arranque
del sistema de control.
3.3.5. Entrada de parada de emergencia.

La entrada de parada de emergencia debe estar conectada para que el sistema funcione. Si
la entrada está abierta, la salida a las bombas quedará configurada en cero sin rampa, para
descomprimir las bombas lo antes posible. Los contactos del enclavamiento de los motores
eléctricos se abrirán después un retardo de tiempo establecido con el parámetro DMD 0x y
con un interruptor rotativo en el extremo superior izquierdo del tablero principal (vea AS4.5.4).
3.3.6. Entradas digitales configurables.

Las funciones de las entradas se configuran en el menú de configuración (vea AS5.2.3).
Todas las entradas son configurables, pero las primeras 24 entradas son la primera opción
seleccionada para monitorear los interruptores de la unidad de potencia.
3.4 Señales de salida

3.4.1. Pistones de las bombas.
Se pueden usar bombas con bobinas separadas para los lados A y B. Si se usan bombas con
una bobina en común para ambas direcciones, el sistema de control sólo podrá ser controlado
en una dirección.
3.4.2. Salidas del enclavamiento del arrancador.

El contacto normalmente abierto del relé auxiliar debe estar conectado en el circuito de
parada para los motores eléctricos. La salida se abrirá al sonar la alarma.
¡Atención! Observe la polaridad del diodo de marcha libre sobre la bobina del relé. La función
del diodo es brindar protección contra el voltaje inducido cuando se apaga el interruptor, y
debe montarse cerca de la bobina del relé.
3.4.3. Salidas digitales configurables.

Las funciones de las salidas se configuran en el menú de configuración (vea AS5.2.4).
¡Atención! Todas las salidas deben estar protegidas contra el voltaje inducido al apagar el
interruptor mediante, por ejemplo, un diodo de marcha libre (vea 3.4.2), un varistor, un circuito
RC u otro dispositivo de protección contra sobretensiones montado cerca de la carga.
3.4.4. Salidas analógicas configurables.

Las salidas están aisladas y requieren alimentación externa. Si no se requiere aislamiento, la
tarjeta puede ser alimentada desde los terminales del Spider. Las funciones de las salidas se
configuran en el menú de configuración (vea AS5.2.7).
3.5 Terminal de interconexión

Para conexión interna.
AS-3 Conexión, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
3.6 Puerto serie

3.6.1. Puerto de SpiderCom.
Conector para comunicación serie RS232. El puerto se utiliza para volcar los datos de registro y
para configurar el sistema a través de una PC y del software de SpiderCom.
Pin1 CD, Detección de portadora

Pin2 RXD, Recepción de datos
Pin3 TXD, Transmisión de datos
Pin4 DTR, Terminal de datos lista
Pin5 GND, Conexión a tierra del sistema
Pin6 DSR, Conjunto de datos listo
Pin7 RTS, Solicitud de envío
Pin8 CTS, Libre para envío
Pin9 RI, Indicador de llamada
3.6.2. Conexión opcional para fieldbus.

Conexión a Profibus para control externo en serie.
Alojamiento Blindaje
Pin1 No conectado
Pin2 No conectado
Pin3 Línea B, TXD/RXD pos
Pin4 RTS, Solicitud de envío
Pin5 Conexión a tierra BUS
Pin6 BUS +5V
Pin7 No conectado
Pin8 Línea A, TXD/RXD neg
Pin9 No conectado
En aplicaciones normales se utilizan Línea A, Línea B y blindaje.
AS-3 Conexión, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
Conexión Modbus para control externo en serie
Alojamiento Blindaje
Pin1 No conectado
Pin2 No se usa
Pin3 No se usa
Pin4 No conectado
Pin5 GND
Pin6 +5V
Pin7 Línea B RS485
Pin8 Línea A RS485
Pin9 No conectado
En aplicaciones normales se utilizan Línea A, Línea B y blindaje.
3.7 Funciones de los terminales

Tabla de funciones de los terminales.
Fila Tipo Nombre N° Función

1 Entrada de potencia DC1 4 24V_IN (+)
3 24V_IN (+)
2 GND (-)
1 GND (-)
Bomba 4 PO4 4 Bomba común 4
3 Con. del pistón Bomba 4. B alta
2 Bomba común 4
1 Con. del pistón Bomba 4. A alta
2 Bomba común 3
2 Bomba común 2
2 Bomba común 1
2 Salidas digitales DO1 14 Salida digital configurable 6

13 Salida digital configurable 6
2 24V_DO
1 GND

3 Salidas digitales DO2 14 Salida digital configurable 13
11 Salida digital común 11-13
2 24V_DO
1 GND
4 Enclavamientos del EO1 8 Enclavamiento del motor eléctrico 3

motor E
7 Enclavamiento del motor eléctrico 3
2 24V_DO
1 GND
5 Entradas del motor E EI 8 Motor E 3 arrancado

arrancado
7 Motor E 2 arrancado
6 Motor E 1 arrancado
5 24V_EI
4 24V_EI
3 GND
Parada de EM 2 Parada de emergencia
emergencia
1 24V_EM
6 Codificador digital DE1 8 Impulso 0 Sistema de control 1+

de velocidad del
sistema de control 1 7 Impulso 2 Sistema de control 1 -
6 Impulso 2 Sistema de control 1+
5 Impulso 1 Sistema de control 1 -
3 12V+
2 24V_DE
1 GND
7 Codificador digital DE2 8 Impulso 0 Sistema de control 2+

de velocidad del
sistema de control 2 7 Impulso 2 Sistema de control 2 -
5 Impulso 1 Sistema de control 2 -
3 12V+
2 24V_DE
1 GND

8 Entradas digitales DI1 8 Entrada config. 6 (Filtro de drenaje)
configurables 7 Entrada config. 5 (Nivel de aceite bajo en tanque)
Entradas de monitoreo 6 Entrada config. 4 (Nivel mín. de aceite en tanque)
predefinidas Entrada config. 3 (Temperatura mín. de aceite en
5 tanque)
Entrada config. 2 (Temperatura alta de aceite en
4 tanque)
Entrada config. 1 (Temperatura máx. de aceite en
3 tanque)
2 24V_DI_1
1 GND
9 Entradas digitales DI2 12 Entrada config. 15

configurables 11 Entrada config. 14 (Presión de trabajo, bomba 2)
Entradas de monitoreo 10 Entrada config. 13 (Presión de cebado, bomba 2)
predefinidas 9 Entrada config. 12 (Línea de succión, bomba 2)
8 Entrada config. 11 (Filtro de retorno 100%, bomba 2)
7 Entrada config. 10 (Presión de trabajo, bomba 1)
6 Entrada config. 9 (Presión de cebado, bomba 1)
5 Entrada config. 8 (Línea de succión, bomba 1)
3 24V_DI_1
2 24V_DI_1
1 GND

configurables 11 Entrada config. 23 (Presión de trabajo, bomba 4)
Entradas de monitoreo 10 Entrada config. 22 (Presión de cebado, bomba 4)
predefinidas 9 Entrada config. 21 (Línea de succión, bomba 4)
7 Entrada config. 19 (Presión de trabajo, bomba 3)
6 Entrada config. 18 (Presión de cebado, bomba 3)
5 Entrada config. 17 (Línea de succión, bomba 3)
3 24V_DI_1
2 24V_DI_1
1 GND

configurables 11 Entrada config. 32
10 Entrada config. 31
3 24V_DI_2
2 24V_DI_2
1 GND

configurables 11 Entrada config. 42
2 24V_DI_2
1 GND
13 Entradas analógicas AI1 12 Entrada config. 2 -

aisladas 11 Entrada config. 2+
10 Entrada config. 1 -
9 Entrada config. 1+
Valor de consigna de velocidad remoto Sistema de
8 control 2 -
7 control 2 +
6 control 1 -
5 control 1 +
4 10VREF - aislada
3 10VREF+ aislada
2 GND aislada
1 GND aislada
14 Entradas analógicas AI2 12 Entrada config. 6 -

no aisladas 11 Entrada config. 6+
4 24V_AI
3 24V_AI
2 GND
1 GND

15 Entradas analógicas AI3 14 Temp. del tanque, fuerza alta
no aisladas 13 Temp. del tanque, detección alta
12 Temp. del tanque, detección baja
11 Temp. del tanque, fuerza baja
4 24V_AI
3 24V_AI
2 GND
1 GND
16 Salidas analógicas AO2 6 Salida de corriente 4

5 Salida de voltaje 4
4 Salida de corriente 3
2 24VCC (alimentación externa)
1 GND (externa)
AO1 6 Salida de corriente 2
4 Salida de corriente 1
2 24VCC (alimentación externa)
1 GND (externa)
17 CAN1 CA 8 DATA2-
7 NC
6 DATA2+
5 0VCAN2
CAN2 4 DATA1-
3 NC
2 DATA1+
1 0VCAN1
Terminales extra IC 6 Para interconexión
5 Para interconexión
AS-4
Spider Indicación y configuración
4.1 Información de la pantalla
AS4, Indicación y configuración, Manual de ingeniería 04-04-02
4.2 Información sobre el sistema de control normal y las alarmas
4.3 Reinicio de alarmas y advertencias
4.4 Botones del panel delantero

4.4.1 Botones de configuración
4.4.2 Botones del sistema de control
05-01-21 reemplaza 04-04-02
4.5 Puentes e indicaciones de la tarjeta principal

4.5.1 Revisión A
4.5.2 Puentes
Función Nombre del Configuraciones

puente
Tipo de señal para el valor de SP D1 Posición superior = señal de voltaje
consigna de velocidad, Sistema de Posición inferior = señal de corriente
control 1
Tipo de señal para el valor de SP D2 Posición superior = señal de voltaje
consigna de velocidad, Sistema de Posición inferior = señal de corriente
control 2
Tipo de señal para entrada AI1 Posición superior = señal de voltaje
analógica configurable 1 Posición inferior = señal de corriente
Tipo de señal para entrada AI 6 Posición superior = señal de voltaje
4.5.3 Indicadores
Función Nombre del Nota

indicador
Cierre D1, rojo Normalmente apagado. Se activará por un
(W-DOG) error del control del microprocesador.
Alimentación de salida digital D170, verde Normalmente encendido. Indica alimentación
(DO) hacia salidas digitales. Se apagará por un
cortocircuito externo o por una parada de
emergencia.
Alimentación de parada de D171, verde Normalmente encendido. Se apagará por un
emergencia (EM) cortocircuito externo.
Alimentación de entrada de D172, verde Normalmente encendido. Se apagará por un
motor E (EI) cortocircuito externo.
Alimentación del codificador D173, verde Normalmente encendido. Se apagará por un
de 24 V (DE) cortocircuito externo.
Alimentación de entrada digital 1 D174, verde Normalmente encendido. Se apagará por un
(DI1) cortocircuito externo.
Alimentación de entrada digital 2 D175, verde Normalmente encendido. Se apagará por un
(DI2) cortocircuito externo.
Alimentación de entrada D176, verde Normalmente encendido. Se apagará por un
analógica (AI) cortocircuito externo.
Alimentación del codificador D181, verde Normalmente encendido. Se apagará por un
de 12 V (DE 12 V) cortocircuito externo.
Más de 10 V de voltaje de ref. D116, verde Normalmente encendido. Se apagará por un
para el potenciómetro (+10 V) cortocircuito externo.
Menos de 10 V de voltaje de ref. D117, verde Normalmente encendido. Se apagará por un
para el potenciómetro (-10 V) cortocircuito externo.
AS4, Indicación y configuración, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
4.5.4 Interruptores
Función Nombre Nota

de Pot.
Cierre de parada de emergencia SW1 Temporizador para respaldo de cierre
de parada de emergencia
Tipo de pantalla SW3-1 On= Tipo de pantalla de cristal líquido

(LCD) (estándar)
Off= Tipo de pantalla fluorescente de
vacío (VFD)
SW3-2 Sin función
4.5.5 Contactos
Función Nombre Nota

de
contacto
Pantalla P24
Teclado delantero P22
Tarjeta de memoria P23
Conexión para Spidercom P26 RS232
Puerto de programación de P27 Conexión JTAG
memoria
Puerto de programación de CPLD P28 Conexión JTAG
Conexión de tarjeta fieldbus J1 Tarjeta opcional
Alimentación de CC DC1
Salida de bomba 1 PO1 Contacto de 4 polos
Salida digital 1 DO1 Contacto de 14 polos
Salida digital 2 DO2 Contacto de 12 polos
Salida de motor eléctrico EO1 Contacto de 8 polos
Entrada de motor eléctrico EI/EM Contacto de 8 polos
Entrada de parada de
emergencia
Codificador digital 1 DE1 Contacto de 8 polos
Codificador digital 2 DE2 Contacto de 8 polos
Entrada digital 1 DI1 Contacto de 8 polos
Entrada analógica 1 AI1 Contacto de 12 polos
Salida analógica 1 AO1 Contacto de 6 polos
Salida analógica 2 AO2 Contacto de 6 polos
Conexión interna IC Contacto de 6 polos
CAN bus 1 CA1 Contacto de 6 polos
CAN bus 2 CA2 Contacto de 6 polos
-4.6 Alimentación de energía
04-04-02
4.7 Tarjeta fieldbus

4.7.1 Profibus
4.7.1.1 Indicadores
Nombre Descripción Función Información
del
indicador
D1 No se usa No se usa Función normal
D2 En línea Verde El módulo está En línea y listo, el

intercambio de datos es posible.
Apagado El módulo no está En línea.
D3 Fuera de línea Rojo El módulo está Fuera de línea.
Apagado El módulo no está Fuera de línea.

D4 Diagnóstico Rojo parpadeando 1 Hz Error de configuración. Longitud de
los datos.
Rojo parpadeando 2 Hz
Error de configuración. Parámetros
del usuario.
Rojo parpadeando 4 Hz
Error de inicialización del ASIC de
comunicación del Profibus.
Apagado
Sin error.
D5 Control Verde parpadeando 1 Hz Inicializado y funcionando bien.
Verde parpadeando 2 Hz No inicializado.
Rojo Error interno no especificado o

funcionando en modo bootloader.
Rojo parpadeando 1 Hz Falla de RAM.
Rojo parpadeando 2 Hz Falla de ASIC o FLASH.
Rojo parpadeando 4 Hz Falla de DPRAM.
04-04-02
4.7.1.2 Interruptores
Nombre Función Información
del
indicador
S1 Interruptor de On= Activado (si es primero o último en una red)
terminación Off= Desactivado
S2 Dirección de nodo x1 para la configuración de la dirección de nodo
S3 Dirección de nodo x10 para la configuración de la dirección de nodo
4.7.2 Modbus
4.7.2.1 Indicadores
Nombre del Descripción Función Información
indicador
D1 Procesando Verde parpadeando Recepción de Consulta y creación de
respuesta.
Apagado Sin consulta
D2 Error de bus Rojo Error de bus
Apagado Operación normal.
D3 Bus listo Rojo El módulo está Fuera de línea.
Apagado El módulo no está Fuera de línea.
D4 Estado de la Verde Bus listo. Operación normal.
configuració
n HW Rojo Error de tiempo límite del bus.
Apagado No se inicializó correctamente el bus.

D12 Control Verde parpadeando 1 Hz Inicializado y funcionando bien.
Verde parpadeando 2 Hz No inicializado.
Rojo Error interno no especificado o
funcionando en modo bootloader.
Rojo parpadeando 1 Hz Falla de RAM.
Rojo parpadeando 2 Hz Falla de ASIC o FLASH.
Rojo parpadeando 4 Hz Falla de DPRAM.
04-04-02
4.7.2.2 Interruptores
Nombre Función Configuración Información
del
indicador
S1 Interruptor de On Activado (si es primero o
terminación último en una red)
Off Desactivado
S2: 1-7 Dirección de nodo Valor binario:
Interruptor: 1234567
0000000 No válida
0000001 1
0000010 2
0000011 3
… …
… …
1111111 127
S2: 8 Velocidad en baudios Valor binario:
S3: 1-2 Interruptor: 812
000 No válida
001 1200
010 2400
011 4800
100 9600
101 19200 (Predeterminada)
110 38400
111 57600
S3: 1-2 Paridad Valor binario:
Interruptor: 34
00 No válida
01 Ninguna (Predeterminada)
10 Par
11 Impar
4.9 Códigos de error

4.9.1 Inicio del programa
WARNING EEPROM READING FAILED (ADVERTENCIA DE FALLA DE LECTURA DE EEPROM)
Este mensaje de error indica que el software del Spider no puede leer los valores de parámetros guardados
en la tarjeta de memoria. Este error se puede producir si: La tarjeta de memoria no está conectada, hay un
defecto en la tarjeta de memoria o está montada de forma incorrecta, o la información en la tarjeta de
memoria está corrupta. El software del Spider se iniciará con valores predeterminados en los parámetros.
WARNING WRONG EEPROM VERSION (ADVERTENCIA DE VERSIÓN DE EEPROM INCOMPATIBLE)
Este mensaje de error indica que el software del Spider no puede usar los valores de parámetros
almacenados en la tarjeta de memoria ya que el formato de los parámetros almacenados en ésta no es
compatible con el software del Spider utilizado. El software del Spider se iniciará con valores
predeterminados en los parámetros.
WARNING WRONG CPLD VERSION (ADVERTENCIA DE VERSIÓN DE CPLD INCOMPATIBLE)
Este mensaje de error indica que la versión del software del Spider utilizada no es compatible con la versión
de software en el Dispositivo de Lógica Programable Complejo (Complex Programmable Logic Device,
CPLD). El CPLD se utiliza para entradas y salidas digitales, contadores, pantalla y Anybus. El Spider
funcionará de forma impredecible.
WARNING LOG INIT ERROR (ADVERTENCIA DE ERROR DE INIC. DE REGISTRO)
Este mensaje de error indica que el software del Spider no puede leer el reloj de tiempo real, las alarmas
guardadas, las advertencias, los tiempos o valores de consigna del sistema de control en la tarjeta de
memoria. Estas funciones no funcionarán.
Este error se puede producir si: La tarjeta de memoria no está conectada, hay un defecto en la tarjeta de
memoria o está montada de forma incorrecta, o la información en la tarjeta de memoria está corrupta.
WARNING 3D-LOG INIT ERROR (ADVERTENCIA DE ERROR DE INIC. DEL REGISTRO DE 3D)
Este mensaje de error indica que el software del Spider no puede leer el registro de 3D en la tarjeta de
memoria. La función de registro de 3D no funcionará. Este error se puede producir si: La tarjeta de memoria
no está conectada, hay un defecto en la tarjeta de memoria o está montada de forma incorrecta, o la
información en la tarjeta de memoria está corrupta.
4.9.2 Monitoreo del hardware

HW ERROR, FC 1 (ERROR DE HW, FC 1)
Esta prueba tiene como objetivo verificar que el retardo del enclavamiento del motor eléctrico configurado
en el hardware con SW1 coincida con el retardo configurado en los parámetros del Spider (para
enclavamientos de motores eléctricos). Si la parada de emergencia es accionada, los relés del hardware se
abrirán después del tiempo configurado: 2-32 s (en pasos de 2 s). Si el resultado de esta prueba no se
encuentra dentro de los límites establecidos más adelante, aparecerá el mensaje de error ”HW ERROR, FC
1” (ERROR DE HW, FC 1).
La prueba se realiza al iniciar el sistema.
Retardo de HW < retardo de SW Se para el software
Retardo de HW > Sólo advertencia, presione un botón para ACEPTAR.

retardo de SW + 4s
Retardo de HW > Se para el software
retardo de SW + 5s
Cuando el software se para aparecen en la pantalla los tiempos de Hardware(M) y de Software(S) en 1/10 s,
a fin de verificar o corregir los tiempos.
Esta prueba tiene como objetivo verificar que se abra el relé que alimenta las salidas de PWM. Si se acciona
la parada de emergencia, el hardware del Spider para parada de emergencia abre este relé. Esta prueba se
realiza cuando todos los motores eléctricos están parados. Si el relé no se abre durante esta prueba,
aparece el mensaje de error ”HW ERROR, FC 2” (ERROR DE HW, FC 2) y el software se para.
Esta prueba tiene como objetivo verificar que se abran los relés del enclavamiento de los motores eléctricos.
Cuando el enclavamiento del motor eléctrico está OK el relé se cierra, y se abre cuando el enclavamiento no
está OK. Si el relé no se abre, aparece el mensaje de error ”HW ERROR, FC 3” (ERROR DE HW, FC 3) y el
software se para. Esta prueba se realiza con la unidad encendida y una sola vez, cuando todos los motores
eléctricos están parados.

La indicación de Control no debe estar activada durante la ejecución normal del programa. Si esto sucede
durante la ejecución normal del programa, aparece el mensaje de error ”HW ERROR, FC 4” (ERROR DE
HW, FC 4) y el software se para. Esta prueba se realiza de forma continua.
Si la corriente medida es 50% mayor que la corriente máx. configurada, se supone que hubo un cortocircuito
y aparece el mensaje de error ”HW ERROR, FC 5” (ERROR DE HW, FC 5) y el software se para. Esta
prueba se realiza de forma continua.
4.9.3 Monitoreo del software

WATCHDOG TIMEOUT (TIEMPO LÍMITE DEL CONTROL)
Si el software se detiene o se ejecuta de forma incorrecta, haciendo que el bucle de control o el bucle de la
interfaz del usuario no se ejecuten dentro de los límites de tiempo establecidos, aparece el mensaje de error
”WATCHDOG TIMEOUT” (TIEMPO LÍMITE DEL CONTROL) y el software se para. También aparece la
dirección del programa donde se paró la ejecución.
4.9.4 Bus
BUS FAIL (FALLA DEL BUS)
La función Anybus está seleccionada, pero no funciona la comunicación. Este error probablemente se
producirá si el cable del bus no está conectado.
BUS HW FAIL (FALLA DEL HW DEL BUS)

La función Anybus está seleccionada, pero el hardware no funciona. Este error probablemente se producirá
si falta el módulo del bus o si está defectuoso.
AS-5
Spider Parámetros V4.1.x
5.1 Árbol de parámetros

Generalidades de los parámetros configurables.
AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
5.2 Parámetros configurables

5.2.1 Configuraciones principales
Interruptor Descripción Tipo Predeterminado Min Max

BASIC = Monitor and Basic BASIC BASIC
function SHREDDER
SHREDDER = Shredder function SYNCHRO
SYNCHRO = Synchro and
Friction function

E-motor 2
E-motor 3
OFF
E-motor 2
E-motor 3 OFF
OFF
E-motor 2
E-motor 3 OFF
OFF
E-motor 2
E-motor 3 OFF
OFF
Drive 2
OFF
Drive 2
OFF OFF
Drive 2
OFF OFF
Drive 2
OFF OFF
MAB09 Separate= One drive or two Separate Separate
separate drives
Common= Two drives with Common
common function

German
French
Spanish
Portuguese
Italian
Japanese
Dutch
Finnish
Swedish
Short
Chinese

*Los caracteres se cambian con los botones ∧ y ∨, y se seleccionan con el botón >.
Main settings-Reset
5.2.2 Salidas de las bombas
Pump outputs-Pump1

Pump outputs-Pump2

Pump outputs-Pump3

Pump outputs-Pump4


5.2.3 Entradas digitales
Digital Inputs
Interruptor Descripción Tipo Predeterminado

* Configuraciones posibles de las funciones de las entradas digitales:

01 H APR P1 Función de monitoreo de presión alta del lado A para bomba 1
01 H BPR P1 Función de monitoreo de presión alta del lado B para bomba 1
02 H APR D1 Función de monitoreo de presión alta del lado A para el sistema de control 1
02 H BPR D1 Función de monitoreo de presión alta del lado B para el sistema de control 1
02 H APR 12 Función de monitoreo de presión alta del lado A para los sistemas de control 1 y 2
02 H BPR 12 Función de monitoreo de presión alta del lado B para los sistemas de control 1 y 2
03 C PRA P1 Función de monitoreo de presión de cebado baja del lado A para bomba 1
03 C PRB P1 Función de monitoreo de presión de cebado baja del lado B para bomba 1
04 C PRA D1 Función de monitoreo de presión de cebado baja del lado A para el sistema de control 1
04 C PRB D1 Función de monitoreo de presión de cebado baja del lado B para el sistema de control 1
04 C PRA D2 Función de monitoreo de presión de cebado baja del lado A para el sistema de control 2
04 C PRB D2 Función de monitoreo de presión de cebado baja del lado B para el sistema de control 2
05 SUCTION1 Monitoreo de la línea de succión para la bomba 1

06 RF 75P1 Monitoreo del filtro de retorno para la bomba 1 obstruido a 3/4

06 RF 100P1 Monitoreo del filtro de retorno para la bomba 1 completamente obstruido
06 DRF 75 Monitoreo del filtro de drenaje obstruido a 3/4
06 DRF 100 Monitoreo del filtro de drenaje completamente obstruido
06 F TEMP Entradas de advertencia de enclavamiento de filtro
07 LO LEVEL Monitoreo del nivel de aceite bajo para el tanque

07 MN LEVEL Monitoreo del nivel mín. de aceite para el tanque
08 MAX TEMP Monitoreo de temperatura máx. del aceite para el tanque

08 HI TEMP Monitoreo de temperatura alta del aceite para el tanque
08 MIN TEMP Monitoreo de temperatura baja del aceite para el tanque
09 ALARM R Reinicio remoto de alarmas y advertencias

09 BUS R Reinicio de alarmas y advertencias mediante Bus
09 BUS 1 Cambiar a señales de comando de Bus, Sistema de control 1
09 BUS 2 Cambiar a señales de comando de Bus, Sistema de control 2
09 BUS M Cambiar a señal de comando de Bus, Maestro externo
10 SHR A D1 Parada de Triturador en avance, Sistema de control 1

10 SHR B D1 Parada de Triturador en reversa, Sistema de control 1
10 SHR A D2 Parada de Triturador en avance, Sistema de control 2
10 SHR B D2 Parada de Triturador en reversa, Sistema de control 2
10 SHR 1+2A Parada de Triturador en avance, Sistemas de control 1 y 2
10 SHR 1+2B Parada de Triturador en avance, Sistemas de control 1 y 2
10 INTERV1 Control de intervalo de Triturador, Sistema de control 1
10 INTERV2 Control de intervalo de Triturador, Sistema de control 2
10 SH RES 1 Reinicio externo de la función Triturador bloqueada, Sistema de control 1
10 SH RES 2 Reinicio externo de la función Triturador bloqueada, Sistema de control 2
10 SH RES12 Reinicio externo de la función Triturador bloqueada, Sistemas de control 1 y 2
11 PL1 Activar la limitación de potencia para el Sistema de control 1

11 PL2 Activar la limitación de potencia para el Sistema de control 2
12 RES EN 1 Activación externa del reinicio del contador en modo Sincronizar, Sistema de control 1
12 RES EN2 Activación externa del reinicio del contador en modo Sincronizar, Sistema de control 2
12 FRICTION Sistema de control de fricción en modo contador de sincronización
12 INV M Inversión de comando de velocidad maestro en modo Sincronizar, Sistema de control 1
13 AUX 1 Conectado a la entrada auxiliar de monitoreo 1

14 START 1 Arranque del sistema de control en modo Remoto, Sistema de control 1

14 START 2 Arranque del sistema de control en modo Remoto, Sistema de control 2
14 START 12 Arranque de sistema de control en modo Remoto, Sistemas de control 1 y 2
14 L START1 Arranque del sistema de control en modo Local, Sistema de control 1 NOTA1
NOTA1
14 L STOP1 Parada del sistema de control en modo Local, Sistema de control 1
NOTA1
14 L START2 Arranque del sistema de control en modo Local, Sistema de control 2
NOTA1
14 L STOP2 Parada del sistema de control en modo Local, Sistema de control 2
15 FORW 1 Sistema de control en avance con velocidad fija, Sistema de control 1

15 REV 1 Sistema de control en reversa con velocidad fija, Sistema de control 1
15 FORW 2 Sistema de control en avance con velocidad fija, Sistema de control 2
15 REV 2 Sistema de control en reversa con velocidad fija, Sistema de control 2
15 FORW 1+2 Sistema de control en avance con velocidad fija, Sistema de control 1 y Sistema de control 2
15 REV 1+2 Sistema de control en reversa con velocidad fija, Sistema de control 1 y Sistema de control 2
15 L REV 1 Sistema de control en Reversa Local con velocidad fija, Sistema de control 1
15 L FORW 1 Sistema de control en Avance Local en modo manual, Sistema de control de Triturador 1
15 L REV 2 Sistema de control en Reversa Local con velocidad fija, Sistema de control 2
15 L FORW 2 Sistema de control en Avance Local en modo manual, Sistema de control de Triturador 2
15 INV 1 Reversa con comando invertido en comando unidireccional, Sistema de control 1
15 INV 2 Reversa con comando invertido en comando unidireccional, Sistema de control 2
16 SP UP1 Aumentar el valor de consigna en modo Local, Sistema de control 1

16 SP DN1 Reducir el valor de consigna en modo Local, Sistema de control 1
16 SP UP2 Aumentar el valor de consigna en modo Local, Sistema de control 2
16 SP DN2 Reducir el valor de consigna en modo Local, Sistema de control 2
16 SP RES1 Reinicio del valor de consigna en modo Local, Sistema de control 1
16 SP RES2 Reinicio del valor de consigna en modo Local, Sistema de control 2
16 REM 1 Entrada activada = modo remoto, Sistema de control 1 - Entrada abierta = modo local
16 REM 2 Entrada activada = modo remoto, Sistema de control 2 - Entrada abierta = modo local
16 REM 1+2 Entrada activada = modo remoto, Sistemas de control 1 y 2 - Entrada abierta = modo local
17 AUTO 1 Entrada activada = modo automático, Sistema de control 1 - Entrada abierta = modo manual
17 AUTO 2 Entrada activada = modo automático, Sistema de control 2 - Entrada abierta = modo manual
17 AUTO 1+2 Entrada activada = modo automático, Sistemas de control 1 y 2 - Entrada abierta = modo manual
18 REG 1 Entrada activada = Realimentación de velocidad de bucle cerrado activa,

Sistema de control 1 - Entrada abierta = Bucle abierto
18 REG 2 Entrada activada = Realimentación de velocidad de bucle cerrado activa,
Sistema de control 2 - Entrada abierta = Bucle abierto
18 REG 1+2 Entrada activada = Realimentación de velocidad de bucle cerrado activa,
Sistemas de control 1 y 2 - Entrada abierta = Bucle abierto
18 ERR1 RES Reinicio externo de la función Error demasiado grande, Sistema de control 1
18 ERR2 RES Reinicio externo de la función Error demasiado grande, Sistema de control 2
18 ERR1+2 R Reinicio externo de la función Error demasiado grande, Sistemas de control 1 y 2
19 EMOTOR 1 Función de monitoreo de temp. alta de motor eléctrico 1

20 PR REM 1 Cambio entre valor de consigna de presión local y remoto, Sistema de control 1
20 PR REM 2 Cambio entre valor de consigna de presión local y remoto, Sistema de control 2
20 PR HI 1 Forzar la salida de la presión a nivel alto, Sistema de control 1
20 PR LO 1 Forzar la salida de la presión a nivel bajo, Sistema de control 1
20 PR ON 1 Encender el regulador de presión, Sistema de control 1
20 PR HI 2 Forzar la salida de la presión a nivel alto, Sistema de control 2
20 PR LO 2 Forzar la salida de la presión a nivel bajo, Sistema de control 2
20 PR ON 2 Encender el regulador de presión, Sistema de control 2
21 OFF No se usa
NOTA1
La entrada estará activa para el arranque/la parada del sistema de control en:
− modo local
− modo remoto si no se usa una entrada digital para el arranque
5.2.4 Salidas digitales


ON=On delay 1
OFF=Off delay 2
PULSE=Output changes during
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
delay time
NO=No delay NO
* Configuraciones posibles de funciones:

01 A1 Alarma, sistema de control 1
01 A2 Alarma, sistema de control 2
01 A1+A2 Alarma, sistema de control 1 o sistema de control 2
01 W 1 Advertencia, sistema de control 1
01 W 2 Advertencia, sistema de control 2
01 W1+W2 Advertencia, sistema de control 1 o sistema de control 2
01 INT 1 Enclavamiento, sistema de control 1
01 INT 2 Enclavamiento, sistema de control 2
01 INT 1+2 Enclavamiento, sistema de control 1 o sistema de control 2
02 START 1 Sistema de control 1 arrancado

02 START 2 Sistema de control 2 arrancado
02 START1+2 Sistema de control 1 o sistema de control 2 arrancado
02 START1*2 Sistema de control 1 y sistema de control 2 arrancados
03 READY 1 Listo para usar, sistema de control 1 (también para usar como válvula a prueba de
fallos, sistema de control 1)
03 READY 2 Listo para usar, sistema de control 2 (también para usar como válvula a prueba de
fallos, sistema de control 2)
03 READY1+2 Sistema de control 1 o sistema de control 2 listo
03 READY1*2 Sistema de control 1 y sistema de control 2 listos
04 REMOTE 1 Sistema de control 1 en modo remoto

04 REMOTE 2 Sistema de control 2 en modo remoto
05 AUTO 1 Sistema de control 1 en modo automático (función Triturador)

05 AUTO 2 Sistema de control 2 en modo automático (función Triturador)
05 REG 1 Sistema de control 1 en modo regulado (funciones Básica y Sincronizar)
05 REG 2 Sistema de control 2 en modo regulado (funciones Básica y Sincronizar)
06 PLIM 1 Límite de potencia activo, sistema de control 1

06 PLIM 2 Límite de potencia activo, sistema de control 2
06 PLIM 1+2 Límite de potencia activo, sistema de control 1 o sistema de control 2
06 PLIM Límite de potencia activo
07 FORW 1 Sistema de control 1 en avance (señal de comando positiva)

07 REV 1 Sistema de control 1 en reversa (señal de comando negativa)
07 FORW 2 Sistema de control 2 en avance (señal de comando positiva)
07 REV 2 Sistema de control 2 en reversa (señal de comando negativa)
08 C ZERO Indicación para la posición cero encontrada en la función contador de sincronización

(sincronización activada)
08 SYNCHRO Sincronizar dentro de los límites establecidos en el parámetro L22
09 AOUT 1- La lectura de registro seleccionada para la salida analógica 1 tiene signo negativo
10 EMOT D1 Motor(es) eléctrico(s) para sistema de control 1 arrancado(s)

10 EMOT D2 Motor(es) eléctrico(s) para sistema de control 2 arrancado(s)
10 EMOTD1+2 Motor(es) eléctrico(s) para sistema de control 1 o 2 arrancado(s)
10 EMOTD1*2 Motor(es) eléctrico(s) para sistema de control 1 y 2 arrancado(s)
11 LOW TEMP Indicador de temp. baja activo

11 HI TEMP Indicador de temp. alta activo
11 MAX TEMP Indicador de máx. temp. activo
11 COOL CONI Control del enfriador enclavado por el arranque del motor eléctrico al usar el sensor
analógico de temperatura
11 COOL COND Control del enfriador sin enclavamiento al usar el sensor analógico de temperatura
11 HEAT CON Control del calefactor al usar el sensor analógico de temperatura
11 FLUSHCON Control de lavado al usar el sensor analógico de temperatura
12 P1 C ACT Control de presión activo, sistema de control 1

12 P1 HI CA Control de alta presión activo, sistema de control 1
12 P1 LO CA Control de baja presión activo, sistema de control 1
12 P2 C ACT Control de presión activo, sistema de control 2
12 P2 HI CA Control de alta presión activo, sistema de control 2
12 P2 LO CA Control de baja presión activo, sistema de control 2
13 SH BLCK1 Triturador bloqueado, sistema de control 1

13 SH BLCK2 Triturador bloqueado, sistema de control 2
14 AUX1 Función auxiliar 1 activa

OFF No se usa
5.2.5 Entradas de impulsos

P1I01 Pulses/rev 1 1000 1 10000

1=Normal 1 1
2=Inverted 2
P1I07 Encoder type
1=Quad 1 1
P2I01 Pulses/rev 1 1000 1 10000

1=Normal 1 1
2=Inverted 2
P2I07 Encoder type
1=Quad 1 1
* Configuraciones posibles de unidades de medida: rpm, m/m, m/s, f/m, f/s
5.2.6 Entradas analógicas


AIA02 Zero point adjustment Set point 1bit 0bit -102bit 102bit
Drive1
AIA03 Max point adjustment Set point 1bit 0bit -102bit 102bit
Drive1
%=% value Actual
Actual = Actual external input
value (AIA01)


AIB02 Zero point adjustment Set point 1bit 0bit -102bit 102bit
Drive2
AIB03 Max point adjustment Set point 1bit 0bit -102bit 102bit
Drive2
%=% value Actual
Actual = Actual external input
value (AIB01)


AIF04 Min input, REG401 1 0 -1000 2000
AIF12 Function for min indication at ****** OFF
4-20mA input type


AIG04 Min input, REG402 1 0 -1000 2000
AIG12 Function for min indication at ****** OFF
4-20mA input type


AIH04 Min input, REG403 1 0 -1000 2000
AIH12 Function for min indication at ****** OFF
4-20mA input type


AII04 Min input, REG404 1 0 -1000 2000
AII12 Function for min indication at ****** OFF
4-20mA input type


AIJ04 Min input, REG405 1 0 -1000 2000
AIJ12 Function for min indication at ****** OFF
4-20mA input type


AIK04 Min input, REG406 1 0 -1000 2000
AIK12 Function for min indication at ****** OFF
4-20mA input type


AIL04 Min input, REG407 1 0 -1000 2000
AIL12 Function for min indication at ****** OFF
4-20mA input type


AIM04 Min input, REG408 1 0 -1000 2000
5
5
AIM12 Function for min indication at ****** OFF
4-20mA input type


AIN04 Min input, REG409 1 0 -1000 2000
AIN12 Function for min indication at ****** OFF
4-20mA input type



* Configuraciones posibles del tipo de entrada:

4-20mA
0-20mA
0-5V
0-10V
** Configuraciones posibles de funciones:

13 AUX1-AUX20 Función de monitoreo auxiliar
02 H APR 12 Función de monitoreo de presión alta del lado A para los sistemas de control 1 y 2
02 H BPR 12 Función de monitoreo de presión alta del lado B para los sistemas de control 1 y 2
04 C PRA D1 Función de monitoreo de presión de cebado baja del lado A para el sistema de
control 1
04 C PRB D1 Función de monitoreo de presión de cebado baja del lado B para el sistema de
control 1
04 C PRA D2 Función de monitoreo de presión de cebado baja del lado A para el sistema de
control 2
04 C PRB D2 Función de monitoreo de presión de cebado baja del lado B para el sistema de
control 2
05 SHPRA D1 Función de presión de Triturador del lado A para el sistema de control 1

05 SHPRB D1 Función de presión de Triturador del lado B para el sistema de control 1
05 SHPRA D2 Función de presión de Triturador del lado A para el sistema de control 2
05 SHPRB D2 Función de presión de Triturador del lado B para el sistema de control 2
OFF No se usa
*** Configuraciones posibles de unidades de medida: rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm, A, kW, hp, °, %
**** Configuraciones posibles de unidades de medida: °C, °F
***** Configuraciones posibles de funciones:

EC1 = corriente del motor eléctrico 1 (A)
AS1 = Velocidad analógica, Sistema de control 1 (rpm)
AS2 = Velocidad analógica, Sistema de control 2 (rpm)
AS1+2 = Velocidad analógica, Sistema de control 1 y Sistema de control 2 (rpm)
SP1= Presión de Triturador, Sistema de control 1 (bar)
SP2 = Presión de Triturador, Sistema de control 2 (bar)
SM = Valor de consigna de velocidad maestro en sincronización, Sistema de control 2 (%)
SO = Compensación de sincronización, Sistema de control 2 (°)
SP1+2 = Presión de Triturador, Sistema de control 1 y Sistema de control 2 (bar)
PR1= Presión real para el control de presión, Sistema de control 1 (bar)
PR2= Presión real para el control de presión, Sistema de control 2 (bar)
PR1+2= Presión real para el control de presión, Sistema de control 1 y Sistema de control 2 (bar)
PR1 SET= Presión configurada para el control de presión, Sistema de control 1 (bar)
PR2 SET = Presión configurada para el control de presión, Sistema de control 1 (bar)
TANK A = Función de monitoreo analógico del tanque (°C)
P FRICT = Control de fricción de la bomba (%)
OFF = No se usa
****** Configuraciones posibles de funciones:

AUX1 – AUX20 Función de monitoreo auxiliar
5.2.7 Salidas analógicas








* Lecturas de registro posibles para la salida:
Sistema de control 1 Pump signals
REG101= Comando de entrada remota REG350 = Pump friction
REG102 = Valor de consigna de velocidad
REG103 = Comando de entrada
REG104= Comando de alimentación de avance Analog in
REG105= Señal de error REG401 = Analog in 1
REG106 = Comando de amplificador REG402 = Analog in 2
REG109 = Velocidad digital REG403 = Analog in 3
REG110= Realimentación de velocidad REG404 = Analog in 4
REG111= Comando de presión REG405 = Analog in 5
REG112 = Comando de presión regulada REG406 = Analog in 6
REG113= Compensación de presión REG407 = Analog in 7
REG114 = Comando maestro REG408 = Analog in 8
REG410 = Tank temp
Sistema de control 2
REG201 = Comando de entrada remota Bus command in
REG202 = Valor de consigna de velocidad REG501 = Bus in 1
REG203 = Comando de entrada REG502 = Bus in 2
REG204 = Comando de alimentación de avance REG503 = Bus in 3
REG205 = Señal de error
REG206 = Comando de amplificador
REG504 = Bus in 4
REG209 = Velocidad digital
OFF = Salida apagada
REG210 = Realimentación de velocidad
REG211= Comando de presión
** Configuraciones posibles de salida
REG212 = Comando de presión regulada
OFF = salida de 0-20mA o 0-10V
REG213 = Compensación de presión
ON = salida de 4-20mA o 2-10V
REG214 = Compensación (Sincronización)
5.2.8 Bus

Profibus
Modbus
Interlock Interlock


* Configuraciones posibles de las funciones de las entradas digitales: Igual que En digital (DIN)
Bus – Analog in 1

Bus – Analog in 2

Bus – Analog in 3

Bus – Analog in 4

** Configuraciones posibles de unidades de medida: %, rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm,
*** Configuraciones posibles de funciones:
BSO = Compensación de sincronización (función Sincronizar)
BP1 = Valor de consigna de presión, Sistema de control 1 (función Presión)
BP2 = Valor de consigna de presión, Sistema de control 2 (función Presión)
BMS = Valor de consigna de velocidad maestro (función Sincronizar)
PF = Fricción de la bomba
OFF = No se usa
Bus – Analog out


**** Lecturas de registro posibles para la salida:

Drive 1 REG109 = Velocidad digital
REG101 = Comando de entrada remota REG110 = Realimentación de velocidad
REG102 = Valor de consigna de velocidad REG111 = Comando de presión
REG103 = Comando de entrada REG112 = Comando de presión regulada
REG104 = Comando de alimentación de avance REG113 = Compensación de presión
REG105 = Señal de error REG114 = Comando maestro
REG106 = Comando de amplificador

REG201 = Comando de entrada remota REG350 = Fricción de la bomba
REG202 = Valor de consigna de velocidad
REG203 = Comando de entrada Analog in
REG204 = Comando de alimentación de avance REG401 = Analog in 1
REG205 = Señal de error REG402 = Analog in 2
REG210 = Realimentación de velocidad REG405 = Analog in 5
REG211 = Comando de presión REG406 = Analog in 6
REG212 = Comando de presión regulada REG407 = Analog in 7
REG213 = Compensación de presión REG408 = Analog in 8
REG214 = Compensación (Sincronización) REG409 = Analog in 9
REG410 = Tank temp
5.2.9 Monitor de bombas
Pump monitor-Pump 1

20, 25sec
Pump monitor-Pump 2

20, 25sec
Pump monitor-Pump 3

20, 25sec
Pump monitor-Pump 4

20, 25sec
* Configuraciones posibles del tiempo de retardo: 0 / 0.1 / 0.5 / 1.0 segundos

** Configuraciones posibles del tiempo de retardo: 7.0 / 10.0 / 30.0 / 60.0 segundos, 3.0 / 5.0 / 8.0 / 10.0 / 12.0 / 15.0 minutos
*** Configuraciones posibles del tiempo de retardo: 0 / 1.0 / 5.0 / 7.0 / 10.0 / 20.0 / 30.0 / 60.0 segundos
**** Configuraciones posibles del tiempo de retardo: 2, 4, ..., 22, 24h, Apagado
5.2.10 Monitor del tanque

Tank monitor-Analog

TMB02 Not used
* Configuraciones posibles del tiempo de retardo: 0 / 0.1 / 0.5 / 1.0 segundos

** Configuraciones posibles del tiempo de retardo: 7.0 / 10.0 / 30.0 / 60.0 segundos, 3.0 / 5.0 / 8.0 / 10.0 / 12.0 / 15.0 minutos
*** Configuraciones posibles del tiempo de retardo: 2, 4, ..., 22, 24h, Apagado
5.2.11 Monitor auxiliar
Aux monitor-Aux1

Aux monitor-Aux2

Aux monitor-Aux3

Aux monitor-Aux4

Aux monitor-Aux5

Aux monitor-Aux6

Aux monitor-Aux7

Aux monitor-Aux8

Aux monitor-Aux9

Aux monitor-Aux10

Aux monitor-Aux11

Aux monitor-Aux12

Aux monitor-Aux13

Aux monitor-Aux14

Aux monitor-Aux15

Aux monitor-Aux16

Aux monitor-Aux17

Aux monitor-Aux18

Aux monitor-Aux19

Aux monitor-Aux20

* Configuraciones posibles de funciones: A D1 (conectado a Alarma del sistema de control 1)
A D2 (conectado a Alarma del sistema de control 2)
W D1 (conectado a Advertencia del sistema de control 1)
W D2 (conectado a Advertencia del sistema de control 2)
A D1 D2 (conectado a Alarma del sistema de control 1 y Alarma del sistema de control 2)
W D1 D2 (conectado a Advertencia del sistema de control 1 y Advertencia del sistema de control 2)
INT D1 (conectado a Enclavamiento del sistema de control 1)
INT D2 (conectado a Enclavamiento del sistema de control 2)
INT D1 D2 (conectado a Enclavamiento del sistema de control 1 y Enclavamiento del sistema de
control 2)
OFF (No conectado a la salida)
***Los caracteres se cambian con los botones ∧ y ∨, y se seleccionan con el botón >.
5.2.12 Monitor del sistema de control


OR
20, 25sec
OR
20, 25sec




* AND (Y) = Se deben arrancar todos los motores E seleccionados para el sistema de control para permitir el arranque
del sistema de control.
* OR (O) = Se puede realizar el arranque del sistema de control si se arranca cualquier motor E para el sistema de control.
** Configuraciones posibles del tiempo de retardo: 0 / 0.1 / 0.5 / 1.0 segundos
*** Configuraciones posibles del tiempo de retardo: : 0 / 1.0 / 5.0 / 7.0 / 10.0 / 20.0 / 30.0 / 60.0 segundos
5.2.13 Sistema de control 1 básico

1=Local 1 1
2=Remote 2
3=Local/remote 3
D1A02 Tipo of command signal
mode
FORW 1)
REV 1)
Drive 1 basic-Ramp


regulated drive
3=Switching between regulated 3
and non-regulated drive
3=No feedback 3


5.2.14 Sistema de control 2 básico

1=Local 1 1
2=Remote 2
3=Local/remote 3
mode
FORW 2)
REV 2)
Drive 2 basic-Ramp


regulated drive
3=Switching between regulated 3
and non-regulated drive
3=No feedback 3


5.2.15 Triturador 1
Shredder 1-Function

2=Speed 2
1=Reverse stop 1
change
change
Shredder 1-Setpoint

remote 2
(D1A05)
SHB01 = 1
Shredder 1-Counter

5.2.16 Triturador 2
Shredder 2-Function

2=Speed 2
1=Reverse stop 1
change
change
Shredder 2-Setpoint

remote 2
(D2A05)
SHB01 = 1
Shredder 2-Counter

5.2.17 Sincronizar
Synchro-Function
SYA01 Tipo of synchronisation:

(synchro)
slaved


2=External reset 2
Drive1:
2=Drive 1 start 2



SYD02 Sync time 0.1sec 1.0 0.0 600.0


2=External reset 2
Drive2:
2=Drive 2 start 2



5.2.18 Presión 11
Pressure 1-Function


1=Local 1
2=Remote 2
3=Local/Remote 3

5.2.19 Presión 2
Pressure 2-Function


1=Local 1
2=Remote 2
3=Local/Remote 3

5.2.20 Lectura 1






5.2.21 Lectura 2






* Lecturas de registro posibles de la pantalla.

Sistema de control 1 Analog in
REG101 = Comando de entrada remota (%, real) REG401 = Analog in 1
REG102 = Valor de consigna de velocidad (%) REG402 = Analog in 2
REG103 = Comando de entrada (%) REG403 = Analog in 3
REG104 = Comando de alimentación de avance (%) REG404 = Analog in 4
REG105 = Señal de error (%) REG405 = Analog in 5
REG106 = Comando de amplificador (%) REG406 = Analog in 6
REG107 = Valor de consigna de velocidad (rpm) REG407 = Analog in 7
REG108 = Comando de alimentación de avance (rpm) REG408 = Analog in 8
REG110 = Realimentación de velocidad (%) REG410 = Tank temp
REG111 = Comando de presión
REG112 = Comando de presión regulada Bus command in
REG113 = Compensación de presión REG501 = Bus in 1
REG114 = Comando maestro REG502 = Bus in 2
REG115 = Ángulo de parada de emergencia (°) REG503 = Bus in 3
REG504 = Bus in 4
Sistema de control 2 REG511 = Bus digital in 1-8
REG201 = Comando de entrada remota (%, real) REG512 = Bus digital in 9-16
REG202 = Valor de consigna de velocidad (%) REG513 = Bus digital in 17-24
REG203 = Comando de entrada (%)
REG204 = Comando de alimentación de avance (%)
REG205 = Señal de error (%) Lecturas de diagnóstico
REG206 = Comando de amplificador (%) REG901= Tarea de control (ms)
REG207 = Valor de consigna de velocidad (rpm) REG902 = Tarea de control máx. (ms)
REG208 = Comando de alimentación de avance (rpm) REG903 = Tarea de la UI (ms)
REG209 = Velocidad digital REG904 = Tarea de la UI máx. (ms)
REG210 = Realimentación de velocidad (%) REG905 = Carga de la CPU (%)
REG211 = Comando de presión REG906 = Carga máx. de la CPU (%)
REG212 = Comando de presión regulada REG907 = Uso de pilas, tarea de control (%)
REG213 = Compensación de presión REG908 = Uso de pilas, tarea de la UI (%)
REG214 = Compensación (Sincronización) REG909 = Uso de pilas, puerto serie (%)
REG215 = Ángulo de parada de emergencia (°) REG911 = Cálc. de resistencia de la bomba 1 (ohmios)
REG912 = Cálc. de resistencia de la bomba 2 (ohmios)
Señales de las bombas REG913 = Cálc. de resistencia de la bomba 3 (ohmios)
REG310 = Comando de amplificador 1 (%) REG914 = Cálc. de resistencia de la bomba 4 (ohmios)
REG311 = Corriente de bomba 1 (mA)
REG320 = Comando de amplificador 2 (%)
REG321 = Corriente de bomba 2 (mA) OFF = Salida apagada
REG350 = Fricción de la bomba (%)
5.2.22 Registro del sistema de control
Función de registro – Hora/Fecha

Configuración de la hora y la fecha para la función de registro


RESET


RESET


RESET


RESET


RESET


RESET


RESET


RESET
* Configuración posible de registro

Sistema de control 1 Señales de las bombas
REG101 = Comando de entrada remota REG310 = Comando de amplificador 1 (%)
REG102 = Valor de consigna de velocidad REG311 = Corriente de bomba 1 (mA)
REG103 = Comando de entrada REG320 = Comando de amplificador 2 (%)
REG104 = Comando de alimentación de avance REG321 = Corriente de bomba 2 (mA)
REG105 = Señal de error REG330 = Comando de amplificador 3 (%)
REG106 = Comando de amplificador REG331 = Corriente de bomba 3 (mA)
REG109 = Velocidad digital REG340 = Comando de amplificador 4 (%)
REG110 = Realimentación de velocidad REG341 = Corriente de bomba 4 (mA)
REG111 = Comando de presión REG350 = Fricción de la bomba
REG112 = Comando de presión regulada
REG113 = Compensación de presión Analog in
REG114 = Comando maestro REG401 = Analog in 1
Sistema de control 2 REG403 = Analog in 3
REG201 = Comando de entrada remota REG404 = Analog in 4
REG202 = Valor de consigna de velocidad REG405 = Analog in 5
REG203 = Comando de entrada REG406 = Analog in 6
REG204 = Comando de alimentación de avance REG407 = Analog in 7
REG205 = Señal de error REG408 = Analog in 8
REG209 = Velocidad digital REG410 = Tank temp
REG210 = Realimentación de velocidad
REG211 = Comando de presión Bus command in
REG212 = Comando de presión regulada REG501 = Bus in 1
REG213 = Compensación de presión REG502 = Bus in 2
REG214 = Compensación (Sincronización) REG503 = Bus in 3
REG504 = Bus in 4
Función de registro – Reiniciar tiempo
Reinicio de los contadores de tiempo para el tiempo en uso
AS-6
Spider Configuraciones y función del software
04-04-02
Índice
Introducción ............................................................................................................ 2
H H
6.1 Configuración general del sistema.................................................................... 3

H H
6.2 Comando de velocidad ..................................................................................... 4

H H
6.3 Rampa .............................................................................................................. 4

H H
6.4 Salida ................................................................................................................ 5

H H
6.5 Realimentación de velocidad ............................................................................ 6

H H
6.6 Limitación de potencia ...................................................................................... 9

H H
6.7 Monitoreo ........................................................................................................ 10

H H
6.8 Entradas analógicas ....................................................................................... 12

H H
6.9 Entradas digitales ........................................................................................... 12

H H
6.10 Salidas digitales............................................................................................ 19

H H
6.11 Monitoreo de señales ................................................................................... 21

H H
6.12 Triturador ...................................................................................................... 23

H H
6.13 Sincronizar.................................................................................................... 24
H H
6.14 Control de presión ........................................................................................ 25

H H
6.15 Comunicación por bus .................................................................................. 28

H H
6.16 Registro de monitoreo del sistema de control............................................... 33

H H
6.17 Salidas analógicas........................................................................................ 35

H H
6.18 Selección de idioma...................................................................................... 35

H H
6.19 Registro de monitoreo del sistema de control............................................... 36

H H
6.20 Parada de emergencia ................................................................................. 37

H H
6.21 Actualización del programa .......................................................................... 38

H H
6.22 Calibración del hardware .............................................................................. 38

H H
AS-6
Spider Configuraciones y función del software
04-04-02
Introducción
Configuraciones de los bloques básicos en el software. Todas las configuraciones son para el
sistema de control 1. El mismo procedimiento se aplica al sistema de control 2 pero con la letra de
parámetro entre ().
Esto también describe el orden lógico para la configuración del sistema.
La lista de parámetros se encuentra en AS5 y los diagramas de bloques con parámetros se
encuentran en AS7.
La elección de los parámetros se realiza usando los botones direccionales (◄, ►, ▲ y ▼) (vea AS5.1).
Después de un cambio, la elección debe ser actualizada con el botón Enter (◄┘). Los parámetros se
actualizan en la memoria cuando se regresa a la lectura Main Status (Estado principal) en la pantalla.
Las configuraciones se pueden proteger con una contraseña (MAIN SETTINGS Æ PROTECTION:
MAD01-02). (CONFIGURACIONES PRINCIPALES Æ PROTECCIÓN: MAD01-02).
La función de monitoreo del sistema de control está protegida por una contraseña independiente bajo la
FUNCIÓN SETUP-LOG (REGISTRO DE CONFIGURACIÓN).
AS6, Configuraciones y función del software, Manual de ingeniería 04-04-02
6.1 Configuración general del sistema

6.1.1 Función del sistema
En MAIN SETTINGS Æ FUNCTION: MAA01 (CONFIGURACIONES PRINCIPALES Æ FUNCIÓN:
MAA01) se selecciona la función básica para el sistema de control. Las funciones seleccionables para
el sistema son (vea también los diagramas de bloques en AS1 y AS7):
• BASIC (BÁSICA) – La función básica y más común. La función incluye monitoreo, realimentación
de velocidad y limitación de potencia. Esta es la función que también se selecciona para monitorear la
unidad tipo.
• SHREDDER (TRITURADOR) – Igual que para BASIC (BÁSICA) con funciones adicionales de
reversa a causa de un sistema de control parado por sobrecarga.
• SYNCHRO (SINCRONIZAR) – Igual que para BASIC (BÁSICA) con dos sistemas de control
accionados conjuntamente, con control de relación de FRICTION (FRICCIÓN) o posición entre
los motores.
La función PRESSURE (PRESIÓN) se puede usar con la función BASIC (BÁSICA), SHREDDER
(TRITURADOR) y FRICTION (FRICCIÓN).
6.1.2 Configuración de la disposición del sistema
El sistema necesita la configuración para saber cómo

se conectan los motores eléctricos a las bombas y
cómo éstas se conectan a los sistemas de control.
Procedimiento de configuración en MAIN SETTINGS

Æ CONFIGURATION (CONFIGURACIONES
PRINCIPALES Æ CONFIGURACIÓN ):
• Para configurar la conexión del motor eléctrico
a la bomba, configure MAB01-04 (bomba 1-4)
al motor eléctrico 1, 2 o 3.
• Para configurar la conexión de la bomba al
sistema de control, configure MAB05-MAB08
(bomba 1-4) al sistema de control 1 o 2.
• Por último, configure el parámetro MAB09 en
común o independiente cuando use dos
sistemas de control, según los sistemas de
control tengan función común o independiente.
6.1.3 Puenteo de los botones de control frontales
Las funciones de los botones del sistema de control frontales se pueden puentear configurando el
parámetro D1A08 (D2A08) en off.
6.2 Comando de velocidad

En ANALOG INPUTS-SETPOINT1 (2): AIA(B)01 - 04
(ENTRADAS ANALÓGICAS-VALOR DE CONSIGNA (2):
AIA(B)01 - 04) se selecciona la fuente del comando de
valor de consigna de velocidad.
El comando de valor de consigna remoto es una señal de
voltaje o corriente conectada a los terminales. El tipo
debe ser configurado con el parámetro AIA(B)01 y con el
puente SP D1(2), vea AS4.5. El valor de consigna remoto
también se puede configurar mediante el fieldbus (para
las configuraciones, vea AS6.15).
El comando local se configura con los botones de
aumento y reducción del frente. Si se necesita un
aumento/reducción externos, la función de valor de
consigna local puede conectarse en paralelo usando las
entradas digitales configurables (Vea AS5.2.3).
El comando de velocidad se puede trabar en control local
o remoto, o ser intercambiable con el botón local/remoto
(configurar con DxA01).
En el cambio local/remoto el comando de valor de
consigna local puede volver automáticamente a cero si
DxA03 está configurado en yes (sí). De lo contrario se
mantendrá la configuración cuando se cambie al modo
remoto. El reinicio se puede hacer usando la entrada digital configurable.
Un aumento/reducción local no afecta el valor de consigna local cuando se use en modo remoto.
La entrada remota debe ser calibrada en la forma descrita para las entradas analógicas (vea el ejemplo
en AS6.8).
Las entradas para el avance (configurar con DxA06) y reversa (configurar con DxA07) a velocidad fija
pueden ser seleccionadas con las entradas digitales configurables.
6.3 Rampa
El tiempo de rampa de arranque es el tiempo que le toma a la señal controlar la bomba hidráulica, ir
desde cero hasta el 100% si el valor de consigna de velocidad es 100% y cuando se activa el arranque
del sistema de control. La rampa de parada es el tiempo que toma ir desde el 100% hasta cero cuando
se activa la parada del sistema de control.
El arranque y la parada del sistema de control son comandos con rampa (como el avance fijo, la reversa
fija y la reversa por retrocesos sucesivos). La rampa de arranque está controlada por los parámetros
DxC01 en dirección de avance y DxC03 en dirección de reversa. La rampa de parada está controlada
por los parámetros DxC02 en dirección de avance y DxC04 en dirección de reversa.
Ejemplo: Si la ”rampa de subida” D1C01 está configurada en 10 s y la rampa de bajada D1C02 está
configurada en 5 s obtendremos el siguiente resultado.
El ejemplo se basa en un valor de consigna de 50 y 100%.
Velocidad
Arranque del sistema de control Parada del sistema de control
100 %
Rampa de parada
50%
Rampa de arranque
0 10 20 25 Tiempo en s
6.4 Salida
6.4.1 Frecuencia PWM
Las configuraciones individuales para cada bomba se realizan en PUMP OUTPUTS (SALIDAS
DE BOMBAS) (Vea AS5.2.2)
Las salidas están Moduladas en Anchura de Impulsos (Pulse Width Modulated) y la frecuencia
modulada en anchura de impulsos (Pulse Width Modulated, PWM) se puede configurar con los
parámetros POx06. La configuración normal es 200Hz pero se puede configurar de 100 a 2000Hz
en pasos de 100Hz. Si se usa un pistón 5A (sólo se puede controlar en una dirección), la frecuencia
debe ser configurada en 2000Hz para evitar dañar el pistón.
6.4.2 Resistencia de la bobina

La resistencia nominal para el pistón debe ser configurada con el parámetro POx05. El sistema
medirá la corriente en la bobina del pistón y compensará el cambio de resistencia debido al aumento
de la temperatura.
Un valor de resistencia típico es:
5A2 (Denison) 25 ohmios
9A2 (Denison) 41 ohmios
SP (Brueninghaus) 20 ohmios
KA (Sauer Sundstrand) 25 ohmios
6.4.3 Configuración de la corriente

Para la configuración de la corriente de salida es fácil usar la identificación de la velocidad si se
conecta un codificador de velocidad (Vea AS6.11 para configuración).
D(J)07
La frecuencia menor a 2000Hz puede destruir el pistón de bomba 5A2
• Corriente de avance mín., parámetro POx01.

Arranque el sistema de control. Aumente la corriente hasta que el sistema de control
comience a avanzar, redúzcalas hasta que pare nuevamente.
Pare el sistema de control.
• Corriente de avance máx., parámetro POx02.
Arranque el sistema de control. Aumente la corriente hasta que se alcance la velocidad de
avance adecuada. Pare el sistema de control.
• Corriente de reversa mín., parámetro POx03.

Arranque el sistema de control. Aumente la corriente hasta que el sistema de control comience a
moverse en reversa, redúzcala hasta que pare nuevamente. Pare el sistema de control.
• Corriente de reversa máx., parámetro POx04.
Arranque el sistema de control. Aumente la corriente hasta que se alcance la velocidad de reversa
adecuada. Pare el sistema de control.
POx01-04
La corriente alta puede destruir
el pistón de bomba
6.5 Realimentación de velocidad

6.5.1 General
La realimentación de velocidad permite mantener una velocidad constante en el eje del motor
hidráulico. El Spider compensa las desviaciones de velocidad debidas a los cambios de carga. Para
lograrlo, hay un regulador PID implementado en el software. Este regulador PID compara el valor de
velocidad real con el valor de consigna de la velocidad. Cualquier desviación entre las dos señales se
detecta como una señal de Error y se transfiere al regulador PID. El regulador PID tiene tres etapas
diferentes.
La parte proporcional amplifica la señal de Error. La Salida es proporcional a la señal de Error.
La etapa Integral (Integral) integra la señal de Error. Una pequeña señal de Error creará, con el
transcurso del tiempo, una gran salida de etapa Integral (Integral).
La etapa Derivative (Derivada) deriva la señal de Error. Un cambio rápido creará una gran salida de la
etapa derivada.
Los resultados de las tres etapas diferentes se agregan a la salida de pistón.
El siguiente ejemplo de configuración se basa en los

siguientes datos:
El codificador analógico de velocidad con señal de salida 4-20mA
para 0-25Rpm conectado a entrada analógica 3.
La velocidad máxima del sistema de control es 22Rpm.
La configuración respecto de la realimentación de velocidad se
realiza en los siguientes menús de parámetros:
"Sistema de control 1 básico - realimentación" (D1E01 - D1E03)
"Entradas analógicas - Analógica en 3" (AIH01 - AIH14)
"Entradas de impulso - Sistema de control 1" (P1I01 - PII07)
"Sistema de control 1 básico - regulador" (D1D01 - D1D11)
La configuración para el sistema de control 2 es idéntica pero los
parámetros comienzan con "D2xx"
6.5.2 Configuración de la señal de entrada del codificador de

velocidad
El tipo de codificador de velocidad se determina con el parámetro
D1E02. Las configuraciones posibles son:
1. Realimentación digital.
2. Realimentación analógica.
3. Sin realimentación.
En este caso, este parámetro se configura en 2 -> Realimentación
analógica.
La velocidad máxima del eje del motor hidráulico se configura en el
parámetro D1E01. Es este caso el parámetro se configura en
22rpm.
El codificador de velocidad está conectado a la entrada analógica 3,
los parámetros AIH01 a AIH14 son válidos para la configuración.
Los parámetros no mencionados abajo se dejan con la
configuración de fábrica.
AIH02 y AIH03 se usan cuando se calibra la entrada. Se puede
realizar el ajuste del cero y del rango.
AIH05 se configura en 25 rpm debido a que este es el rango del
codificador de velocidad.
AIH06 se configura en rpm.
AIH07 se configura en 1 debido a que queremos que la señal sea
presentada con un decimal
AIH09 se configura en AS1 y significa Sistema de Control Analógico de Velocidad 1.
AIH12 se configura en AUX 1 que se configura como una advertencia, activada cuando falta 4 mA. La
advertencia indicará un codificador de velocidad roto.
Si se va a usar un codificador digital de velocidad, deben configurarse los parámetros P1I01 a P1I07.
El valor del parámetro P1I01 debe ser la cantidad de impulsos digitales que produce el codificador de
velocidad durante una rotación.
P1I06 puede configurarse si la rotación del motor hidráulico/codificador está dando una polaridad
errónea de la lectura. Si se configura en 1, cambiará la polaridad.
P1I07 determina el tipo de codificador de velocidad usado.
1= Cuad. Este es el tipo estándar con dos trenes de impulsos.

2= Impulso único con dirección. Este codificador de velocidad proporciona un tren de impulsos y
además una señal direccional ON/OFF.
3= Impulso único sin dirección. El codificador de velocidad proporciona un tren de impulsos como
salida.
6.5.3 Configuración del regulador
Todos los parámetros del Regulator (Regulador) están comprendidos bajo “Sistema de control 1
básico - Regulador”, parámetros D1D01 – D1D11. A continuación se incluye una descripción de cada
parámetro.
El parámetro D1D11 presenta las siguientes opciones:
1. Sistema de control no regulado (indicación en blanco en la 4ta. posición de la línea 1 de la
pantalla)
2. Sistema de control regulado (indicación REG en la 4ta. posición de la línea 1 de la pantalla)
3. Cambio entre sistema de control regulado y no regulado.
El parámetro debe estar configurado en 2 o 3 para lograr la realimentación de velocidad. En este
caso, el parámetro D1D11 se configura en 3.
Entonces es posible activar/desactivar el regulador PID desde el frente del Spider con el botón
pulsador predefinido REG/UNREG (REG/NO REG).
D1D01 configura la función del regulador en ON u OFF. En este caso en ON, el regulador está
activado.
D1D02 La función de alimentación de avance está configurada en ON u OFF. En este caso en
ON, el valor de consigna de velocidad se coloca en la salida del pistón como valor inicial
y el regulador compensa las desviaciones de la velocidad.
Si el parámetro está configurado en OFF la salida del regulador será la única
señal a la salida del pistón.
D1D03 Configura la función de la etapa Proportional (Proporcional) del regulador en ON u OFF.
En este caso, seleccione ON. La etapa proporcional reacciona en forma proporcional a
la señal de entrada de Error. La acción de esta etapa se determina por el parámetro
D1D06.
D1D04 Configura la función Integrator (Integrador) en ON u OFF. En este caso, seleccione ON.
Esta función otorga al sistema de control la posibilidad de alcanzar la velocidad de valor
de consigna con el transcurso del tiempo. La acción de esta etapa se determina por el
parámetro D1D07.
D1D05 Configura la función Derivative (Derivada) en ON u OFF. En este caso, seleccione OFF.
La etapa derivada se usa cuando se esperan cambios de velocidad muy rápidos en el
sistema de control. Reacciona ante el índice de variación en la señal de entrada de
Error. La etapa D se usa muy poco debido a que es difícil ajustarla. La acción de esta
etapa se configura por los parámetros D1D08 y D1D09.
D1D06 El parámetro de ganancia Proportional (Proporcional) configura la ganancia de la etapa
P. En este caso, configúrela en 0.5 como valor de arranque. La ganancia 0.5 de P
significa que la mitad del valor de la entrada de señal de Error será transferida a la salida
de la etapa. La etapa Proportional (Proporcional) sin embargo, no hará que el sistema de
control alcance la velocidad del valor de consigna. Siempre existirá un Error remanente.
Sin embargo, el valor del Error remanente depende de la configuración de la ganancia
Proportional (Proporcional). Si la señal de Error es pequeña, cercana a cero, la ganancia
P no producirá ninguna salida en esta salida de etapa. La etapa P siempre necesita una
señal de Error para modificar.
D1D07 El parámetro de tiempo Integrator (Integrador) configura el tiempo de integración de la
etapa I. En este caso, configure 10 segundos como valor de arranque. El tiempo
Integrator (Integrador) de 10 segundos significa que el valor de salida de esta etapa
alcanzará el 63% del valor de la entrada de la señal de Error en 10 segundos. La
introducción de la Integration (Integración) eliminará la señal de Error remanente. La
velocidad real corresponderá, con el transcurso del tiempo, al valor de consigna de la
velocidad. Puede ser comparado con un Capacitor (Capacitor) que se carga con la señal
de Error.
D1D08 El parámetro de tiempo Derivative (Derivado) configura el tiempo Derivative (Derivado)
de la etapa D. En este caso se deja el valor predeterminado, 10 segundos. El tiempo
Derivative (Derivado) de 10 segundos significa que la “ganancia” de derivación es un
factor 10. La salida de la etapa es el factor de “ganancia” multiplicado por el índice de
variación de la señal de Error.
D1D09 El parámetro de tiempo de declinación de Derivative (Derivado) configura el tiempo de

declinación de Derivative (Derivado) de la etapa D. En este caso se deja al valor
predeterminado, 10 segundos. El tiempo de declinación de Derivative (Derivado) de 10
segundos significa que el valor de salida de esta etapa declinará un 63 % en 10
segundos.
D1D10 La desviación máxima de realimentación es la diferencia permitida entre el comando y la
velocidad real. Si supera los 10 s, el sistema de control cambiará al sistema de control
no regulado y dará la advertencia ERROR TOO LARGE (ERROR DEMASIADO
GRANDE).
6.5.4 Ajuste del regulador
Las configuraciones anteriores dan en la mayoría de los casos un buen rendimiento del sistema de
control. Sin embargo, para optimizar los parámetros se puede utilizar el siguiente método.
En pocas palabras, el método es el siguiente:
Aumente la ganancia proporcional hasta que el sistema de control comience a oscilar. Tome nota del
tiempo de oscilación. Reduzca la ganancia Proportional (Proporcional) con un 50 %. Configure el
tiempo Integrator (Integrador) mínimo al doble del valor del tiempo de oscilación.
Esta es una lista paso a paso recomendada de cómo ajustar el regulador PI:
1 Seleccione el modo UNREG (NO REGULADO).
2 Asegúrese de que las corrientes del pistón estén ajustadas correctamente.
3 Anule la selección de la etapa Integrator (Integrador), configurando el parámetro D1D04 en Off.
4 Reduzca la configuración del tiempo de rampa a cero o tanto como el sistema de control
pueda tolerar.
5 Arranque el sistema de control.
6 Dé un comando de velocidad de aproximadamente un 50 %.
7 Seleccione el modo REG (REGULADO). Esto activa el regulador. Controle el rendimiento del
sistema de control. Si el sistema de control comienza a oscilar, pare el sistema de control y
reduzca el valor del parámetro Proportional (Proporcional).
8 Aumente la ganancia Proportional (Proporcional) de a poco. Arranque y pare el sistema de
control. Controle la estabilidad del sistema de control. Cuando el sistema de control comienza a
oscilar, intente determinar el tiempo de ciclo de la oscilación (el tiempo desde un límite de
impulso hasta el próximo).
9 Reduzca el valor de ganancia proporcional a la mitad de lo que configuró en 8.
10 Active la parte Integral (Integral) configurando el parámetro D1D04 en On.
11 Configure el parámetro Integrator (Integrador), como mínimo, al doble del tiempo de oscilación.
6.6 Limitación de potencia

La función de limitación de potencia no es posible en el Spider tipo
monitor.
Para tener la función de limitación de potencia se necesita la función
básica o superior.
La limitación de potencia se adquiere utilizando una entrada
analógica para detectar
la corriente del motor eléctrico. Vea AS 5.2.6 para la configuración
de la entrada analógica.
Primero configure la función para la entrada analógica en
AS5.2.6:Analog inputs -Analog in x:AIF09-AIN09 (AS5.2.6:Entradas
analógicas-Entrada analógica x:AIF09-AIN09) en EC1, EC2 o EC3.
El nivel de limitación se configura con los parámetros Analog inputs -
Power limit:AIR01-AIR03 (Entradas analógicas -Límite de
potencia:AIR01-AIR03)
La función de limitación se configura con los parámetros Drive 1(2)
basic - power limitation: D1(2)F01-D1(2)F02 (Sistema de control 1(2)
básico - limitación de potencia: D1(2)F01-D1(2)F02), vea AS3.3 para
la conexión y el tipo de entrada analógica.
Ejemplo de configuración de la limitación de potencia Sistema
de control 1, Motor eléctrico 1:
Motor eléctrico = 163A (de la hoja de datos o de la placa de datos de
servicio del motor)
Transformador de corriente 200A = 20mA
Estamos usando la entrada analógica 3 para este ejemplo.
Queremos limitar el motor eléctrico 1 en el sistema de control 1.
AIH05, Entrada máx. = 200
AIH06, Unidades para indicación = A
AIH09, Función => Limitación de potencia = EC1
AIR01, Nivel para limitación de potencia (motor e 1) = 163
D1F01, Tiempo de retardo = el tiempo que se permite que la
potencia sea mayor
que el nivel (AIR01) antes de que arranque la función de limitación
DIF02, Tiempo de rampa = la rapidez de reacción para bajar el
recorrido
de la bomba al nivel de limitación
Ejemplo de configuración de la limitación de potencia Sistema
de control 2, Motor eléctrico 3:
Motor eléctrico = 240A (de la hoja de datos o de la placa de datos de
servicio del motor)
Transformador de corriente 400A = 20mA
Estamos usando la entrada analógica 5 para este ejemplo.
Queremos limitar el motor eléctrico 3 en el sistema de control 2.
AIJ05, Entrada máx. = 400
AIJ06, Unidades para indicación = A
AIJ09, función => Limitación de potencia = EC3
AIR03, Nivel para limitación de potencia (motor e 3) = 240
D2F01, Tiempo de retardo = el tiempo que se permite que la
potencia sea mayor
que el nivel (AIR03) antes de que arranque la función de limitación
D2F02, Tiempo de rampa = la rapidez de reacción para bajar el
recorrido
de la bomba al nivel de limitación
La configuración del tiempo de rampa debe ser configurada
mediante una prueba con el sistema de control. Un tiempo
demasiado corto puede causar oscilación en el sistema y un tiempo
demasiado largo no regulará la corriente a la configuración máx. (la
misma función que para la regulación P, vea AS6.5).
6.7 Monitoreo
La función de monitoreo está disponible en todas las configuraciones. Las entradas digitales
predefinidas (para monitoreo) deben configurarse en off si no se desea el monitoreo. Vea la
configuración de las entradas digitales incluida en AS 5.2.3.
6.7.1 Funciones para monitoreo

Las funciones preprogramadas pueden usarse en cualquiera de las 43 entradas digitales disponibles.
Las funciones preprogramadas tienen tres tipos diferentes de indicación:
Warning (Advertencia) = indicación en la pantalla y por una salida digital si la función está configurada
(vea AS6.10)
Alarm (Alarma) = indicación en la pantalla y por una salida digital si la función está configurada
(vea AS6.10)
Esta función parará el sistema de control sin rampa y, después de un retardo corto, abra la
salida del enclavamiento del motor eléctrico para parar el motor.
Interlock (Enclavamiento) = igual que la alarma pero sin parar el motor eléctrico.
Las indicaciones de Advertencia, Alarma y Enclavamiento deben ser reiniciadas en la lista
Alarm/Warning (Alarmas/Advertencias) después de que se corrija el motivo que originó la indicación
(vea AS 4.3).
Las funciones preprogramadas se describen en AS 6.9.2.
6.7.2 Entrada de monitoreo extra

Existen 20 canales auxiliares preprogramados que pueden usarse para diferentes funciones. Una es
la función de monitoreo. Si cualquiera de las entradas digitales está configurada como AUX x (vea
AS5.2.3, Entradas digitales: 13 AUX x) la función de la entrada será la de monitoreo. Puede
configurarse la función Alarm (Alarma), Warning (Advertencia) o Interlock (Enclavamiento) en cuanto
a entrada, retardo de tiempo, memoria para la entrada y el texto en la lista alarm/warning
(alarmas/advertencias), vea AS5.2.11, Configuración – monitor Aux.
Ejemplo: Entrada digital 25 como entrada de advertencia por alta temperatura Sistema
de control 1.
Vea AS 3.3 para la conexión eléctrica de las entradas digitales.

Establezca el parámetro Setup - Digital inputs- DIN25 (Configuración - Entradas digitales -
DIN25: AUX1).
Establezca el parámetro Setup - Aux monitor - Aux 1 AMA01 (Configuración - Monitor Aux - Aux 1:
AMA01) en W1 (advertencia Sistema de control 1).
Configure AMA03 (puenteo de memoria) a la función preferida:
(Si el puenteo de memoria = off: se activará la indicación de advertencia si se abre la entrada.

La indicación de advertencia se mantendrá si se cierra la entrada.
y debe ser reiniciada en el menú Alarm / warning
(Alarmas/Advertencias)).
(Si el puenteo de memoria = on: se activará la indicación de advertencia si se abre la entrada.
La indicación de advertencia desaparecerá si se cierra la entrada).
Configure AMA02 al tiempo de retardo que se necesite entre la entrada abierta y la indicación
de advertencia.
Configure el texto en AMA04 a HIGH OIL TEMP (TEMP. DE ACEITE ALTA) usando los
botones ∧, ∨ y ↵ .
NOTA: La línea debe ser completada con caracteres en blanco, pulsando ↵ hasta que se complete
la línea. Los caracteres disponibles son todos caracteres posibles para la pantalla. Para caracteres
chinos, se debe montar una pantalla VFD y el interruptor SW3-1 se debe configurar en off.
La configuración de esta función puede realizarse en el frente del Spider o mediante el programa de
SpiderCom.
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6.7.3 Salidas del enclavamiento del motor eléctrico

Existen 3 salidas digitales normalmente altas para el enclavamiento de los motores eléctricos (serán
conectadas mediante un relé en el circuito de parada del motor eléctrico). La salida del enclavamiento
abrirá con retardo de tiempo después de una Alarma.
El tiempo de retardo se configura en Setup-Drive monitor-Emotor interlock: DMD01-DMD03
(Configuración-Monitor del sistema de control-enclavamiento del motor E: DMD01-DMD03)
Vea AS 3.4.2 para la conexión eléctrica. El enclavamiento depende de cómo se realiza la
configuración en Setup-Main settings-Configuration, (Configuración-Configuraciones principales-
Configuración), vea AS6.1 para la descripción.
La secuencia normal de parada en el momento de la alarma:

1. La salida a la bomba se configura en cero sin rampa.
2. Después de un retardo de tiempo (configurable), se abre el enclavamiento del motor eléctrico.
6.7.4 Salidas de monitoreo

Existen 13 salidas digitales que pueden configurarse en Setup – Digital outputs (Configuración –
Salidas digitales).
Se pueden usar para monitorear Alarm (Alarma), Warning (Advertencia) o Interlock (Enclavamiento) o
monitorear una salida digital.
Es posible usar una función auxiliar solamente para controlar una salida digital. En ese caso, AMx01
se configura en OFF y se debe dirigir una salida digital a la función aux.
Vea las configuraciones y funciones posibles para las salidas digitales en AS6.10.
6.7.5 Monitoreo de la temp. del tanque

La temperatura del tanque se puede monitorear con señal digital o analógica seleccionada por el
parámetro TMB01. Para la entrada de tipo digital se deben seleccionar funciones, vea AS6.9.
La elección del sensor analógico puede ser de tipo Pt100 (estándar) conectado a las entradas
preparadas o del tipo de señal analógica estándar conectado a una entrada analógica configurable. Si
se usa una entrada analógica configurable, la función se configura en TANK A (TANQUE A). La
selección de entrada configurable desconectará la entrada de tipo Pt100. Usando un sensor
analógico los niveles de cambio para Alarm (Alarma), Warning (Advertencia), Filter interlock
(Enclavamiento de filtro), Min temp (Temperatura mín.), Cooling control (Control de enfriamiento),
Heating control (Control de calentamiento) y Flushing control (Control de lavado) pueden ser
configurados dentro de límites preestablecidos. Si es necesario, todos los interruptores, excepto el
enclavamiento del filtro, pueden ser monitoreados en salidas digitales.
Función Configuración [°] Histéresis [°] On [°] Off [°]

Alarma 60 (TMB03) -- 60 60 (debe ser reiniciada)
Advertencia 55 (TMB04) -- 55 55 (debe ser reiniciada)
Enfriamiento 40 (TMB05) 3 (TMB06) 40 (temp. en aumento) 37
Enclavamiento de filtro 0 (TMB07) -- 0 0
Calentamiento 15 (TMB08) 3 (TMB09) 15 (temp. en descenso) 18
Mín. 10 (TMB10) -- 10 10
Lavado 15 (TMB11) 3 (TMB12) 30 (temp. en descenso) 33
6.7.6 Parada por alarma

En forma predeterminada, la salida del comando a las bombas estaría configurada en cero sin rampa
para parar el sistema lo más rápido posible. En algunas aplicaciones, configurar las salidas
rápidamente en cero puede causar daños mecánicos. Se puede configurar un tiempo de rampa de
alarma con el parámetro MAB10 para permitir al sistema realizar una parada controlada.
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6.8 Entradas analógicas

Todas las entradas analógicas pueden usarse para señales de corriente o voltaje.
El Spider tiene 9 entradas analógicas. 2 están dedicadas al valor de consigna de velocidad del
sistema de control 1 y del sistema de control 2.
Las 7 entradas restantes son generales y se pueden usar para diferentes fines (vea a continuación).
El valor de consigna 1 y el valor de consigna 2 de las entradas analógicas y las entradas analógicas
1-2 están aislados en sus propias conexiones a tierra de referencia.
La entrada analógica 3-9 está aislada pero comparte la misma conexión a tierra de referencia con la
alimentación de energía.
Todas las entradas analógicas pueden conectarse a señales de corriente o voltaje. Se deben
configurar la función y el punto cero y máximo de la entrada (vea AS5.2.6).
Las configuraciones de las funciones se describen para cada función en AS6.5 para la realimentación
de velocidad analógica, en AS6.6 para la limitación de potencia, en AS6.12 para la presión de
Shredder (Triturador), en AS6.13 para Synchro offset (Compensación de sincronización) y en AS6.14
para pressure control (control de presión).
Ejemplo de configuración en cero y punto máximo:

Valor de consigna de velocidad con una señal 0-10V para el sistema de control 1. 10 V corresponde
al 100% de velocidad, parámetro AIA01=0-10V.
Monitoree la señal en REG101 (vea AS5.2.20).

Conecte una señal de 0 V a los terminales para la entrada analógica 1 (+ al terminal AI1:5 y – al
terminal AI1:6).
Ajuste el parámetro AIA02 hasta que la lectura cambie de 1% a 0%.
Conecte una señal de 10V a los terminales.
Ajuste el parámetro AIA03 hasta que la lectura cambie de 99% a 100%.
Repita los ajustes para 0 y 10V hasta que se logre la lectura correcta. Como prueba, controle que la
lectura en 5.0V (50%) sea 50%.
Entrada analógica 4 con una señal 4-20mA para limitación de potencia sistema de control 1. 20 mA
corresponde a 200A, parámetro AII01=4-20mA y AII06=A
Vea AS6.6 para las configuraciones de limitación de potencia.

Monitoree la señal en REG403 (vea AS5.2.20).
Conecte una señal 4mA a los terminales para la entrada analógica 3 (+ al terminal AI2:7 y – al
terminal AI2:8).
Ajuste el parámetro AII02 hasta que la lectura cambie de 1A a 0A.
Conecte una señal de 20mA a los terminales.
Ajuste el parámetro AII03 hasta que la lectura cambie de 199A a 200A.
Repita los ajustes para 4 y 20mA hasta que se logre la lectura correcta. Como prueba, controle que la
lectura en 12mA (50%) sea 100A.
6.9 Entradas digitales

Las entradas digitales en los terminales EI1, DI1, DI2, DI3, DI4, DI5 son todas funciones de 24VCC y
están preconfiguradas como se muestra en la lista de terminales en AS3.7:
-Entradas de motor eléctrico arrancado
-Señales de entrada desde la unidad de potencia
-Entradas configurables
-Alimentación para las entradas
6.9.1 Entradas de motor eléctrico arrancado
Las entradas de motor eléctrico arrancado sirven para puentear la alarma de presión de cebado en la
parada del motor eléctrico y prevenir el envío de corriente de control a las bobinas de la bomba en la
parada. También controlan el control de enfriamiento cuando se usa un
transductor de temperatura analógico.
6.9.2 Entradas configurables
Las entradas digitales configurables se pueden usar para control y monitoreo.
Función: A=Alarma, W=Advertencia, C=Control
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Abreviatura Descripción Estado Función

normal de la
entrada
01 H APR P1 Función de monitoreo de presión alta del lado A para bomba 1 Alta, baja a W
Para monitorear la presión alta de la bomba en dirección de presión alta
avance.
01 H BPR P1 Función de monitoreo de presión alta del lado B para bomba 1 Alta, baja a W
Para monitorear la presión alta de la bomba en dirección de presión alta
reversa.
01 H APR P2 Función de monitoreo de presión alta del lado A para bomba 2, Alta, baja a W
vea 01 H APR P1 presión alta
01 H BPR P2 Función de monitoreo de presión alta del lado B para bomba 2, Alta, baja a W
vea 01 H BPR P1 presión alta
02 H APR D1 Función de monitoreo de presión alta del lado A para el sistema Alta, baja a W
de control 1 presión alta
Para monitorear la presión alta del sistema de control en
dirección de avance.
02 H BPR D1 Función de monitoreo de presión alta del lado B para el sistema Alta, baja a W
de control 1 presión alta
Para monitorear la presión alta del sistema de control en
dirección de reversa.
02 H APR D2 Función de monitoreo de presión alta del lado A para el sistema Alta, baja a W
de control 2, presión alta
vea 02 H APR D1
02 H BPR D2 Función de monitoreo de presión alta del lado B para el sistema Alta, baja a W
de control 2, presión alta
vea 02 H BPR D1
02 H APR 12 Función de monitoreo de presión alta del lado A para los Alta, baja a W
sistemas de control 1 y 2, presión alta
vea 02 H APR D1
02 H BPR 12 Función de monitoreo de presión alta del lado B para los Alta, baja a W
sistemas de control 1 y 2, presión alta
vea 02 H BPR D1
03 C PRA P1 Función de monitoreo de presión de cebado baja del lado A Alta, baja a A
para bomba 1 presión baja
Para monitorear la presión de cebado baja de la bomba en
dirección de avance.
03 C PRB P1 Función de monitoreo de presión de cebado baja del lado B Alta, baja a A
para bomba 1 presión baja
Para monitorear la presión de cebado baja de la bomba en
dirección de reversa.
para bomba 2, presión baja
vea 03 C PRA P1
vea 03 C PRA P2
vea 03 C PRA P1
vea 03 C PRA P2
vea 03 C PRA P1
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04-04-02
para bomba 4, vea 03 C PRA P2 presión baja
04 C PRA D1 Función de monitoreo de presión de cebado baja del lado A Alta, baja a A
para el sistema de control 1 presión baja
Para monitorear la presión de cebado baja del sistema de
control en dirección de reversa.
04 C PRB D1 Función de monitoreo de presión de cebado baja del lado B Alta, baja a A
para el sistema de control 1 presión baja
Para monitorear la presión de cebado baja del sistema de
control en dirección de reversa.
04 C PRA D2 Función de monitoreo de presión de cebado baja del lado A Alta, baja a A
para el sistema de control 2, presión baja
vea 04 C PRA D1
04 C PRB D2 Función de monitoreo de presión de cebado baja del lado B Alta, baja a A
para el sistema de control 2, presión baja
vea 04 C PRB D2
05 SUCTION1 Monitoreo de la línea de succión para la bomba 1 Alta, baja con A
Para monitorear el indicador de la línea de succión cerrada la línea de
aceite cerrada
05 SUCTION2 Monitoreo de la línea de succión para la bomba 2, Alta, baja con A
vea 05 SUCTION1 la línea de
aceite cerrada
05 SUCTION3 Monitoreo de la línea de succión de la bomba 3, Alta, baja con A
aceite cerrada
05 SUCTION4 Monitoreo de la línea de succión para la bomba 4, Alta, baja con A
aceite cerrada
06 RF 75P1 Monitoreo del filtro de retorno para la bomba 1 obstruido a 3/4 Alta, baja con W
Para monitorear el filtro obstruido a 3/4. filtro obstruido
Aplicable únicamente cuando se usan dos indicadores de nivel
de filtro.
06 RF 100P1 Monitoreo del filtro de retorno para la bomba 1 completamente Alta, baja con W/(A)
obstruido filtro obstruido
Para monitorear filtro completamente obstruido (debe ser
cambiado)
06 RF 75P2 Monitoreo del filtro de retorno para la bomba 2 obstruido a 3/4, Alta, baja con W
vea 06 RF 75P1 filtro obstruido
obstruido, filtro obstruido
vea 06 RF 100P1
vea 06 RF 100P1
vea 06 RF 100P1
06 DRF 75 Monitoreo del filtro de drenaje obstruido a 3/4, vea Alta, baja con W
06 RF 75P1 filtro obstruido
06 DRF 100 Monitoreo del filtro de drenaje completamente obstruido, Alta, baja con W/(A)
06 F TEMP Entradas de advertencia de enclavamiento de filtro Alta, baja con W
Usadas cuando el enclavamiento de temp. externa deseada temp. superior
para el filtro funciona al valor de
consigna
07 LO LEVEL Monitoreo de nivel de aceite bajo para tanque Alta, baja W
Monitorea el nivel de aceite bajo en el tanque PU cuando es
inferior al nivel
de consigna
07 MN LEVEL Monitoreo de nivel mín. de aceite para tanque Alta, baja A
Monitorea el nivel mín. de aceite en el tanque PU cuando es
inferior al nivel
de consigna
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08 MAX TEMP Monitoreo de la temperatura máx. del aceite para el tanque Alta, baja A
Monitorea la temperatura máx. de consigna en el tanque PU cuando es
superior a la
temp. de
consigna
08 HI TEMP Monitoreo de la temperatura del aceite alta para el tanque Alta, baja W
Monitorea la temperatura alta de consigna en el tanque PU cuando es
superior a la
temp. 1
08 MIN TEMP Monitoreo de la temperatura del aceite baja para el tanque Alta, baja A
Monitorea la temperatura baja de consigna en el tanque PU cuando es
inferior a la
temp. de
consigna
09 ALARM R Reinicio remoto de alarmas y advertencias Baja, C
Alta=Reinicio
09 BUS R Reinicio de alarmas y advertencias mediante bus Alta=Reinicio C
mediante bus
09 BUS 1 Cambiar a señales de comando de Bus, Sistema de control 1 Alta=Sistema C
de control 1 de
bus
09 BUS 2 Cambiar a señales de comando de Bus, Sistema de control 2 Alta=Sistema C
de control 2 de
bus
09 BUS M Cambiar a señal de comando de Bus, External master (Maestro Alta=maestro C
externo) ext. de Bus
10 SHR A D1 Parada de Shredder (Triturador) en avance, Sistema de Alta, baja en la C
control 1 parada
10 SHR B D1 Parada de Shredder (Triturador) en reversa, Sistema de Alta, baja en la C
control 1 parada
10 SHR A D2 Parada Shredder (Triturador) en avance, Sistema de control 2 Alta, baja en la C
parada
10 SHR B D2 Parada de Shredder (Triturador) en reversa, Sistema de Alta, baja en la C
control 2 parada
10 SHR 1+2A Parada de Shredder (Trirurador) en avance, Sistemas de Alta, baja en la C
control 1 y 2 parada
10 SHR 1+2B Parada de Shredder (Trirurador) en avance, Sistemas de Alta, baja en la C
control 1 y 2 parada
10 INTERV1 Control de intervalo de shredder (triturador), Sistema de Alta=Intervalo C

control 1
10 INTERV2 Control de intervalo de shredder (triturador), Sistema de Alta=Intervalo C
control 2
10 SH RES 1 Reinicio externo de la función Shredder (triturador) bloqueada, Alta=Reinicio C
10 SH RES 2 Reinicio externo de la función Shredder (Triturador) bloqueada, Alta=Reinicio C
10 SH RES12 Reinicio externo de la función Shredder (Triturador) bloqueada, Alta=Reinicio C
Sistemas de control 1 y 2
11 PL1 Activar la limitación de potencia para el Sistema de control 1 Alta= Límite de C
potencia
11 PL2 Activar la limitación de potencia para el Sistema de control 2 Alta= Límite de C
potencia
12 RES EN 1 Activación externa del reinicio del contador en modo Synchro Alta=Activa la C
(Sincronizar), Sistema de control 1 entrada de
reinicio
12 RES EN2 Activación externa del reinicio del contador en modo Synchro Alta=Activa la C
(Sincronizar), Sistema de control 2 entrada de
reinicio
12 FRICTION Sistema de control de fricción en modo contador Synchro Alta=Sistema C
(Sincronizar) de control de
fricción
12 INV M Inversión de comando de velocidad maestro en modo Synchro Alta=Inversión C
(Sincronizar), Sistema de control 1 del comando
de velocidad
13 AUX 1 Conectado a la entrada auxiliar de monitoreo 1 Alta, baja para A/W/I
indicación

indicación

indicación
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13 AUX 4 Conectado a la entrada auxiliar de monitorero 4 Alta, baja para A/W/I

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación

indicación
14 START 1 Arranque del sistema de control en modo Remote (Remoto), Alta=Arranque C
14 START 2 Arranque del sistema de control en modo Remote (Remoto), Alta=Arranque C
14 START 12 Arranque de sistema de control en modo Remote (Remoto), Alta=Arranque C
Sistemas de control 1 y 2
14 L START1 Arranque del sistema de control en modo Local (Local), Sistema Impulso C
de control 1 alto=Arranque
14 L STOP1 Parada del sistema de control en modo Local (Local), Sistema Alta, impulso C
de control 1 bajo=parada
14 L START2 Arranque del sistema de control en modo Local (Local), Sistema Impulso C
de control 2 alto=Arranque
14 L STOP2 Parada del sistema de control en modo Local (Local), Sistema Alta, impulso C
de control 2 bajo=parada
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15 FORW 1 Sistema de control en avance con velocidad fija, Sistema de Alta=Avance C

control 1
15 REV 1 Sistema de control en reversa con velocidad fija, Sistema de Alta=Reversa C
control 1
15 FORW 2 Sistema de control en avance con velocidad fija, Sistema de Alta=Avance C
control 2
15 REV 2 Sistema de control en reversa con velocidad fija, Sistema de Alta=Reversa C
control 2
15 FORW 1+2 Sistema de control en avance con velocidad fija, Sistema de Alta=Avance C
control 1 y Sistema de control 2
15 REV 1+2 Sistema de control en reversa con velocidad fija, Sistema de Alta=Reversa C
control 1 y Sistema de control 2
15 L REV 1 Sistema de control en Reversa Local con velocidad fija, Sistema Alta=Reversa C
de control 1
15 L FORW 1 Sistema de control en Avance Local en modo manual, Sistema Alta=Avance C
de control de Shredder (Triturador) 1
15 L REV 2 Sistema de control en Reversa Local con velocidad fija, Sistema Alta=Reversa C
de control 2
15 L FORW 2 Sistema de control en Avance Local en modo manual, Sistema Alta=Avance C
de control de Shredder (Triturador) 2
15 INV 1 Inversión del comando de velocidad en sistema de control Alta=Inversión C
unidireccional, Sistema de control 1 del comando
de velocidad
15 INV 2 Inversión del comando de velocidad en sistema de control Alta=Inversión C

unidireccional, Sistema de control 2 del comando
de velocidad
16 SP UP1 Aumentar el valor de consigna en modo Local, Sistema de Impulso alto = C
control 1 aumenta el 1%
16 SP DN1 Reducir el valor de consigna en modo Local, Sistema de Impulso alto = C

control 1 se reduce el
1%
16 SP UP2 Aumentar el valor de consigna en modo Local, Sistema de Impulso alto = C

control 2 aumenta el 1%
16 SP DN2 Reducir el valor de consigna en modo Local, Sistema de Impulso alto = C

control 2 se reduce el
1%
16 SP RES1 Reinicio del valor de consigna en modo Local, Sistema de Impulso alto = C
control 1 reinicio
16 SP RES2 Reinicio del valor de consigna en modo Local, Sistema de Impulso alto = C
control 2 reinicio
16 REM 1 Modo Remoto, Sistema de control 1 Alta=Remoto C
Baja=Local
16 REM 2 Modo Remoto, Sistema de control 2 Alta=Remoto C
Baja=Local
16 REM 1+2 Modo Remoto, Sistemas de control 1 y 2 Alta=Remoto C
Baja=Local
17 AUTO 1 Modo automático de Triturador, Sistema de control 1 Alta=Auto C
Baja=Manual
17 AUTO 2 Modo automático de Triturador, Sistema de control 2 Alta=Auto C

Baja=Manual
17 AUTO 1+2 Modo automático de Triturador, Sistemas de control 1 y 2 Alta=Auto C

Baja=Manual
18 REG 1 Realimentación de velocidad de bucle cerrado activa, Sistema Alta=Activa C
de control 1 Baja=Bucle
abierto
18 REG 2 Realimentación de velocidad de bucle cerrado activa, Sistema Alta=Activa C
de control 2 Baja=Bucle
abierto
18 REM 1+2 Realimentación de velocidad de bucle cerrado activa, Sistemas Alta=Activa C

de control 1 y 2 Baja=Bucle
abierto
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18ERR1 RES Reinicio de la función error too large (error demasiado grande), Impulso alto = C
Sistema de control 1 reinicio
18ERR2 RES Reinicio de la función error too large (error demasiado grande), Impulso alto = C
Sistema de control 2 reinicio
18ERR1+2R Reinicio de la función error too large (error demasiado grande), Impulso alto = C
Sistemas de control 1 y 2 reinicio
19 EMOTOR 1 Función de monitoreo de temp. alta de motor eléctrico 1 Alta=Temp. A

OK

OK

OK
20 PR REM 1 Valor de consigna remoto de control de presión, sistema de Alta=Remoto C

control 1 Baja=Local
20 PR REM 2 Valor de consigna remoto de control de presión, Sistema de Alta=Remoto C

control 2 Baja=Local
20 PR HI 1 Configurar la salida de control de presión al nivel de aceleración Alta=Salida C

máx., Sistema de control 1 máx.
Baja=Control
normal
20 PR LO 1 Configurar la salida de control de presión al nivel de Alta=Salida C

desaceleración máx., Sistema de control 1 mín.
Baja=Control
normal
20 PR ON 1 Activación de la función de control de presión, Sistema de Alta=Activa C

control 1 Baja=No se
usa
20 PR HI 2 Configura la salida de control de presión al nivel de aceleración Alta=Salida C

máx., Sistema de control 2 máx.
Baja=Control
normal
20 PR LO 2 Configura la salida de control de presión al nivel de Alta=Salida C

desaceleración máx., Sistema de control 2 mín.
Baja=Control
normal
20 PR ON 2 Activación de la función de control de presión, Sistema de Alta=Activa C

control 2 Baja=No se
usa
21 OFF No se usa
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6.10 Salidas digitales

6.10.1 Salidas del enclavamiento del motor eléctrico
Las salidas del enclavamiento del motor eléctrico deben estar conectadas mediante un relé de
24VCC al circuito eléctrico de parada del arrancador. La salida es alta cuando se le permite operar el
motor eléctrico y se abre a causa de una alarma, de que se abra la entrada de la parada de
emergencia, o del control del microprocesador (controla la función del programa).
Los relés de salida son monitoreados para detectar fallas en los contactos de relé. Cuando se
enciende el sistema y cuando se paran todos los motores E, los relés serán probados si la entrada de
la parada de emergencia no está abierta. Para evitar alarmas erróneas de los relés, éstos serán
puestos en on y off 5 veces para eliminar la oxidación de los contactos antes de la prueba.
6.10.2 Salidas configurables

Las salidas digitales configurables se pueden usar para control y monitoreo, configuradas con el
parámetro DOx01.
Las siguientes funciones son comunes para todas las salidas
1 Indicación únicamente desde el sistema de control 1
2 Indicación únicamente desde el sistema de control 2
1+2 Indicación únicamente desde el sistema de control 1 o desde el sistema de control 2
1*2 Indicación de que el sistema de control 1 y el sistema de control 2 están afectados
1...x La misma función para todas las salidas con el número 1 a x
Función de salida
Abreviatura Función Estado normal de la salida
01 A(1,2, 1+2) Monitoreo de alarma común Abierta, cerrada al momento de
la alarma
01 W(1,2, 1+2) Monitoreo de advertencia común Abierta, cerrada al momento de
la advertencia
01 INT(1, 2, 1+2) Monitoreo de enclavamiento común Abierta, cerrada al momento
del enclavamiento
02 START(1, 2, 1+2, 1*2) Sistema de control arrancado Abierta, cerrada al momento
del arranque
03 READY(1, 2, 1+2, 1*2) Sistema de control listo para usar después del retardo de Abierta, cerrada cuando está
arranque listo
04 REMOTE(1, 2) Sistema de control modo remoto Abierta, cerrada, en modo
remoto
05 AUTO(1, 2) Triturador en modo automático del sistema de control. Abierta, cerrada en modo
automático
05 REG(1, 2) Sistema de control con realimentación de velocidad Abierta, cerrada en modo
regulada. regulado
06 PLIM(1, 2, 1+2) Límite de potencia activo Abierta, cerrada en limitación
activa
07 FORW(1, 2) Sistema de control operando con comando de avance Abierta, cerrada operando
en avance
07REV(1, 2) Sistema de control operando con comando de reversa Abierta, cerrada operando
en reversa
08 C ZERO Contadores en reinicio de función contador Synchro Abierta, cerrada en
(Sincronizar) y función sincronizar activada sincronización activada
08 SYNCHRO Sincronización dentro de los límites de consigna. Abierta, cerrada cuando está
dentro de los límites
09 AOUT(1...4) El registro para una salida analógica tiene un signo Abierta, cerrada cuando es
negativo negativo
10 EMOTD(1, 2, 1+2, 1*2) Motores eléctricos arrancados Abierta, cerrada cuando están
arrancados
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11 LOW TEMP Indicación para temp. mín. del aceite activa Abierta, cerrada cuando está
activa
11 HI TEMP Indicación para temp. alta del aceite activa Abierta, cerrada cuando está
activa
11 MAX TEMP Indicación para temp. máx. del aceite activa Abierta, cerrada cuando está
activa
11 COOL CONI Enfriamiento del arranque enclavado con el motor eléctrico Abierta, cerrada para
arrancado enfriamiento
(con sensor analógico de temperatura)
11 COOL COND Enfriamiento del arranque controlado directamente desde Abierta, cerrada para
el sensor de temp. enfriamiento
(con sensor analógico de temperatura)
11 HEAT CON Calentamiento del arranque (con sensor analógico de Abierta, cerrada para
temperatura) calentamiento
11 FLUSHCON Circuito de control de lavado (con sensor analógico de Abierta para enfriamiento,
temperatura) cerrada para calentamiento
12 P(1, 2) C ACT Control de presión de la salida activo Abierta, cerrada en el control

de presión
12 P(1, 2) HI CA Control de presión alta de la salida activo Abierta, cerrada en el control

de presión
12 P(1, 2) LO CA Control de presión alta de la salida activo Abierta, cerrada en el control

de presión
13 SH BLCK(1, 2) Triturador bloqueado en modo automático Abierta, cerrada cuando está

bloqueada
14 AUX(1...20) Función auxiliar activa Abierta, cerrada cuando está

activa
15 OFF Salida no usada
6.10.3 Función invertida

Una salida puede pasar de función invertida a estado normal configurando el parámetro DOx02 en
yes (sí).
6.10.4 Función retardada

Una salida puede recibir un retardo de tiempo por el parámetro DOx04. El tiempo del retardo se
configura con el parámetro DOx03.
La función se puede configurar en:
ON Retardo en On Desde el momento en que se activa la función para la salida, ésta no estará
activa hasta que haya pasado el tiempo de retardo.
OFF Retardo en Off Desde el momento en que se desactiva la función para la salida, ésta no estará
inactiva hasta que haya pasado el tiempo de retardo.
IMPULSO Impulso de salida Desde el momento en que se activa la función para la salida, ésta estará activa
únicamente durante el tiempo de retardo.
OFF Sin retardo
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6.11 Monitoreo de señales

El monitoreo de señales es la lectura de los valores de proceso (REGxx) indicados con un marco en
los diagramas de bloques, vea AS7. Es posible seleccionar y monitorear 4 valores fijos y una lista de
desplazamiento de hasta 9 valores en cada pantalla. Las posibles configuraciones se encuentran en
AS5.2.20 y se configuran en la Lectura 1(2).
Las lecturas se pueden usar para mostrar valores de proceso durante el funcionamiento del sistema
de control, pero también pueden usarse para solucionar fallas. Los valores internos normalmente se
indican como un valor de %
6.11.1 Indicación del valor de consigna

El valor de consigna para la velocidad se puede indicar como un valor de % con REG102(202). Si
debe indicarse el valor de consigna como un valor rpm, éste puede monitorearse con REG107(207).
Para esta indicación, el parámetro D1(2)E01 debe ser configurado en la velocidad correspondiente al
comando del 100%.
6.11.2 Indicación de entrada analógica

Las entradas analógicas pueden ser indicadas con REG 40x donde x representa el número de
entrada entre 1 y 9, p. ej., REG 405 para la entrada analógica 5. Para cada entrada, las unidades
pueden configurarse con el parámetro AIx06, y la cantidad de decimales con el parámetro AIx07. La
lectura también puede ser escalada para adaptarse p. ej., a una velocidad de transportador con el
parámetro AIx08.
6.11.3 Indicación de entrada de bus analógica

Las entradas analógicas desde el fieldbus pueden indicarse con REG 50x, donde x representa el
número de entrada entre 1 y 4, p. ej., REG 502 para la entrada analógica 2. Para cada entrada, las
unidades pueden configurarse con el parámetro BAx03, y la cantidad de decimales con el parámetro
BAx04.
6.11.4 Indicación de temperatura

Un sensor analógico de temperatura A PT100 puede indicarse con REG 410. La temperatura por lo
general se indica en °C. Si la unidad se cambia a °F la lectura se calcula automáticamente.
6.11.5 Indicación de salida

Para los controles de la bomba, la corriente a la bobina puede indicarse en mA con REG3x1, donde x
representa el número de bomba p.ej., REG 321 para la bomba 2.
6.11.6 Indicaciones internas

Las indicaciones internas pueden usarse para solucionar fallas o como indicaciones durante la
configuración.
Registro Función Lectura
REG 101(201) Comando de entrada % o señal real
REG102(202) Valor de consigna de velocidad %
REG107(207) Valor de consigna de velocidad rpm
REG103(203) Comando de entrada %
REG104(204) Comando con rampa %
REG108(208) Comando con rampa rpm
REG105(205) Señal de error de velocidad %
REG106(206) Amplificador de entrada a salida %
REG110(210) Señal de velocidad %
REG111(211) Comando de presión %
REG112(212) Comando de presión regulada %
REG113(213) Compensación de presión %
REG114 Comando maestro %
REG115(215) Ángulo de parada °
REG 310 Comando de bomba 1 %
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6.11.7 Lecturas de diagnóstico

Las lecturas de diagnóstico pueden usarse para controlar la carga del microcontrolador.
REG 901 Tiempo para la tarea de la PC interna (ms)
REG 902 Tiempo máx. para la tarea de la PC interna (ms)
REG 903 Tiempo para la tarea de la UI (interfase de usuario)
interna (ms)
REG 904 Tiempo máx. para la tarea de la UI interna (ms)
REG 905 Carga de la CPU (%)
REG 906 Carga máx. de la CPU (%)
REG 907 Uso de pilas, tarea de la PC (%)
REG 908 Uso de pilas, tarea de la UI (%)
REG 909 Uso de pilas, puerto serie (%)
REG 911 Resistencia calculada, bomba 1 (ohmios)
6.11.8 Lecturas del bus

Las lecturas del bus se usan para indicar las entradas digitales desde el fieldbus.
REG 511 Entradas digitales 1-8
6.11.9 Menú de desplazamiento

Para cada lectura de la lista de desplazamiento, es posible configurar un texto y un REG. El texto y el
REG se mostrarán en la misma línea.
La lista de desplazamiento es activada por ◄ para la pantalla izquierda y por ►para la pantalla
derecha, y la lista activa se indica con dos flechas en la lista de desplazamiento. El desplazamiento
se realiza con ▲ o ▼ y únicamente se mostrarán las indicaciones activadas.
El desplazamiento se activará 10 s después de que se use ▲ o ▼ y deben ser activados nuevamente
para el desplazamiento
Ejemplo:
Temp. del tanque y transductor de presión en la entrada analógica en 3 indicados en la pantalla 2:
R2A01 - TANK TEMP (R2A01 - Temp. del tanque)
R2A02 – REG401
R2A03 – PRESSURE (R2A03 – Presión)
R2A04 – REG403
Dará:
→ TANK TEMP 37.8ºC (Temp. del tanque 37.8ºC) ←
PRESSURE 143bar (Presión 143bar)
▲ o ▼ se alterará entre estas dos lecturas.
6.11.10 Indicación de ángulo de parada de emergencia

El ángulo de movimiento del cilindro entre la parada de emergencia activada y la parada real puede
ser indicado en ° con REG115(215). Esta función requiere codificador digital de velocidad.
6.12 Triturador
La selección de la función Triturador (shredder) se realiza configurando el parámetro MAA01 en
SHREDDER (vea AS6.1).
Los parámetros específicos se encuentran en SETUP – SHREDDER 1(2) (CONFIGURACIÓN –
TRITURADOR).
En Triturador están disponibles todas las características descritas en 6.1.- 6.11, excepto por la
posibilidad de cambiar entre sistema de control con y sin regulación de velocidad. La selección de la
regulación de velocidad debe configurarse con el parámetro SHA(G)10.
Las funciones adicionales son para las reversas a causa de un sistema de control sobrecargado.
El triturador tiene dos modos del sistema de control: manual y automático.
En el modo manual del sistema de control, el botón de avance (o por entrada configurable establecida
en L FORW1(2)) se utiliza para avanzar y el botón de reversa (o por entrada configurable establecida
en L REV1(2)) se utiliza para funcionar en reversa. El sistema de control funcionará mientras la
entrada esté activada y parará cuando se abra la entrada. La función de reversa se puentea en el
sistema de control manual.
En el modo automático del sistema de control, el botón de arranque (o por entrada configurable
establecida en L START1(2)) hace arrancar el sistema de control con la función de reversa
automática y para con el botón de parada (o por entrada configurable establecida en L STOP1(2)). Se
puede usar una entrada digital configurable para arrancar en modo remoto.
El cambio entre el modo manual y el modo automático se realiza con el botón MAN/AUT o con una
entrada digital configurable (que puentea el botón).
Se puede usar una salida digital para indicación del modo automático.
6.12.1 Valor de consigna de velocidad

El valor de consigna de velocidad de avance se maneja conforme se describe en AS6.2, pero debe
ser una señal positiva. El valor de consigna de velocidad de reversa puede ser el valor de consigna
de avance invertido escalado con el parámetro SHB(H)02 (p. ej., reverse always 50% of forward
speed (velocidad de reversa siempre 50% de velocidad de avance)) o un comando fijo configurado
con el parámetro SHB(H)01 y SETUP – DRIVE 1(2) BASIC: D1(2)A05 (CONFIGURACIÓN –
SISTEMA DE CONTROL 1(2) BÁSICA: D1(2)A05).
6.12.2 Detección de sobrecarga

La detección del sistema de control sobrecargado se realiza con el parámetro SHA(G)01. Se puede
seleccionar entre:
-Interruptores de presión que se abren a alta presión
-Codificador de velocidad para detectar el sistema de control parado
-Un transductor de presión en un puerto de presión común para ambas direcciones
6.12.3 Contador de reversas

La cantidad de reversas dentro de un intervalo de tiempo limitado se puede configurar con el
parámetro SHC(I)01 y 02 para parar el sistema de control. Si no se quiere la función, se puede
configurar el intervalo de tiempo en 1. Si se alcanza la configuración del contador, el sistema de
control pasará a manual y aparecerá el texto de advertencia SHREDDER BLOCKED (TRITURADOR
BLOQUEADO) en la lista de alarmas/advertencias. Se debe reiniciar la advertencia antes de que sea
posible el arranque automático. La advertencia también puede reiniciarse mediante una entrada
digital configurable.
6.12.4 Bloqueo de reversas

La función "si el sistema de control se bloquea durante la reversa del sistema de control", puede
configurarse con el parámetro SHA(G)02.
Si se selecciona 1 (Parar), aparecerá el mismo resultado que si se hubiera alcanzado la configuración
del contador.
Si se configura 2 (Avanzar), el sistema de control cambiará nuevamente a sistema de control en
avance sin interrupción.
6.12.5 Temporizador de intervalos

Una función para un intervalo de avance/reversa preconfigurado puede activarse con el parámetro
SHA(G)07 o con una entrada digital configurable establecida en INTERV 1(2).
El tiempo de avance del sistema de control se configura con el parámetro SHA(G)08, y el tiempo de
reversa del sistema de control se configura con el parámetro SHA(G)09.
6.13 Sincronizar
La configuración de la función Synchro (Sincronizar) se encontrará en los siguientes menús de
parámetros
"Synchro - Function" (Sincronizar - Función)
"Synchro - Drive 1 reset" (Sincronizar - Reinicio del sistema de control 1)
"Synchro - Drive 2 setpoint" (Sincronizar - Valor de consigna del sistema de control 2)
"Synchro - Drive 2 indication" (Sincronizar - Indicación del sistema de control 2)
"Synhcro - Drive 2 reset" (Sincronizar - Reinicio del sistema de control 2)
"Synchro - External Master" (Sincronizar - Maestro externo)
"Synchro - Drive 1 setpoint" (Sincronizar - Valor de consigna del sistema de control 1)
Vea también el diagrama de bloques AS7-7.

La función Synchro (Sincronizar) se divide en dos partes: RATIO (RELACIÓN) y COUNTER
(CONTADOR). La selección se realiza con el parámetro SYA01.
6.13.1 Sistema de control de relación

La función de sistema de control de relación se selecciona con el parámetro SYA01 = RATIO. Con el
parámetro SYA02 =1, la función sistema de control de relación controla dos sistemas de control con
una relación de fricción entre los sistemas de control. El Sistema de control 1 es el maestro y el
Sistema de control 2 es el subordinado. El valor de consigna de velocidad del Sistema de control 1 se
multiplica por el valor de consigna de relación del Sistema de control 2 creando el comando de
velocidad del Sistema de control 2. El valor de consigna de la relación puede ser un valor entre -300%
y 300%. SYC01 y SYC02 pueden usarse para limitar el rango. Los valores de consigna pueden ser
señales de hardware o señales a través de la conexión del bus. En el modo local, los valores de
consigna se proporcionan a través de las unidades de teclado y pantalla.
6.13.2 Sistema de control de relación - Maestro externo

La función de sistema de control de relación se selecciona con el parámetro SYA01 = RATIO. Con el
parámetro SYA02 =2, la función de relación de sincronización controla dos sistemas de control con
una relación de fricción independiente para cada sistema de control. El Sistema de control 1 y el
Sistema de control 2 son subordinados. El valor de consigna de velocidad de un maestro externo se
multiplica por el valor de consigna de relación del Sistema de control 1 creando el comando de
velocidad del Sistema de control 1. Lo mismo vale para el sistema de control 2. El valor de consigna
de la relación puede ser un valor entre -300% y 300%. SYC01 y SYC02 pueden usarse para limitar el
rango para el Sistema de control 2. SYG01 y SYG02 pueden usarse para limitar el rango para el
Sistema de control 1. Se puede ajustar un tiempo de rampa independiente, únicamente válido para el
valor de consigna del maestro externo, configurando SYF01 - SYF04.
Los valores de consigna pueden ser señales de hardware o señales a través de la conexión del bus.
En el modo local, los valores de consigna se proporcionan a través de las unidades de teclado y
pantalla.
6.13.3 Sistema de control de contador

La función de contador de sincronización puede controlar la posición relativa entre dos sistemas de
control. La función de sistema de control de contador se selecciona con el parámetro SYA01 =
COUNTER. La función requiere codificadores de Velocidad digitales. Deben tener una cantidad
idéntica de impulsos por vuelta. El Sistema de control 1 es el maestro y el Sistema de control 2 es el
subordinado. El valor de consigna de velocidad del Sistema de control 1 se transfiere a ambos
sistemas de control como un valor de consigna de velocidad básico. El Sistema de control 1 funciona
en control de velocidad de bucle cerrado. El Sistema de control 2 funciona en control de posición de
bucle cerrado. Los impulsos de cada codificador se cuentan en dos contadores y se comparan. Si hay
una diferencia entre los dos contadores, hay una diferencia en la posición de los dos sistemas de
control. La señal de diferencia es procesada por el regulador del Sistema de control 2 y se suma al
valor de consigna de velocidad para control de la posición del Sistema de control 2.
Los dos contadores deben reiniciarse originalmente cuando la diferencia de la posición es cero entre
los dos cilindros.
El parámetro SYB02 y SYE02 determina cuándo los contadores están activados para el reinicio.
1= Activar reinicio cada vez que se arranca el motor eléctrico
2= Activar reinicio cada vez que se activa el arranque del sistema de control
3= Activar reinicio mediante una entrada digital configurable, establecida en 12 RES EN 1(2)
Los parámetros SYB01 y SYE01 determinan cuándo/cómo deben reiniciarse los contadores.
1= Reiniciar cada vez que se activa el arranque del sistema de control
2= Reiniciar mediante la activación de la entrada de impulso cero externa
El control de la posición del sistema de control 2 se activa cuando se reinician ambos contadores. El
tiempo de rampa se puede ajustar para alcanzar una sincronización uniforme; esto se realiza con el
parámetro SYD02. La activación del regulador se puede indicar con una salida digital, establecida en
08 C ZERO. Mientras opera en modo de contador, el sistema de control de relación se puede activar
a través de una entrada digital configurable, establecida en 12 FRICTION. La entrada puede ser una
señal de hardware, o en modo bus, una señal del bus.
La compensación entre dos sistemas de control puede configurarse de dos maneras:

-Como valor constante con el parámetro SYC04.
-Con una entrada analógica, el rango es máximo 0 a 180°.
-A través de la conexión del bus.
6.14 Control de presión

La configuración de la función de control Pressure (Presión) se encontrará en los siguientes menús
de parámetros
"Pressure 1 - Function" (Presión 1 - Función)
"Pressure 1 - Pr.function" (Presión 1 - Función de pr.)
"Pressure 1 - Regulator" (Presión 1 - Regulador)
"Pressure 2 - Function" (Presión 2 - Función)
"Pressure 2 - Pr.function" (Presión 2 - Función de pr.)
"Pressure 2 - Regulator" (Presión 2 - Regulador)
Vea el diagrama de bloques AS7-8.

En esta sección, se describe la función de control Pressure 1 (Presión 1), las funciones de control
Pressure 1 y Pressure 2 son idénticas. La función de control Pressure (Presión) brinda una posibilidad
para compensar el valor de consigna de la velocidad según el nivel de presión en el sistema
hidráulico. Se puede usar como una protección de sobrecarga o como una función para mejorar la
producción, se puede lograr un par de torsión estable. Las salidas digitales pueden configurarse para
que indiquen si el control de presión está activo. Hay tres opciones disponibles, P1 C ACT, P1 HI CA
y P1 LO CA. Para obtener una explicación de las salidas, vea el capítulo sobre salidas digitales. El
diagrama que aparece a continuación describe la función de control de presión, acción de avance. Si
la presión aumenta, el valor de consigna de velocidad aumenta.
Alterando un parámetro, PRA02 = On, se selecciona la acción de reversa. El diagrama que aparece a
continuación describe la función de control de presión, acción de reversa. Si la presión aumenta, el
valor de consigna de velocidad disminuye.
6.14.1 Presión 1 - función

La función de control de presión se activa con el parámetro PRA01 = On. Además, el control alto y
bajo puede activarse por separado. Esto se realiza con los parámetros PRA03 y PRA04.
PRA05 y 06 determinan el retardo de tiempo que demora el arranque del control de presión.
Configura el tiempo de retardo entre un cambio de presión por encima o por debajo del valor de
consigna y el arranque de regulación.
6.14.2 Presión 1 - Valor de consigna

El valor de consigna de presión puede ser local o remoto. PRB01 selecciona si el valor de consigna
es local, remoto, o si se puede cambiar a través de una entrada digital. La entrada digital se
denomina PR REM 1. El valor de consigna remoto puede establecerse mediante entradas de
hardware o de entradas de bus. El valor de consigna local debe ingresarse en el parámetro PRB02.
PRB03 y 04 definen la banda muerta del control de presión. Cuando la presión real se encuentra
dentro del valor de consigna de Presión - PRB03 y el valor de consigna de Presión + PRB04, el
comando de velocidad no se altera. PRAB05 y 06 definen la influencia máxima que puede tener el
control de presión en el comando de velocidad. La unidad es un % y se relaciona con el rango de
velocidad total del sistema de control.
6.14.3 Presión 1 - Regulador

El regulador PID tiene un parámetro similar configurado como el control PID de realimentación de
velocidad estándar. Vea el capítulo AS6.5 para recomendaciones de ajuste.
PRC01 Configura la función de la etapa del regulador Proportional (Proporcional) en ON u OFF.
La etapa proporcional reacciona en forma proporcional a la señal de entrada de Error. La
acción de esta etapa se determina por el parámetro PRC04.
PRC02 Configura la función Integrator (Integrador) en ON u OFF. Esta función le da al sistema
de control una posibilidad para alcanzar la presión del valor de consigna con el
transcurso del tiempo. La acción de esta etapa se determina por el parámetro PRC05.
PRC03 Configura la función Derivative (Derivada) en ON u OFF. La etapa derivada se usa
cuando se esperan cambios de presión muy rápidos en el sistema de control. Reacciona
en el índice de variación en la señal de entrada de Error. La etapa D raramente se utiliza
debido a dificultades en el procedimiento de ajuste. La acción de esta etapa se configura
con los parámetros PRC06 y PRC07.
PRC04 El parámetro de ganancias Proportional (Proporcional) configura la ganancia de la etapa

P. Ganancia P 0.5 significa que la mitad del valor de la entrada de señal de Error será
transferida a la salida de la etapa. Sin embargo, la etapa Proportional (Proporcional) no
hará que el sistema de control alcance la presión del valor de consigna. Siempre existirá
un Error remanente. Sin embargo, el valor del Error remanente depende de la
configuración de la ganancia Proportional (Proporcional). Si la señal de Error es
pequeña, cercana a cero, la ganancia P no producirá ninguna salida en esta salida de
etapa. La etapa P siempre necesita una señal de Error para modificar.
PRC05 El parámetro de tiempo Integrator (Integrador) configura el tiempo de integración de la
etapa I. Un tiempo de integración de 10 segundos significa que el valor de salida de esta
etapa alcanzará el 63% del valor de la entrada de la señal de Error en 10 segundos. La
introducción de la Integration (Integración) eliminará la señal de Error remanente. La
presión real, con el transcurso del tiempo, corresponderá al valor de consigna de la
presión. Puede ser comparado con un Capacitor (Capacitor) que se carga con la señal
de Error.
PRC06 El parámetro de tiempo Derivative (Derivado) configura el tiempo Derivative (Derivado)
de la etapa D. Un tiempo Derivative (Derivado) de 10 segundos significa que la
“ganancia” de derivación es un factor 10. La salida de la etapa es el factor de “ganancia”
multiplicado por el índice de variación de la señal de Error.
PRC07 El parámetro de tiempo de declinación de Derivative (Derivado) configura el tiempo de
declinación de Derivative (Derivado) de la etapa D. Un tiempo de declinación de
Derivative (Derivado) de 10 segundos significa que el valor de salida de esta etapa
declinará un 63 % en 10 segundos.
PRC08 El tiempo de filtro para el parámetro de realimentación de presión configura el tiempo de
filtro para la presión. Esto es útil cuando la señal de presión contiene mucho ruido, dado
que el filtro eliminará los picos de presión.
6.15 Comunicación por bus

La comunicación por bus se configura en los siguientes menús
"Bus - Type & Function" (Bus - Tipo y función)
"Bus - Digital Inputs" (Bus - Entradas digitales)
"Bus - Analog in 1 - 4" (Bus - Entrada analógica 1 - 4)
"Bus - Analog out" (Bus - Salida analógica)
Vea el diagrama de bloques AS7.2 y la lista de parámetros AS5.2.8 para obtener más detalles.
6.15.1 General
La función Bus requiere la instalación de una tarjeta de bus. La tarjeta es un subordinado Profibus-DP
conforme al estándar PROFIBUS-DP EN 50 170. Debe conectarse a un Profibus-DP maestro. La
tarjeta sólo responderá a los comandos entrantes funcionando como subordinada.
La función Bus se activa cuando se activa una entrada digital o entrada de bus y se selecciona el
modo remoto con el teclado. Las entradas digitales son BUS 1 y BUS 2, estas entradas permiten
seleccionar el control de bus por separado para el sistema de control 1 y el sistema de control 2. Los
valores de consigna de velocidad se encuentran en direcciones de bus predefinidas. Vea el capítulo
AS 6.15.9. El esquema que aparece a continuación explica los posibles cambios de modo.
Si se pierde la comunicación por bus, se dispara una alarma o un enclavamiento. Un temporizador

ajustable determina el tiempo de filtro para la alarma/enclavamiento. El modo local se activa si el bus
tiene una falla. Para arrancar la comunicación por bus nuevamente, debe reiniciarse la unidad Spider
mediante el reinicio o el encendido.
6.15.2 Bus - Tipo y función

La comunicación por bus se activa configurando el parámetro BTF01 en "Profibus". BTF02 configura
el intervalo de desconexión de la comunicación. El rango del temporizador es de 0 a 10 segundos. La
función BTF03 en la pérdida de la comunicación determina si se activa una Alarma o un
Enclavamiento en una falla de bus.
6.15.3 Bus - Entradas digitales

Se pueden configurar un total de 24 entradas digitales en los parámetros BDI01 a BDI24. Las
opciones son iguales a las opciones posibles en la configuración de entradas digitales del hardware,
vea la lista en el capítulo AS5.2.3. Las siguientes opciones de dicha lista no son válidas para las
entradas de bus:
- START 12
- FORW 1+2
- REV 1+2
- REM 1+2
El estado de entradas digitales es posible para monitorear la pantalla del Spider. Los registros REG
511 a REG 513 representan el estado de las entradas. Cada registro contiene 8 señales digitales. El
valor de cada señal puede ser 0 o 1; el formato es binario.
REG/BIT 8 7 6 5 4 3 2 1
6.15.4 Bus - Entrada analógica 1 - 4

Se pueden configurar un total de 4 señales de entradas analógicas en los parámetros BAAxx a
BADxx. Los valores Mín. y Máx. se definen en BAx01 y BAx02, y proporcionan el rango de la señal.
BAx03 define el tipo de unidad y BAx04 define la cantidad de decimales para la señal. La señal ahora
está preparada para ser mostrada en pantalla. Las señales se denominan REG501 a REG 504. El
paso final consiste en definir la función. Esto se realiza con el parámetro BAx05, las configuraciones
posibles son:
- BSO = Compensación de sincronización.
- BP1 = Sistema de control del valor de consigna de presión 1
- BP2 = Sistema de control del valor de consigna de presión 2
- BMS = Valor de consigna de velocidad maestro
- OFF = No se usa (Se selecciona sólo cuando se debe mostrar la señal).
Vea las direcciones en el bus en AS6.15.9.
6.15.5 Bus - Salida analógica

Se pueden configurar un total de 8 señales de salida analógicas en los parámetros BAK01 a BAK08.
Vea la lista de parámetros para la lista de registros seleccionables y AS6.15.10 para las direcciones
en el bus.
6.15.6 Bus - Salida digital

Hay un total de 144 señales de salida digitales para que lea el maestro Profibus-DP. Las señales
están predefinidas y las direcciones del bus se describen en el capítulo AS6.15.11.
6.15.7 Tabla de direcciones - Datos entrantes

En total se reciben 16 bytes del Bus. Los datos de valores analógicos deben aparecer en el formato
de datos de "palabra con signo" que debe limitarse a un rango de valores comprendidos entre -10 000
y +10 000. Las primeras dos palabras se reservan para los valores de consigna para el sistema de
control 1 y el sistema de control 2. Las siguientes 4 palabras son las entradas analógicas
seleccionables, como se describió anteriormente. Las señales digitales están representadas por un
bit, en total para 24 entradas, 3 bytes.
Función Bit-> 7 6 5 4 3 2 1 0 Ejemplo

Byte
Valor de consigna 0 15 8 0001 1101
= 7500
sistema de control 1 1 7 0 0100 1100
Valor de consigna 2 1101 1000
= -10000
sistema de control 2 3 1111 0000
4 0010 0111
Entrada analógica 1 = 10000
5 0001 0000
6
Entrada analógica 2
7
8
9
10
11
12 7 0
Entrada digital 13 15 8
14 23 16
Reservado 15 0000 0000
Los valores analógicos se encuentran en formato de datos de "palabra con signo". Los números
negativos son el complemento 2 de los positivos. A continuación se incluye una tabla con algunos
ejemplos
Valor de palabra con signo, formato binario Valor decimal % del valor de la
señal
Byte más significativo Byte menos significativo
0010 0111 0001 0000 10000 100
1101 1000 1111 0000 -10000 -100
0001 0011 1000 1000 5000 50
1110 1100 0111 1000 -5000 -50
0000 1001 1100 0100 2500 25
1111 0110 0011 1100 -2500 -25
6.15.8 Tabla de direcciones - Datos salientes

En total se transfieren 38 bytes al Bus. Los datos de valores analógicos aparecen en el formato de
datos de "palabra con signo", limitado a un rango de valores comprendido entre -10 000 y +10 000. La
primera palabra se reserva para la versión del protocolo, la segunda, para la versión del software. Las
siguientes 8 palabras son las salidas analógicas seleccionables, como se describió anteriormente.
Los últimos 18 bytes son las salidas digitales. Las señales digitales están representadas por un bit, en
total para 144 salidas, 18 bytes. Las direcciones de salidas digitales se describen por separado en el
capítulo 6.15.11.
Función Bit-> 7 6 5 4 3 2 1 0 Ejemplo

Byte
0 0000 0000 Reservado
Versión del protocolo
1 3 0 3 0 0001 0000 = vea 1.0
2 3 0 3 0 0011 0001
Versión del software = vea 3.1.2
3 7 0 0000 0010
4 15 8 0000 1001
Salida analógica 1 = 2500
5 7 0 1100 0100
6
Salida analógica 2
7
8
Salida analógica 3
9
10
Salida analógica 4
11
12
Salida analógica 5
13
14
Salida analógica 6
15
16
Salida analógica 7
17
18
Salida analógica 8
19
20 7 0
Salida digital
21 15 8
…
…
…
37 143 136
05-01-21
reemplaza
04-04-02
6.15.9 Tabla de direcciones de salidas digitales




DB20 a DB25 son señales que se encuentran en la lista de funciones disponibles para las salidas
digitales, descritas en AS6.10.
DB26 a DB37 son, en parte, señales que se encuentran en la lista de funciones disponibles para las
entradas digitales de relé, descritas en AS6.9.
6.16 Registro de monitoreo del sistema de control

El registro de monitoreo del sistema de control está compuesto por tres partes: listas de
alarmas/advertencias, contadores de tiempo del sistema de control y 8 canales de registro
escalables. Las listas de alarmas/advertencias y los contadores de tiempo del sistema de control
se pueden indicar en la pantalla del sistema de control 1. La información de registro total del
sistema de control debe descargarse a una PC para su examen. Esto requiere un cable módem
nulo 576 00xx-801, una PC con Windows XP y el software de SpiderCom instalado.
Las listas de alarma se encuentran en el menú bajo LOG READINGS – DRIVE 1 – ALARM
(LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ALARMA) y LOG READINGS –
DRIVE 2 – ALARM (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2 – ALARMA).
Las listas de advertencia se encuentran en el menú bajo LOG READINGS – DRIVE 1 –
WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ADVERTENCIA) y LOG
READINGS – DRIVE 2 – WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2
– ADVERTENCIA).
Las cuatro listas tienen una extensión de 10 alarmas o advertencias. La más reciente se
encontrará en la parte superior y cuando ingrese una nueva advertencia o alarma a una lista que
ya se encuentra llena, se eliminará la más antigua. Las alarmas y advertencias están marcadas
con la fecha y la hora del incidente. Para configurar la hora real, vea HORA/FECHA a
continuación.
Los contadores de tiempo del sistema de control se encuentran en el menú bajo LOG READINGS
– DRIVE 1 – TIME IN USE (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 –
TIEMPO EN USO) y LOG READINGS – DRIVE 2 – TIME IN USE (LECTURAS DEL REGISTRO
– SISTEMA DE CONTROL 2 – TIEMPO EN USO). Los contadores son DRIVE (SISTEMA DE
CONTROL) (el tiempo con el sistema de control arrancado) y PUMPS (BOMBAS) (el tiempo con
motor eléctrico arrancado para cada bomba). Los contadores pueden reiniciarse, vea REINICIAR
TIEMPO a continuación.
Las configuraciones para el registro de monitoreo del sistema de control, el reloj y el reinicio de
los contadores de tiempo se realizan en SETUP – DRIVE LOG (CONFIGURACIÓN – REGISTRO
DE SISTEMA DE CONTROL) y están protegidas por una contraseña. Las contraseñas sólo
pueden realizarse desde el teclado frontal.
TIME/DATE (HORA/FECHA) es para configurar la fecha y hora reales. El formato es AAMMDD

HH:MM y se selecciona con el botón > y se cambia con los botones ∧ y ∨. La fecha/hora se utiliza
para las marcas de la hora en la lista de alarmas y advertencias. El reloj cuenta con respaldo de
baterías.
LOG1 a LOG 8 son para configurar uno de los ocho canales de registro de monitoreo del sistema
de control escalables dimensionales.
Las entradas analógicas utilizadas deben configurarse antes de configurar los canales de
registro, vea AS6.8.
Cada canal consiste en un área de medición dividida en 6 niveles. Se almacena el tiempo que la
lectura medida se encuentra dentro de cada uno de estos niveles. La medición sólo está activa
con el sistema de control arrancado. El tiempo total de medición es de 100 000 horas.
Paralelamente con el registro total de tiempo, se almacenan 4 registros más cortos con la misma
configuración del total en orden cronológico. El tiempo de registro es ajustable.
Ejemplo:
- Canal de registro 2
- Transductor de presión, 0-400 bar en Ain 4.
- Tiempo de medición de períodos de 200 horas
1.Configuración de entradas analógicas:

AII01=4-20mA para el tipo de señal de entrada.
AII02,03 para el ajuste del cero y el punto
máximo de la entrada (vea el ejemplo en AS6.8)
AII04=0 para configurar la presión en 4mA.
AII05=400 para configurar la presión en 20mA.
AII06=bar para las unidades de lectura.
2.Configuración del registro:

SETUP – DRIVE LOG – LOG 2
(CONFIGURACIÓN – REGISTRO DEL
SISTEMA DE CONTROL – REGISTRO 2):
STA=ON activará la función de registro
MT=200 para configurar las celdas de medición
de tiempo cortas (período 1-4) en 200 horas. La
celda del período 1 mostrará la última medición
de hasta 200 horas. Cuando esta celda se encuentre llena, el contenido se moverá a la celda
del período 2 y la celda del período 1 comenzará desde cero nuevamente. La próxima vez
que la celda del período 1 se llene, el contenido de la celda del período 2 se moverá a la
celda del período 3, el contenido de la celda del período 1 se moverá a la celda del período 2
y la celda del período 1 comenzará desde cero nuevamente, y así sucesivamente. Cuando
todas las celdas estén llenas, se borrará el contenido de la celda más antigua antes del
siguiente movimiento de datos.
LHI=300 para configurar dónde comienza el nivel 6
LLO=100 para configurar dónde para el nivel 1. El área entre LLO y LHI se dividirá en 4
partes iguales. En este caso, los niveles serán:
300-400bar drivetime (Tiempo del sistema de control 300-400bar)
REG=REG404 para seleccionar la lectura de registro de la entrada analógica 4.
Al finalizar la configuración aparece la pregunta RESET LOG? (¿REINICIAR REGISTRO?)
Seleccione con el botón > y presione ∧ para obtener una Y (Sí) y luego presione el botón >
para reiniciar. La pregunta aparece si se produce un cambio en cualquiera de los parámetros
en la configuración del canal de registro específico y no afecta los otros tres canales. El
registro se puede configurar en on u off con STA=OFF u ON sin necesidad de reiniciar el
canal de registro.
RESET TIME (REINICIAR TIEMPO) para configurar los contadores de tiempo del sistema de
control. Cuando se selecciona la función con el botón >, presione ∧ para obtener una Y (Sí) y
luego presione el botón > para reiniciar.
05-01-21
reemplaza
04-04-02
6.17 Salidas analógicas

La tarjeta del Spider tiene cuatro canales de salida. Se puede seleccionar cada canal como
salida de voltaje de 0-10V o 2-10V, o como salida de corriente de 0-20mA o 4-20mA. La
selección entre corriente y voltaje se realiza mediante los puentes que se encuentran en la
tarjeta y mediante diferentes terminales.
La selección entre 0-10V y 2-10V, o entre 0-20mA y 4-20mA se realiza con los parámetros
del menú de configuración.
Se pueden ajustar el cero y el punto máximo de las salidas.
Ejemplo para el canal 1, 4-20mA para una velocidad de 0-20rpm desde el codificador digital
de velocidad.
1. Configure el parámetro D1E01 en 20.0rpm (la velocidad que equivale al 100%).
2. Conecte un medidor de corriente en serie con la señal de salida.
3. El parámetro AOA02 debe estar en ON para una salida de 4mA.
4. Seleccione el parámetro AOA03. El sistema proporciona el 0% a la tarjeta. Ajuste el
parámetro hasta que se acerque lo más posible a la salida de 4mA.
5. Seleccione el parámetro AOA04. El sistema proporciona el 100% a la tarjeta. Ajuste el
parámetro hasta que se acerque lo más posible a la salida de 20mA.
6. Repita los pasos 4 y 5 hasta alcanzar los mejores resultados.
6.18 Selección de idioma
Se puede seleccionar el idioma para los textos de las listas de alarmas/advertencias y, en
algunos casos, los textos de las indicaciones de la pantalla principal en el menú (SETUP – MAIN
SETTINGS - LANGUAGE :MAC01) (CONFIGURACIÓN – CONFIGURACIONES PRINCIPALES -
IDIOMA :MAC01).
Los idiomas que se pueden seleccionar son: Inglés (Idioma predeterminado)
Alemán
Francés
Español
Italiano
Japonés (Requiere una pantalla de cristal
líquido (LCD) estándar)
Neerlandés
Finlandés
Sueco
Forma corta (abreviaciones)
Chino (Requiere una pantalla fluorescente de
vacío (VFD)
6.19 Registro de monitoreo del sistema de control

El sistema guarda el registro en una tarjeta de memoria independiente (compartida con la
memoria de parámetros).
El registro de monitoreo del sistema de control está compuesto por cuatro partes: listas de
alarmas/advertencias, contadores de tiempo del sistema de control, seis canales de registro
escalables y dos canales de registro en 3D escalables. Las listas de alarmas/advertencias y los
contadores de tiempo del sistema de control se pueden indicar en la pantalla del sistema de
control 1. La información de registro total del sistema de control debe descargarse a una PC para
su examen. Esto requiere un cable módem nulo 576 3521-003, una PC con Windows XP y el
software de SpiderCom2 instalado.
Las listas de alarma se encuentran en el menú bajo LOG READINGS – DRIVE 1 – ALARM
(LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ALARMA) y LOG READINGS –
DRIVE 2 – ALARM (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2 – ALARMA).
Las listas de advertencia se encuentran en el menú bajo LOG READINGS – DRIVE 1 –
WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ADVERTENCIA) y LOG
READINGS – DRIVE 2 – WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2
– ADVERTENCIA).
Las cuatro listas tienen una extensión de 10 alarmas o advertencias. La más reciente se
encontrará en la parte superior y cuando ingrese una nueva advertencia o alarma a una lista que
ya se encuentra llena, se eliminará la más antigua. Las alarmas y advertencias están marcadas
con la fecha y la hora del incidente. Para configurar la hora real, vea HORA/FECHA a
continuación.
Los contadores de tiempo del sistema de control se encuentran en el menú bajo LOG READINGS
– DRIVE 1 – TIME IN USE (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 –
TIEMPO EN USO) y LOG READINGS – DRIVE 2 – TIME IN USE (LECTURAS DEL REGISTRO
– SISTEMA DE CONTROL 2 – TIEMPO EN USO). Los contadores son PUMP (BOMBA) (el
tiempo con motor eléctrico arrancado) y DRIVE (SISTEMA DE CONTROL) (el tiempo con el
sistema de control arrancado). Los contadores pueden reiniciarse, vea REINICIAR TIEMPO a
continuación.
Las configuraciones para el registro de monitoreo del sistema de control, el reloj y el reinicio de
los contadores de tiempo se realizan en SETUP – LOG FUNCTION (CONFIGURACIÓN –
FUNCIÓN DE REGISTRO) y están protegidas por una contraseña.
TIME/DATE (HORA/FECHA) es para configurar la fecha y hora reales. El formato es AAMMDD

HH:MM y se selecciona con el botón > y se cambia con los botones ∧ y ∨. La fecha/hora se utiliza
para las marcas de la hora en la lista de alarmas y advertencias. El reloj cuenta con respaldo de
baterías.
LOG1 a LOG8 son para configurar ocho canales de registro de monitoreo del sistema de control
escalables.
Las entradas analógicas utilizadas deben configurarse antes de configurar los canales de
registro, vea AS6.8.
Cada canal consiste en un área de medición dividida en 6 niveles. Se almacena el tiempo que la
lectura medida se encuentra dentro de cada uno de estos niveles. La medición sólo está activa
con el sistema de control arrancado. El tiempo total de medición es de 100 000 horas.
Paralelamente con el registro total de tiempo, se almacenan 4 registros más cortos con la misma
configuración del total en orden cronológico. El tiempo de registro es ajustable.
RESET TIME (REINICIAR TIEMPO) reiniciará los contadores del tiempo total del sistema
de control.
05-01-21
reemplaza
04-04-02
6.20 Parada de emergencia

El circuito de parada de emergencia consta de dos sistemas paralelos. El sistema principal es un
canal de monitoreo configurado como Alarm (Alarma). El tiempo de retardo entre la apertura de la
entrada de la parada de emergencia y el cierre de los motores eléctricos se configura con el
parámetro DMD01-03.
El sistema de seguridad es un temporizador de hardware en el tablero que brinda la posibilidad de
configurar el retardo entre 2 y 32 s con SW1 (vea AS4.5).
El temporizador debe configurarse en 0 a 4 s más que el sistema principal, como máximo. Un tiempo
configurado en más de 4 s emitirá una advertencia. Si la configuración es menor o mayor de 5 s el
sistema se cerrará en el momento de la prueba del hardware.
Configuración Tiempo de retardo

0 2s
1 4s
2 6s
3 8s
4 10 s
5 12 s
6 14 s
7 16 s
8 18 s
9 20 s
A 22 s
B 24 s
C 26 s
D 28 s
E 30 s
F 32 s
En cada encendido y cada vez que se paren los motores eléctricos, el sistema verificará que los relés
para las salidas del enclavamiento del motor eléctrico no estén trabados en la posición cerrada.
La alarma de parada de emergencia está predeterminada con la memoria y se debe reiniciar, pero se
puede configurar en reinicio automático con MAB11:ON.
05-01-21
reemplaza
04-04-02
6.21 Actualización del programa

La versión del programa se puede actualizar usando el cable utilizado para SpiderCom
(576 3521-003) y el programa de software Loader.exe (cargador de flash Spider).
Ejecute Loader.exe. Seleccione el archivo que desea descargar Inicie el procedimiento
Reinicie el tablero de Spider presionando el botón de reinicio, o encendiendo y apagando la potencia

a la tarjeta para iniciar el procedimiento de descarga.
Cuando haya finalizado la descarga, reinicie el sistema Spider y configure los nuevos parámetros.
6.22 Calibración del hardware

Cuando se actualiza el software, se requiere una calibración del hardware. Esta calibración es
necesaria para compensar la compensación en los canales de medición para la realimentación de
corriente del pistón. Esta calibración debe realizarse con las bobinas de pistón desconectadas.
Desconecte los contactos PO1, PO2, PO3 y PO4.

En el menú principal, hay una opción para esta calibración
HW CALIBRATION (CALIBRACIÓN DEL HW)
↵ ⇒ PWM OFFSET (COMPENSACIÓN PWM)
↵ ⇒ CAL. OFFSET NO (CAL COMPENSACIÓN NO)
∧ ⇒ CAL. OFFSET YES (CAL COMPENSACIÓN SÍ)
↵ arrancará la calibración. Calibración OK y las configuraciones de calibración se indicarán cuando el
procedimiento esté listo. Este ajuste se almacenará en una EEProm en el tablero principal.
AS-7.1
Spider Entradas digitales
AS7.1, Entradas digitales, Manual de ingeniería 05-01-21
EN DIGITAL BUS 1
EN DIGITAL BUS 2
EN DIGITAL BUS 3
EN DIGITAL BUS 4
EN DIGITAL BUS 5
EN DIGITAL BUS 6
EN DIGITAL BUS 7
EN DIGITAL BUS 8
EN DIGITAL BUS 9
EN DIGITAL BUS 10
EN DIGITAL BUS 11
EN DIGITAL BUS 12
EN DIGITAL BUS 13
EN DIGITAL BUS 14
EN DIGITAL BUS 15
EN DIGITAL BUS 16
EN DIGITAL BUS 17
EN DIGITAL BUS 18
EN DIGITAL BUS 19
EN DIGITAL BUS 20
EN DIGITAL BUS 21
EN DIGITAL BUS 22
EN DIGITAL BUS 23
EN DIGITAL BUS 24
AS7.1, Entradas digitales, Manual de ingeniería 05-01-21
AS-7.2
Spider Entradas y salidas analógicas
AS7.2, Entradas y salidas analógicas, Manual de ingeniería 05-01-21
AS7.2, Entradas y salidas analógicas, Manual de ingeniería 05-01-21
AS-7.3
Spider Salidas de la bomba
AS-7.4
Spider Monitor
AS7.4, Monitor, Manual de ingeniería 05-01-21
AS7.4, Monitor, Manual de ingeniería 05-01-21
AS-7.5
Spider Función Básica
AS7.5, Función Básica, Manual de ingeniería 04-04-02
AS-7.6
Spider Función Triturador
AS7.6, Función Triturador, Manual de ingeniería 04-04-02
AS-7.7
Spider Función Sincronizar
AS7.7, Función Sincronizar, Manual de ingeniería 04-04-02
AS-7.8
Spider Función Presión
AS-7.9
Spider Parada de emergencia
HYDRAULIC DRIVE SYSTEM
OPERATION AND INSTRUCTION
MANUAL
CUSTOMER INFORMATION
Name THYSSENKRUPP ROBINS
Purchase Order 0 507 001 57 27
Reference
Notes B E LT F E ED ER
HÄGGLUNDS INFORMATION
Project 2 005 032
Sales Order 2 005 302 2
Notes

2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
1
Project Specifications
Bill of Materials
Test Reports

2
Columbus, Ohio 43228 USA
Phone: (614) 527-7400
Fax: (614) 527-7401

5041 Mainway Unit #7 Hydraulic Motor
Burlington, Ontario L7L 7G5, Canada
Phone: (905) 319-6338
Motor Accessories
Fax: (905) 319-6615
www.hagglunds.com
3
Hydraulic Power Unit
Project Drawings
Spider Control Documentation

NORTH AMERICAN SALES OFFICES
United States Regional Offices Canadian Regional Offices
NORTHEAST EASTERN
1273 Bound Brook Road 87B Marie-Victorin
Suite 11 Suite 202
Middlesex, New Jersey 08846 Candiac, Quebec J5R 1C3
(732) 469-0411 (450) 659-4244
(732) 469-8047 (fax) (450) 659-3792 (fax)
MIDWEST CENTRAL
2275 International Street 5040 Mainway, Unit #7
Columbus, Ohio 43228 Burlington, Ontario L7L 7G5
(614) 527-7400 (905) 319-6338
(614) 527-7401 (fax) (905) 319-6615 (fax)
NORTHWEST WESTERN
19219 West Valley Highway #3 7201-72 Street
Suite M-101 Delta, British Columbia V4G 1H2
Kent, Washington 98032 (604) 940-8281
(425)-251-9661 (604) 940-8241 (fax)
(425)-251-9280 (fax)
SOUTHEAST
4335 South Lee Street
United States Headquarters
Suite F Hägglunds Drives Inc.
Buford, Georgia 30518 2275 International Street
(770) 945-6223 Columbus, Ohio 43228
(770) 945-6246 (fax) (614) 527-7400
(614) 527-7401 (fax)
NORTH-CENTRAL
(262) 594-3762 Canadian Headquarters
(262) 594-3764 (fax)
CENTRAL 5040 Mainway, Unit #7
(913) 515-8047 Burlington, Ontario L7L 7G5
(913) 322-6910 (fax) (905) 319-6338
(905) 319-6615 (fax)
SOUTH-CENTRAL
220 Spring Hill Drive Worldw ide Headquarters
Suite 200 Hägglunds Drives AB
Spring, Texas 77386 SE-890 42
(281) 292-6700 Mellansel, Sweden
(281) 292-6768 (fax) +46 660 870 00
+46 660 871 60 (fax)
SOUTHWEST
(602) 790-4632
(480) 474-1039 (fax)

PROJECT INFORMATION
Hägglunds Salesperson: CHUCK SEITZ
Customer Name: THYSSENKRUPP ROBINS
Address: 7730 EAST BELLEVIEW AVE. SUITE 404
GREENWOOD VILLAGE, CO. 80111
Contact Name: PETER SEHL
Phone: 303-793-2605 Fax: 303-770-8233
E-mail: SEHLP@KRUPPROBINS.COM
Customer P.O. : 0507 001 5727 Customer Ref.: 507-001
Customer Spec. No. Copy Attached: NO
Spec. Exceptions List YES Copy Attached: NO
Equipment : BELT FEEDER 220 FE-006,007,008
Description :
Location : SAN CRISTOBAL,BOLIVA
NEMA Classification NEMA 4X (IP-65)
Ambient Temp. Range -10.3 C TO 21.6 C
Cooling Water Temp. N/A
Elev. Above Sea Level 3900 M
DESIGN INFORMATION
Drive Speed, Run 0-6.9 RPM
Drive Speed, Max 6.9 RPM
Nominal Torque 44,800 Ft. Lbs.
Starting Torque 79795 Ft. Lbs.
Duty Cycle CONT
Flow Range: 42.6 GPM
Motor Case Flushing: 1.11 GPM
Nominal Pressure: 2716 PSI
Peak Pressure: 4764 PSI
Horsepower Installed: 100 HP, 1470 RPM
High Pressure Switch Setting: PSI
Max Volume Stop : GPM (Forward) GPM (Reverse)
Uni / Bi-Directional Drive: UNI W/JOG REVERSE
Port "A" of Pump to Port A MOTOR
SCOPE OF SUPPLY
Hydraulic Motor 3 X CB-400-360-C-A-0-N-0 178-5041-1602
Hydraulic Power Unit 3 X PBC-0202-073/XXX-21-1110-11B-0000-0-0380/50
Elec. Control System 3 X SPIDER CONTROL II
Torque Arm 3 X TCA-40-2 278-5014-602
Mounting Tool 1 X MTMB 378-0846-801
Shaft Adaptor N/A
Speed Encoder 3 X SPDB-3600 378-5036-802
Encoder Mounting Set 3 X SMCB 178-5049-801
Axial Locking Set N/A
Customer Supplied N/A

DESCRIPTION OF OPERATION
xx
xx LONG TERM STORAGE REQUIRED
xx PACKING FOR SEAWORTHY EXPORT
xx SPECIAL TAGGING REQUIREMENTS PER SPEC APPENDIX B AND M-020, 7.5 AND
xx GD-11
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
HYDRAULIC NOTES
xx 3 X 25FT. HOSE KITS REQUIRED
xx
xx
xx
xx
ELECTRICAL NOTES
xx
xx
xx
xx
xx
MECHANICAL NOTES
xx
xx
xx
xx
xx
DOCUMENTATION NOTES
Drawings: 2 copies For Approval and 2 copies of For Construction. Please specify other requirements.
Drawing Due Date: 3 weeks after receipt of Tech Clarified order
Manuals: 8 TOTAL REQUIRED IN BOTH ENGLISH AND SPANISH PER SYSTEM
Manuals Due Date: 1 week after the ship date

Revision: B Designation System
Date: 11/10/2005 POWER UNITS, North America
P B CC - 0 2 0 2 - 0 7 3 / X X X - 1 0 0 / X X X - 2 1 - 1 1 1 0 - 1 1 B - 0 0 0 0 - 0 - 0 3 8 0 / 5 0
PAC
PBC
PHS Electric Motor Frequency
PAX 60 Hz
50 Hz
Tank Size
Liter(Gallon) Voltage
1000 (264) = 100 200 (53) = 020 460/575 VAC
1200 (317) = 120 400 (106) = 040 2300/4160 VAC
Other (Specify) 600 (159) = 060
800 (211) = 080 Electric Motor Supplied By
1 = Customer
Number of Doors 0 = Hägglunds
2
3 000 = Standard Design
001-999 = Special Design
Pump Displacement
Left Door/Right Door Accumulator Package
cu. cm/rev cu. in./rev 1 = With
SP-40 = 040 P6S = 060 0 = Without
SP-71 = 071 P7S = 073
SP-125 = 125 P11S = 110 Control Box Voltage
SP-180 = 180 P14S = 140 A = 24 VDC
SP-250 = 250 P24S = 240 B = 110 VAC
SP-355 = 355 P30S = 300 C = 220 VAC
SP-500 = 500 9A2 Pump Stroker(5A2/9A2 for Denison, EP for SP pumps)
SP-750 = 750 1 = Air/ Oil Cooler
0 = Water/Oil Cooler
Electric Motor Size Water Valve Voltage X
Left Door/Right Door Air Cooler EM Voltage X
kW HP
22 = 022 30 = 030 1 = Oil Heater
30 = 030 40 = 040 0 = Without
37 = 037 50 = 050 Oil Heater Voltage 220V
45 = 045 60 = 060
55 = 055 75 = 075 1 = Duplex Filters
75 = 075 100 = 100 0 = Single Filters
90 = 090 125 = 125
110 = 110 150 = 150 1 = Cabinet Feet
132 = 132 200 = 200 0 = Without
160 = 160 250 = 250
200 = 200 300 = 300 1 = High Pressure Switch
250 = 250 350 = 350 0 = Without
315 = 315 400 = 400
450 = 450 1 = Pressure Transmitter
500 = 500 0 = Without
HP Specify HP or kW
Control Box Mounting
Control Box Options 0 = Shipped Loose
None = 0 1 = Mounted Inside Power Unit
Driver Card = 1 2 = Mounted in Power Unit Door
Spider = 2 3 = Supplied as Separate Item, with Bracket
Other = 3 4 = Supplied as Separate Item, with Flange
5 = Mounted outside of Power Unit (Specify)

XX ft.
XX ft.
XX ft.
XX ft.

Bill Of Material
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN : -
21-Nov-2005 2005 032
C
No. Qty. D Part No.
E
K 24 * MM2005032-E OPERATION AND INSTRUCTION MANUALS, ENGLISH
J 24 * MM2005032-S OPERATION AND INSTRUCTION MANUALS, SPANISH
I 3 * HDE-30826-0 ORIFICE FITTING 1/2" BSP X 1/2" JIC WITH 4MM ORIFICE, CB 280-840 F3
H 3 * HK2005032-0 HOSE KIT, 25 FT. LONG, PBC-200 W/ MAINLINE,DRAINLINE,AND CASE FLUSHING HOSES
G 3 * HAS-10392-0 LONG TERM OIL FILLING, ALL COMPACT MOTORS
F 3 * 178 5049-801 ENCODER MTG. SET, SMCB-1, For All CA and CB motors
E 3 * 378 5036-802 SPDB-3600
D 1 * 378 0846-801 MOUNTING TOOL, MTMB-Swedish
C 3 * 278 5014-602 TORQUE ARM, For CB-280 & CB-400, TCA-40-2, w/ Pivot Attachment
B 3 * 178 5041-1602 HYDRAULIC MOTOR, CB 400-360 C A 0 N 0
A 3 HB2005032 PBC-202-073-100-21-1110-11B-0000-0-380/50
1 1 HAS-10534-100 POWER UNIT FRAME ASSEMBLY PBC-202
1a 1 FM-2005032-0 POWER UNIT FRAME MODIFICATION
2 1 HAS-10723-100 RESERVOIR ASSEMBLY, 200 LITER, 2" SUCTION
3 1 517-00054-0 GATE VALVE FOR RESERVOIR DRAIN, 1" NPT
4 NOT USED
5 4 * 229-10120-0 CABINET FEET, 600 KG. FOR PAC/PBC-202/203
6 1 237-00023-0 BASE PLATE, 24.5 X 24.5 FOR PAC/PBC-202/203
7 4 H606-25309-0 SHOCK MOUNTS, PAC/PBC
8 1 L 023-07706-0 HYDRAULIC PUMP #P7S-2R1A-9A2-B00-0A1-M2-07706, W/ TB-006
8a 2 038-58361-0 1-1/2" CODE 62 PROTECTIVE COVER WITH SEAL
8b 2 H492-15407-0 TEST POINT, SAE-4, VA AND VB PORTS
8c 1 H492-15408-0 TEST POINT, SAE-6, DG PORT
9 1 H513-50391-0 CHARGE PRESSURE CHECK VALVE, 3/4", 65 PSI, FOR P6/P7/P11/P14 PUMPS
10 1 H171-00233-0 PUMP/MOTOR ADPT., 444/445 TSC TO P6/P7, SIZE 55/70
11 COUPLING CONSISTING OF 11a, 11b, 11c:
11a 1 S H212-85283-0 E-MOTOR HALF: 2-3/8" X 5/8", Frame: 444/445/447/449 TSC, SIZE 55-02 CAST IRON
11b 1 S H212-85284-0 PUMP HALF: 1-1/4" X 5/16", PUMP: P6S & P7S, SIZE 55-01 CAST IRON
11c 1 S H212-85258-0 INSERT, 92 SHORE A, SIZE 55, YELLOW SPIDER (104 HP)
12 1 L H135-80534-0 ELECTRIC MOTOR, 100 HP, 1500 RPM, 380V/3/50, 444TSC
13 2 H506-85473-0 SINGLE FILTER ASSY', SIZE 160, 10 µm, W/ ELEMENT & 30°C THERMAL LOCKOUT TYPE INDICATOR
13a 1 HDE-30561-0 MOUNTING BRACKET, SHORT, FOR FLN FILTERS
13b 1 HDE-30562-0 MOUNTING BRACKET, LONG, FOR FLN FILTERS
14 2 *M 478 3233-620 FILTER REPLACEMENT CARTRIDGE, SIZE 160, 10 µm
15 2 S H502-00228-0 PRESSURE GAUGE, 0-6000 PSI, 2-1/2" DIAL, SYSTEM PRESSURE
16 2 S H502-00227-0 PRESSURE GAUGE, 0-1000 PSI, 2-1/2" DIAL, CHARGE & SERVO PRESSURE
17 1 502-00001-500 GAUGE MANIFOLD ASSEMBLY, W/ NEEDLE VALVE
18 1 502-00001-501 NAME PLATE, GAUGE MANIFOLD, DENISON PUMPS
19 1 H503-80003-0 OIL LEVEL INDICATOR, 10"
20 1 M 506-85181-0 FILTER AIR BREATHER, 10 MICRON AND 3/4" NPT ADAPTER
21 NOT USED
22 1 S H170-00213-0 TEMP/ LEVEL ASSEMBLY, 20-32VDC INPUT, IP 65, , TEMPERATURE RANGE: 32°F TO 140°F
ANALOG OUTPUT: 4-20mA, SWITCHING OUTPUTS: 2 ADJUSTABLE LEVELS, 1.2A MAX EACH
22a 1 H492-30042-0 1" NPT ADAPTER FOR HYDAC ENS-3000 TEMP/LEVEL ASSEMBLY
22b 1 H115-15220-0 ELECTRICAL CONNECTOR, M12, 5-POLE
23 NOT USED
24 1 492-15321-0 QUICK DISCONNECT COUPLING
25 1 HDE-30570-0 QUICK DISCONNECT COUPLING BLOCK
26 1 HDE-30571-0 QUICK DISCONNECT 45° FITTING
27 1 L H505-65337-0 AIR COOLER, WITHOUT ELECTRIC MOTOR
27a 1 L H135-80542-0 ELECTRIC MOTOR, 3/4 HP, 1500 RPM, 380V/3/50, 145TC
28 1 513-50133-0 COOLER BYPASS CHECK VALVE, 1 1/4 SAE
29 NOT USED
30 1 S H115-15218-0 CHARGE PRESSURE SWITCH, 0-1000 PSI, IP 65, 18-35 VDC Input, 4-20 mA Output, 1 Switching/ 1 analogue Outpu
30a 1 S H115-15212-0 ELECTRICAL CONNECTOR, M12, 4-POLE
31 1 S H115-15219-0 HIGH PRESSURE SWITCH, 0-6000 PSI, IP 65, 18-35 VDC Input, 4-20 mA Output, 1 Switching/ 1 analogue Outpu
31a 1 S H115-15212-0 ELECTRICAL CONNECTOR, M12, 4-POLE
32 1 S H130-15209-0 OIL IMMERSION HEATER 0.5 kW, 240 VAC, 1 PH, EXP. RESISTANT, BUILT IN THERMOSTAT, 1"
33 1 H517-00343-0 BUTTERFLY VALVE 2" CODE 61 WITH LIMIT SWITCH, M12 x 1.75 pitch METRIC THREAD
34 NOT USED
35 1 HDE-31397-0 SUCTION LINE MANIFOLD, FOR P6-P14 PUMPS
36 NOT USED
37 NOT USED
Bill Of Material
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN : -
21-Nov-2005 2005 032
C
No. Qty. D Part No.
E
38 CB2005032-0 CONTROL BOX CONSISTING OF 38a, 38b, 38c:
38a 1 CB2005032-A CONTROL BOX
38b 1 276 0023-801 SPIDER II CONTROLS, 1 PUMP - SINGLE DRIVE
38c 1 576 7942-025 RUBBER FLANGE FL21 (USED WITH EVERY SPIDER II)
38d 1 HAS-10778-0 CONTROL BOX MOUNTING BRACKET
38e 1 276 0003-001 MOUNTING FRAME (FOR DOOR OR BOX MOUNTED SPIDER II)
38f 1 HU3 3872-801 HEATER ASSEMBLY
39 1 HDE-30988-0 MTG ANGLE, DRAIN/FLUSHING CONNECTION
40 1 HDE-30569-0 CHECK VALVE MANIFOLD, PAC/PBC 200-400 UNITS, 1-1/4" SAE
41 NOT USED
42 1 513-50133-0 CHECK VALVE, 1-1/4" SAE, 65 PSI
43 NOT USED
44 NOT USED
45 1 TAG-2005032-0 LOT OF LAMACOID TAGS PER CUSTOMER SPEC
46 1 SP-2005032-0 ENGRAVED PLATE OF HYDRAULIC SCHEMATIC: HS-2005032 (11 X 17)
47 2 HDE-30576-1 1/2" CONDUIT BRACKET
48 1 HDE-30576-2 3/4" CONDUIT BRACKET
49 1 038-54612-0 S/N PLATE
50 NOT USED
51 1 HAS-10014-0 LONG TERM OIL FILLING, GOLDCUP P6 THRU P14 AND HAGGLUNDS SP250, SP355
52 1 EXPORT CRATING, 200 UNIT

Bill of Material No.: CB2005032
Bill Of Material
Issued By: RHW 2275 International Street; Columbus, Ohio 43228, USA P.O. 0507 001 5727
TITLE: Assembly Ref(s) :
CONTROL CONSOLE Revised By : CC-2005 032
HYDRAULIC POWER UNIT CS-2005 032
2005 032
C
No. Qty. D Part No.
E
1 1 CB2005032-A CONTROL PANEL
2 1 276 0023-801 SPIDER 2 CONTROL, FULL FUNCTION
3 1 H103-20469 ENCLOSURE NEMA 4X, 24 X 24 X 12
4 1 H103-20420 PANEL FOR ABOVE ITEM
5 1 H103-20394 ENCLOSURE MOUNTING KIT
6 1 H103-20415 DOOR LOCK KIT FOR ENCLOSURE
7 1 H153-15301 PUSHBUTTON, GREEN FLUSH HEAD, 1 N.O., 1 N.C. CONTACTS
8 1 H153-15302 PUSHBUTTON, RED EXT. HEAD, 1 N.O., 1 N.C. CONTACTS
9 1 H153-10363 INDICATING LIGHT, GREEN, FULL VOLTAGE, 120VAC
10 1 H151-15318 MUSHROOM HEAD PUSH/PULL MAINTAINED PUSHBUTTON, 2 N.O. CONTACTS
11 1 155-10060 LEGEND PLATE, GRAY, E-MOTOR START
12 1 155-10055 LEGEND PLATE, RED, E-MOTOR STOP
13 1 H155-10487 LEGEND PLATE, GRAY, E-MOTOR STARTED
14 1 155-10057 JUMBO LEGEND PLATE, RED, EMERGENCY STOP
15 62 123-75144 TERMINAL, UKK5
16 6 123-75048 END ANCHOR, E/UK
17 4 ft. 123-75047 MOUNTING RAIL, NS 35/7.5
18 3 123-75146 END COVER D-UKK 3/5
19 3 123-75147 SPACER PLATE, DP-UKK 3/5
20 3 H123-75421 END SPACER COVER, DG-UKK 3/5
21 10 H123-75422 PARTITION PLATE, ATP-UKK 3/5
22 10 H123-75453 ISOLATING BRIDGE BAR, ISSBI 10-6
23 10 H123-75465 BRIDGE BAR ISOLATOR, IS-K 4
24 2 H123-75477 DOUBLE TERMINAL BLOCK, UDK 4
25 1 H123-75478 END COVER FOR DOUBLE TERMINAL BLOCK, D-UDK-4
26 2 H123-75489 UNIVERSAL GROUNDING DOUBLE TERMINAL BLOCK, UDK-4-PE
27 2 123-75069 MARKER STRIP, 11-20
28 2 123-75070 MARKER STRIP, 21-30
29 2 123-75077 MARKER STRIP, 91-100
30 2 123-75086 MARKER STRIP, 121-130
31 2 123-75089 MARKER STRIP, 151-160
32 2 123-75126 MARKER STRIP, 301-310
33 2 123-75127 MARKER STRIP, 311-320
34 2 H123-75467 MARKER STRIP, 331-340
35 2 H123-75468 MARKER STRIP, 341-350
36 2 123-75162 MARKER STRIP, 401-410
37 2 123-75163 MARKER STRIP, 411-420
38 2 H123-75493 MARKER STRIP, 421-430
39 2 H123-75495 MARKER STRIP, 441-450
40 2 123-75139 MARKER STRIP, 501-510
41 2 123-75141 MARKER STRIP, 521-530
42 2 H123-75427 MARKER STRIP, L, N, GND
43 10 ft. 104-25020 WIRE DUCT, 2" X 3", WHITE
44 10 ft. 104-25021 WIRE DUCT COVER, 2", WHITE

CB2005032.xls Form No.: F10203-2 | Release Date: 4/12/2000 | Revision: ORIG

Job Number: 2005 032-1 Serial Number: 517-2-21187


Jupiter 900:
Jupiter 500:
Spider Controller:
Full Function:
Other:
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Installation
Other Items

Other (List):
Spider Controller
Page 1
SW SW SW SW
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA

C C C
JP2: JP3: JP4:
A A A

Input SW1
± 10VDC 6 9
± 0-20mA 8 7
12 ± 8mA 8 7
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Inputs and Outputs

Page 2
Miscellaneous
Tested By: WK
Date: 6SEP05
Approval By: JFDIII
Date: 10-28-2005
Notes:
Page 3




If Yes how many: 2

If Yes how many: 6

Pump No. 1



Page 1

Serial Number: BG


Page 2
Miscellaneous
General Arrangement Rev. - Hydraulic Schematic Rev. -
Electrical Schematic Rev. - Power Unit Bill of Material Rev. A
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Rev. -
Rev. -

Approval By:JFDIII Date:10-28-2005
Notes:
*PS-1 (Charge): Hydac EDS 3476-3-1000-400 / Rng.1000 Psig / Art No:908841 / S/n 507C022881
S/n 517D026703

ART.NO.: 908578 / S/N: 521A001154
Page 3


Jupiter 900:
Jupiter 500:
Spider Controller:
Full Function:
Other:
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Installation
Other Items

Other (List):
Spider Controller
Page 1
SW SW SW SW
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA

C C C
JP2: JP3: JP4:
A A A

Input SW1
± 10VDC 6 9
± 0-20mA 8 7
12 ± 8mA 8 7
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Inputs and Outputs

Page 2
Miscellaneous
Tested By: WK
Date: 6SEP05
Approval By: JFDIII
Date: 10-28-2005
Notes:
Page 3
Job Number: 2005 032-2A Serial Number: 517-2-21188




If Yes how many: 2

If Yes how many: 6

Pump No. 1



Page 1

Serial Number: BG


Page 2
Miscellaneous
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Rev. -
Rev. -

Notes:
S/n 524D030724

ART.NO.: 908578 / S/N: 521A001150
Page 3


Jupiter 900:
Jupiter 500:
Spider Controller:
Full Function:
Other:
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Installation
Other Items

Other (List):
Spider Controller
Page 1
SW SW SW SW
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA

C C C
JP2: JP3: JP4:
A A A

Input SW1
± 10VDC 6 9
± 0-20mA 8 7
12 ± 8mA 8 7
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Inputs and Outputs

Page 2
Miscellaneous
Tested By: WK
Date: 13SEP05
Approval By: JFDIII
Date: 10-28-2005
Notes:
Page 3




If Yes how many: 2

If Yes how many: 6

Pump No. 1



Page 1

Serial Number: BG


Page 2
Miscellaneous
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Rev. -
Rev. -

Notes:
S/n 524D030722

ART.NO.: 908578 / S/N: 417A000504
Page 3
COMPACT CB MOTOR MANUAL
Installation and Maintenance Manual
Compact CB 280-840
EN683-2h 2002
Preface Installation and Maintenance Manual, Compact CB
Preface
Hägglunds Drives is one of the worlds leading manufacturers of large hydrau-
lic Drive Systems. A leading position, made possible by unbeatable service
spirit and of continuing development of both products and markets all over the
world. Our drives are to be found in most industrial and marine segments,
where there are extremely high demands for efficiency and reliability. Our main
office and production plant is in Mellansel, Sweden and we have our own
sales- and representation offices in some 40 different countries.
Our high quality Drive Systems, are based upon our unique hydraulic piston
motors, developed through a wealth of experience accumulated over 30 years
in marine and industrial areas.Today this ongoing development work has
resulted in the powerful COMPACT CB industrial motor. New, as well as esta-
blished technical solutions, contribute to the creation of this product. The most
desirable features and operating reliability have been designed in this hydrau-
lic motor.

of the motor. In order to find particular information, just search for the wanted
section as listed in the table of contents. However, changes in the equipment
may occur. We therefore reserve the right to introduce amendments in the
manual as we deem necessary without notice or obligations.
This Installation and Maintenance Manual is valid

for motors manufactured after 02-01-01.
Original EN683-1h, 2001
2
Installation and Maintenance Manual, Compact CB Contents
Contents
1. GENERAL ....................................................................................................................... 4
1.1 Safety precautions .. ........................................................................................................ 4
1.2 Motor data ........................................................................................................................ 5
1.3 Functional description ...................................................................................................... 6
2. TECHNICAL DATA .......................................................................................................... 7

2.1 Recommended charge pressure ...................................................................................... 7
2.2 Sound from a complete installation .................................................................................. 8
2.3 Choice of hydraulic fluid ................................................................................................... 9
Environmentally acceptable fluids .................................................................................. 10
3. INSTALLATION ............................................................................................................. 11
3.1 Mounting instructions ..................................................................................................... 11
Thread for mounting tool ................................................................................................ 12
Spline ............................................................................................................................. 12
3.1.1 Lifting methods ............................................................................................................... 13
Standing the motor on a flat surface ............................................................................... 14
3.1.2 Mounting the coupling onto the motor shaft .................................................................... 15
3.1.3 Fitting the torque arm to the motor . ................................................................................ 17
3.1.4a Mounting the motor onto the driven shaft - shaft coupling .............................................. 18
3.1.4b Mounting the motor onto the driven shaft - splines ......................................................... 21
3.1.5 Removing the motor from the driven shaft ..................................................................... 22
3.1.6 Mounting the reaction point . .......................................................................................... 23
3.2 Oil connections .............................................................................................................. 24
3.2.1 Direction of rotation of motor shaft ................................................................................. 26
3.2.2 Draining and venting the motor ...................................................................................... 36
3.2.3 Flushing .......................................................................................................................... 27
4. OPERATING INSTRUCTIONS .................................................................................... 28

4.1 Storage ........................................................................................................................... 28
4.2 Before commissioning .................................................................................................... 28
4.3 Commissioning .............................................................................................................. 29
4.4 Periodic maintenance ..................................................................................................... 29
Maintenance chart ......................................................................................................... 29
Motor .............................................................................................................................. 30
Filters ............................................................................................................................. 31
Oil ................................................................................................................................... 31
4.5 Oil inspection ................................................................................................................. 31
5. FAULT FINDING............................................................................................................ 32
DECLARATION OF CONFORMITY ............................................................................ 33
3
1. GENERAL
It is of high importence that the Safety precautions are always followed, if you are
unsure about something, please don´t hesitate to contact your nearest HD-office
for advice.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will
cause personal enjury or substantial property damage. Depending on the probability of the hazard,
and how serious the injury or property damage could be, there are three levels of classification.



Application area
All new and rebuild applications, should always be approved and supervised by Hägglunds
personel.
Mounting
Before starting up
Before starting up new, rebuild or just worked on applications, all accessories and safety
arrangements functions, should be controlled/tested.
Periodic maintenance
Notice the intervals in maintenance chart (4.4) and keep a record.
Dismounting
4
Installation and Maintenance Manual, Compact CB General
1.2 Motor data
Table 1.1
Metric
Displacement
torque speed 1) speed pressure torque 2) Intermittently
Motor type
Vi Ts n n p
kNm kW
CB 280-240 15 100 240 53 68 350 79 530
CB 280 17 600 280 44 58 350 92 530
CB 400-240 15 100 240 94 125 350 79 970
CB 400-280 17 600 280 73 105 350 92 950
CB 400-320 20 100 320 71 94 350 110 970
CB 400-360 22 600 360 59 82 350 120 960
CB 400 25 100 400 58 75 350 130 970
CB 560-440 27 600 440 49 65 350 140 930
CB 560-480 30 200 480 48 62 350 160 970
CB 560-520 32 700 520 41 57 350 170 960
CB 560 35 200 560 40 53 350 180 970
CB 840-600 37 700 600 30 45 350 200 880
CB 840-640 40 200 640 28 41 350 210 850
CB 840-680 42 700 680 27 40 350 220 890
CB 840-720 45 200 720 25 37 350 240 870
CB 840-760 47 800 760 23 34 350 250 840
CB 840-800 50 300 800 23 34 350 260 890
CB 840 52 800 840 21 32 350 280 870
US
Displacement speed 1)
torque speed pressure torque 2) Intermittently
Motor type Vi Ts n n p
lbf·ft/1000 lbf·ft hp
in3/rev psi rev/min rev/min psi
CB 280-240 920 12 200 53 68 5000 57 000 710
CB 280 1070 14 200 44 58 5000 67 000 710
CB 400-240 920 12 200 94 125 5000 57 000 1300
CB 400-280 1070 14 200 73 105 5000 67 000 1300
CB 400-320 1230 16 300 71 94 5000 76 000 1300
CB 400-360 1380 18 300 59 82 5000 86 000 1300
CB 400 1530 20 300 58 75 5000 95 000 1300
CB 560-440 1690 22 400 49 65 5000 100 000 1300
CB 560-480 1840 24 400 48 62 5000 110 000 1300
CB 560-520 1990 26 400 41 57 5000 120 000 1300
CB 560 2150 28 500 40 53 5000 130 000 1300
CB 840-600 2300 30 500 30 45 5000 140 000 1200
CB 840-640 2450 32 500 28 41 5000 150 000 1100
CB 840-680 2610 34 600 27 40 5000 160 000 1200
CB 840-720 2760 36 600 25 37 5000 170 000 1200
CB 840-760 2910 38 700 23 34 5000 180 000 1100
CB 840-800 3070 40 700 23 34 5000 190 000 1200
CB 840 3220 42 700 21 32 5000 200 000 1200
*) Related to a required pressure of 12 bar/175 psi for motors in braking mode. (Special considerations regarding
charge pressure, cooling and choice of hydraulic system for speeds above rated, 4 ports must be used for higher
speed).
**) The motors are designed according to DNV-rules. Test pressure and peak pressure 420 bar/6000 psi is allowed.
1
) Special considerations regarding charge pressure, cooling and choice of hydraulic system for speed above rated.
2
) Calculated as : Metric= Ts·(350-15)·0,98 US= Ts·(5000-218)·0,98.
3
) Valid for minimum permissible oil viscosity 20 cSt in the motor case.
5
1.3 Functional description

Hägglunds hydraulic industrial motor Oil main lines are connected to ports A and C
COMPACT CB is of the radial-piston type with in the connection block and drain lines to ports
a rotating cylinder block/hollow shaft and a D1, D2, D3 or D4 in the motor housing.
stationary housing. The cylinder block is
The motor is connected to the shaft of the dri-
mounted in fixed roller bearings in the housing.
ven machine through the hollow shaft of the
An even number of pistons are radially located
cylinder block.The torque is transmitted by
in bores inside the cylinder block, and the valve
using a mechanical shaft coupling, or alterna-
plate directs the incoming and outgoing oil to
tively by splines.
and from the working pistons. Each piston is
working against a cam roller.
Valid patents
When the hydraulic pressure is acting on the
pistons, the cam rollers are pushed against the US 4522110, US 005979295A, SE 456517,
slope on the cam ring that is rigidly connected EP 0102915, JP 83162704, GB 1385693,
to the housing, thereby producing a torque.The EP No 0524437.
cam rollers transfer the reaction force to the
piston which are guided in the rotating cylin- Quality
der block. Rotation therefore occurs, and the
torque available is proportional to the pressure To assure our quality we maintain a Quality
in the system. Assurance system, certified to standard ISO
9001, EN 29001 and BS 5750; Part 1.
Fig. 1 The COMPACT CB motor
1
1. Cam ring
2. Cam roller
2 A, C
3. Piston
3
D 4. Shaft coupling
4 8
5. Cylinder block /
hollow shaft
5 6. Cylinder block / spline
7. Front end cover
8. Cylindrical roller bearing
11 9. Connection block
10. Valve plate
6 11. Axial bearing
7 9 A = inlet or outlet port »A«

10 C = inlet or outlet port »C«
D = drain port
6
2. TECHNICAL DATA
2.1 Recommended charge There are two distinct cases:
pressure Case 1:
The hydraulic system must be such that the The motor works in braking mode. Required
motor will recieve sufficient charge pressure charge pressure at the inlet port is according
at the low-pressure port. This applies to all to diagram below.
types of installations.
Case 2:
The motor works in driving mode only. Required
back pressure at the outlet port corresponds
to 30% of value given in diagram below, but
may not be lower than 2 bar (29 psi).
In hanging load applications, charge

pressure at motors connection must
be according to graph below under
all conditions.
Table 2.1a Charge pressure

Single port connection (2 ports) oil viscosity 40 cSt / 187 SSU
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 400 / CB 400-360
CB 560 / CB 560-520
CB 280-240
CB 400-320
CB 840-720
CB 840-600
CB 840
CB 280
20
18
250
16
14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80
Recommended charge pressure - CB 280-840 2-port connection Speed [rpm]
Note:
The diagram is valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge
pressure must be increased accordingly. The graph is valid when 4 ports are used. Max casing
pressure is 3 bar (43,5 psi)(for 1% of the operation time evenly divided, pressure peaks of max 5
seconds upto 8 bar (116 psi) are allowed). Max permitted case pressure at stand-still is 8 bar (116
psi).
7

Double port connection (4 ports) oil viscosity 40 cSt / 187 SSU
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
Table 2.1b Charge pressure
CB 560 / CB 560-520
CB 400 / CB 400-360
CB 840-720
CB 840-600
CB 280-240
CB 400-320
CB 840
CB 280
20
18
250
16

14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
2.2 Sound from a complete installation
Background noise
Pump Pipe Hydraulic Noise from

motor noise motor driven unit
Foundation and construction noise
Remarks:
Background noise
Hydraulic motor
The background noise can not normally be
influenced but is usually known or easy to The hydraulic motor is a known noise level.
measure. (Tables of sound data - see subsection 4.9 in
the Engineering Manual).
Pump unit
Driven unit
The pump unit is a known noise level.
The driven unit is an unknown sound source
(for us) but can through certain information
Pipe noise probably be obtained from the supplier. When
The pipe noise is probably the source of the securing the torque arm of a hydraulic motor
majority of mistakes in installations: all pipe to the foundation or casing of a driven machine,
clamps should be of vibration insulating type it is highly important to study the construction
secured to concrete ceiling, wall or floor. of the foundation or casing. This may well be
Securing to non-rigid metal structures or the most important factor to consider, since
structures is likely to give resonance and many structures may give rise to resonance,
should be avoided. resulting in severe noise problems.
8

The Hägglunds hydraulic motors are primarily designed to operate on conventional petroleum based
hydraulic oils. The hydraulic oil can be chosen in consultation with the oil supplier of your local
sales office, bearing the following requirements in mind:
GENERAL
The oil shall have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354). The oil must
also contain inhibitors to prevent oxidation, corrosion and foaming. The viscosity of mineral oil is
highly dependent of the temperature. The final choice of oil must depend on the operating tempera-
ture that can be expected or that has been established in the system and not in the hydraulic tank.
High temperatures in the system greatly reduce
the service life of oil and rubber seals, as well RECOMMENDED VISCOSITY AT
as resulting in low viscosity, which in turn prov- OPERATING TEMPERATURE
ides poor lubrication. 40-150 cSt/187-720 SSU.
Content of water shall be less than 0,1%.
Temperature limits
In Industrial applications with high demands
for service life, the content of water shall be Normal operating temperature should be less
less than 0,05%. than +50°C (122°F)
Viscosity limits Nitrile seals (std motor) -35°C to +70°C

Viton seals -20°C to +100°C
= 100 recommended
Viscosity index = 150* for operation
with large temperature
Nitrile seals (std motor) -31°F to +158°F
difference
Viton seals -4°F to +212°F
Min. permitted in continuous duty 40 cSt/187 SSU
Min. permitted in intermittent duty 20 cSt/98 SSU**
Max. permitted 10000 cSt/48000 SSU
* Many hydraulic fluids with VI-improvers are subject to temporary and permanent reductions of the viscosity.
** Low viscosity gives reduced service life for "COMPACT CB".
Fire resistant fluids

OPERATING WITH FIRE RESISTANT FLUIDS
The following fluids are tested for Hägglunds motors: (ISO/DP 6071)
HFA: Oil (3-5%) in water emulsion No - -
HFB: Inverted emulsion 40-45% water in oil Yes Nitrile (std motor) Not painted*
HFC: Water-glycol Yes Nitrile (std motor) Not painted*
HFD synthetic fluids

HFD:R - Phosphate esters Yes Viton Not painted*
HFD:S - Chlorinated hydrocarbons Yes Viton Not painted*
HFD:T - Mixture of the above Yes Viton Not painted*
HFD:U - Other compositions Yes Viton Not painted*
* Must be specified in the order.
IMPORTANT!
Down rating of pressure data and service life must be considered when using fire
resistant fluid. The Hägglunds company or its authorised representative must always
be contacted for approval in the case of these types of fluids.
9
Environmentally acceptable fluids
Vegetable */** Nitrile

Yes -
Fluid HTG (std motor)
Synthetic ** Nitrile
Yes -
Esters HE (std motor)
* Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids
must be controlled every 3 months and temperature shall be less than +45° (113°F) C to give good service life for
the fluid.
** Environmental acceptabel fluid gives the same servicelife for the drive, as mineral oil.
Filtration Explanation of
"GRADE OF FILTRATION"
The oil in a hydraulic system must always be
filtered and also the oil from your supplier has Grade of filtration β 10=75 indicates the
to be filtered when adding it to the system. The following:
grade of filtration in a hydraulic system is a β 10 means the size of particle ≥10µm that will
question of service life v.s. money spent on filt- be removed by filtration.
ration.
=75 means the grade of filtration of above
In order to obtain stated service life it is mentioned size of particle. The grade of filt-
important to follow our recommendations ration is defined as number of particles in the
concerning contamination level. oil before filtration in relation to number of
When choosing the filter it is important to particles in the oil after filtration.
consider the amount of dirt particles that the Ex. Grade of filtration is β 10=75.
filter can absorb and still operate satisfactory.
For that reason we recommend a filter with an Before the filtration the oil contains N number
indicator that gives a signal when it is time to of particles ≥10µm and after passing the filter
change the filter cartridge.
once the oil contains number of particles
Filtering recommendations ≥10µm.
Before start-up, check that the system is This means that number of
thoroughly cleaned.
particles have been filtered (=98,6%).
1. In general the contamination level in our
motors should not exceed ISO 4406 19/15.
(NAS 10)
2. For heavy-duty industrial applications the
contamination level should not exceed ISO
4406 16/13. (NAS 7)
3. When filling the tank and motor housing, we
recommend the use of a filter with the grade
of filtration β 10=75.
10
3. INSTALLATION
3.1 Mounting instructions Design of driven shaft end on heavily-
loaded shaft
If the motor is to work properly it must be
installed with the greatest possible precision. Where the driven shaft is heavily loaded and
Every item connected to the motor that does is subject to high stresses, for example on
not meet the requirements of the following changes in the direction of rotation, it is
instructions may result in stresses that recommended that the driven shaft should
adversely affect the service life of the motor. have a stress relieving groove; see Fig. 3.1 and
tables 3.1 and 3.4.
Normally the motor must be completely filled
with oil. When the motor is installed with the
shaft in the horizontal plane, the drain ports G
must be positioned vertically. The higher of the F
four ports must be used: see fig. 3.25. Fig. 3.1 Max R 3,2
a
When the motor is mounted with the shaft in

the vertical plane, see 3.2.2 "Draining and ven-
ting the motor".
C
A
D
The drain line must be dimensioned so that
E
max. 3 bar (43.5 psi) motor housing pressure 30°
is not exceeded.
6±0,5 R 50
(0,24±0,02) (R 1,97)
The max housing pressure is 3 bar (43.5 psi). B±0,5
(B±0,02)
Brief peaks during operation up to 8 bar (116
psi) are permissible. The permitted housing
pressure when the motor is stationary is 8 bar Normally-loaded shaft
(116 psi). In drives with only one direction of rotation
The motor must always be connected in such where the stresses in the shaft are moderate,
a way as to give a sufficient boost, make-up the shaft can be plain, see Fig. 3.2 and tables
flow at the low pressure connection. This is 3.1 and 3.5
particularly important at high speeds and with Fig. 3.2
rapid reversing, see 2.1 "Recommended
charge pressure".
Max
Table 3.1 Valid for couplings
Dim CB 280 CB 400 CB 560/840

A Table 3.2
-0,014 -0,015 -0,017
mm 180 -0,054 200 -0,061 260 -0,069 Unidirectional drives
-0,00055 -0,00059 -0,00067
in 7.0866 -0,00213 7.8740 -0,00240 10.2362 -0,00272
B Steel with yield strength Relmin= 300 N/mm2

106 117 153
mm
4.17 4.61 6.02 Bidirectional drives
in
C Steel with yield strength Relmin= 450 N/mm2
174 194 254
mm
6.85 7.64 10
in
Note! The dimensions are valid for +20°C (68°F)
11
Spline Thread for mounting tool

The splines shall be lubricated, either oiled with To make it easier to mount the motor on the
hydraulic oil at assembly, or filled with trans- driven shaft end or to remove the motor from
mission oil from the connected gearbox. To the shaft it is recommended that a hole (Table
avoid wear in the splines, the installation must 3.5) should be drilled and tapped in the centre
be within the specified tolerances in fig. 3.3. of the shaft for a mounting tool; see 3.1.4
"Mounting the motor onto the driven shaft", and
For production of the shaft, see 278 5023, 278 3.1.5 "Removing the motor from the driven
5024, 278 5025 and 278 5026. For control of shaft".
spline see table 3.4.
The tool has both a UNC thread and a metric
Table 3.3 thread, so that the hole can be drilled and
Unidirectional drives tapped to conform to one of the two alternatives
given in table 3.5.
Bidirectional drives

Table 3.5 Alternative thread (Fig.3.1 and 3.2)
CB 280 - 840
Table 3.4
D M20 UNC 5/8"
Motor CB 280/400 CB 560/840
E >17 (0,67) >13,5 (0,53)
F 25 (0,98) 22 (0,87)
Toth profile and G 50 (1,97) 30 (1,18)
DIN 5480 DIN 5480
bottom form
Tolerance 8f 8f
Guide Back Back
Pressure angle 30° 30°

Fig 3.3
Module 5 5
Number of teeth 38 50 A
Pitch diameter ø 190 ø 250

ø
ø
0 0
Minor diameter ø 188 ø 248
-1,201 -1,201
0 0
Major diameter ø 199 ø 259
-0,290 -0,320
-0,088 -0,103
Measure over
210,158 270,307
measuring pins -0,157 -0,181 0,15 A
(0,006) 0,4 A
Diameter of
ø 10 ø 10 (0,015)
measuring pins
Addendum
+2,25 +2,25
modification X M
12
3.1.1 Lifting methods

Always make sure where the centre of gravity
is before any lifting. Always make sure where
the centre of gravity is
Fig. 3.4a before any lifting. Never
stand below a hanging
motor or torque arm.
Fig. 3.5
Fig. 3.4b Fig. 3.4c
13
Standing the motor on a flat surface
When the motor is placed on a flat surface

Table 3.6
such as a floor, it must stand either on its outer
Motor with
diameter or on the suitably protected end face
shrink disc and of the hollow shaft (see Fig. 3.6 and 3.7).
Motor torque arm
kg lb
CB 280 928 2042 Fig. 3.6
CB 400 1288 2834
CB 560 1514 3331
CB 840 1844 4057
Support
Table 3.7
Weight
Torque arm
kg lb
TCA 40 128 282

Fig. 3.7
TCA 84 224 493
Lifting straps must be

chosen with reliable saftey
margin over the total weight
of the lifted object.
Support
NOTE:
The motor must not be placed on the end face
of the hollow shaft when the coupling is fitted,
since this may cause damage to the coupling.
When in storage, the motor must always be
placed on the end face to the hollow shaft. It is
also advisable to provide supports at the
mounting surface of the motor; see Fig. 3.7.
14
3.1.2 Mounting the coupling onto the motor shaft

Before the motor is mounted there are some preconditions which must be fulfilled:
- You should note that the couplings are from the factory lubricated with MoS2 (Molycote) on the
conical surfaces and the bolts,see fig. 3.8. This lubricants shall remain on those surfaces but:
Molycote must under no circumstances be

trans-ferred to the surfaces between the
driven shaft and the motor.
It is therefore important that you clean your hands free from Molycote. If those conditions are
fullfilled you may start the mounting.
- Clean the driven shaft and the out- and inside of the Compact motor hollow shaft.
- Remove the spacers between the two clamping rings of the coupling.
- Mount the coupling on the hollow shaft of the motor. The coupling must be pushed right up to the
stop of the shaft. Use a screwdriver to open the coupling ring for easier mounting.
Never tighten the coupling screws until the

motor has been mounted onto the driven
shaft.
- Mount the motor onto the driven shaft by following the instruction in the section 3.1.4. (With or
without using the mounting tool).
Remember:
-The conical surface between the coupling ring and the clamping rings + the bolts shall be coated
with MoS2 (Molycote), see Fig. 3.8. This is done from the factory at delivery! When a motor has
been in for overhaul or service and shall be reassembled it may be necessary to relubricate those
surfaces with Molycote again but remember only the specified surfaces!
-Absolutely No Molycote on the surfaces between shaft-motor. Clean the driven shaft and the
inside of the motor hollow shaft.
- Alignment of the motor on the shaft. (Dimensional check).
- Minimum variation in the gap between the clamping rings (Dimensional check).
- Right torque on the bolts. (Use torque wrench).
Before starting the motor, check

that the rotating coupling can not
cause damage.
15
Clamping rings
Fig. 3.8
Seal Coupling ring
Washer - - - - - = Coated surface
Motor hollow Cleaned surface

shaft
Centre of motor
16
3.1.3 Fitting the torque arm to the motor

The torque arm is fitted to the motor before the Fig. 3.9 CB 280/400
motor is mounted on the driven shaft.
- Clean the spigot surface on the torque arm
and motor with trichlorethylene or similar sol-
vent.
- Oil the screws.
- Make sure that the torque arm will be pointing
in the right direction when the motor is
mounted in place on the machine. To achieve
the highest possible oil level in the motor
housing, the motor must be turned until the
drain outlets are positioned according to fig
3.12.
- Line up the torque arm on the motor by
using the screws with washers.
- Tighten the screws to the torque stated in the
table below.
Fig. 3.9a CB 560/840
Do not weld, drill, grind or

carry out any similar work on
the torque arm without
Hägglunds approval.
Table 3.8
Tightening torque
Number
Motor Screw dimension
of screws
Nm lbf·ft

Note: Use torque wrench and oiled screws!
17
3.1.4a Mounting the motor onto the driven shaft - shaft coupling
The motor can be mounted onto the driven shaft with or without a mounting tool, but the use of a
mounting tool is recommended since it makes the work easier.
It is important to arrive at the correct clamping length between the driven shaft and the hollow shaft
of the motor.
Ensure that the full clamping length is used by, for example, measuring and marking the driven
shaft. This is of particular importance if the duty is so severe that a stress relieving groove has
been made on the driven shaft. See Fig. 3.11, 3.11a and the table 3.9.
Mounting the motor with a mounting tool (Fig. 3.10a)

- Remove the End cover together with screws and washers.
- Align the motor with the driven shaft.
- Locate the existing plastic washer between the nut on the mounting tool and the bearing retainer.
- Pass the mounting tool through the centre of the motor, and screw it into the driven shaft to
stated depth by using the key handle in the end of the tool.
- Pull the motor onto the shaft by turning the nut on the mounting tool until the length B is obtained;
see Fig. 3.11, 3.11a and table 3.9. Push and pull the end of the torquearm for easier mounting.
- Tightening the shaft coupling see table 3.10.
- Remove the mounting tool.
- Refit the plug.
- Refit the end cover and tighten the screws together with washers. Torque 80 Nm (59 lbf·ft).
Fig.3.10b
Clean the driven shaft and the

inside of the motor hollow
shaft.
Fig. 3.10a Mounting the CB 280...840
2 1; Bearing retainer
2; Plastic washer
3; Nut
4; Mounting tool
3
4
18
Fig. 3.11 Without stress relieving groove Fig. 3.12
Fig. 3.11a With stress relieving groove
Mounting the motor without a

mounting tool
The motor can be mounted onto the driven
shaft without using a mounting tool, though this
is more difficult and takes longer time. However,
it is easier to mount the motor if during
mounting the compressed air trapped within
the hollow shaft is evacuated. To do this,
remove the End cover as described in
"Mounting the motor with a mounting tool"
Align the motor with the driven shaft using an
overhead crane or lifting truck and press it
carefully onto the shaft so that the length
stated in the table beside is obtained, see
Table 3.9 Fig. 3.11.
Length To achieve the highest possible oil level in the

Motor motor housing, the motor must be turned until
B mm B in the drain outlets are positioned according to
fig 3.12.
CB 280 106 4.17
CB 400 117 4.61
CB 560
153 6.02
CB 800
19
Tightening of shaft coupling
However for the tightening of the coupling Mark the screw heads at 12 oćlock with a pen
screws the following must be observed: or paint so that you can follow the turning
sequence of the screws.
Keep tension in your lifting wires to avoid
a skew setting of the motor on the shaft Set the torque wrench for the specified maxi-
during the tightening of the screws. mum torque. Tightening torque of the coupling
Wobbling caused by a skew setting of the screws; see the sign on the coupling, or table
motor gives extra forces on the main 3.10.
bearings.
Now start tightening the screws in sequence
In order to avoid the misalignment of the two shown in Fig. 3.14.
clamping rings during the screw tightening, the
Keep on doing this until you have reached the
gap between the rings must be measured in
stated torque. Several passes are required
several places during the process, see Fig.
before the screws are tightened to specified
3.14. The difference between the measured
torque. Keep checking the alignment of the
gaps must never vary more than 1 mm (0,04")
coupling. (15-20 passes may be necessary).
during any stage of the tightening process.
When the specified torque is reached it is
Pre-set the coupling screws in opposite pairs
important that all screws are tightened with
(12-6-3-9 oćlock) until you reach max. 50%
specified torque and that no further movement
of the torque specified for the screws. It is very
can be observed.
important that when you reach this stage the
misalignment is controlled as described above.
Table 3.10
Tightening torque
Motor No of Screw Strength Type of
type screws dim class head
Nm lbf·ft
CB 280 12 M20x80
CB 400 15 M20x90
10.9 490 362
Hexagon
CB 560 20
M20x100
CB 840 20
Note 1 Uncoated screws greased with MoS2.

Note 2 There is a metallic sign on every coupling with a tightening torque stamped on it.
This torque is always to be used.
Note 3 Tightening torque value is critical. Use calibrated torque wrench.
20
Fig. 3.14
Fig. 3.14a
3.1.4bMounting the motor onto the driven shaft - splines
Flange mounted motors

o-ring
For flange mounted motors, the spline shall
normally not be subject to radial load.With no
radial load, the splineshaft can be greased before
mounting the motor. If the motor is subject to radial
load, the splines shall be filled up with oil.
- Bolt the motor to the flange. Tightening torque,
see Table 3.10.
Axial clearance min 5 (0.2)
tightening G1 plugg
- Fill up hydraulic oil to the G1 plug.
If oil here, it can be
used for the spline. - Torque the G1 plug. MV=125 Nm/90 lbf.ft.
Then take away
the o-ring. - Mount the end cover. MV=80 Nm/59 lbf.ft.
o-ring 10 (0,4) during Torquearm mounted motors

filling of oil
Motors that carry radial load, must have the
splines filled up with oil.
Spacer
- Mount the spacer on the shaft. MV=450 Nm/300
lbf.ft.
- Fill hydraulic oil to the G1 plug.
- Mount special designed bolt.
- Torque the bolt. MV=385 Nm/280 lbf.ft.
tightening bolt M20 - Mount the end cover. MV=80 Nm/59 lbt.ft.
L=100 mm
21
3.1.5 Removing the motor from the driven shaft

Before dismounting the motor from the driven Removal by using the mounting tool
shaft the oil in the motor housing must be drai-
ned through the lower draining hole. - Slacken the shaft coupling screws gradually;
The motor can be removed from the shaft with see Fig. 3.14 and 3.14a. Each screw should
or without the mounting tool. The operation is be slackened only about a quarter of a
easier if the tool is used. turn each time. Thus tilting and jamming of
the collars or thread stretching will be
avoided. The screws must be slackened until
the coupling ring is fully released.
- Remove the End cover and Bearing retainer
together with screws and washers; see Fig.
Never stay below the mo-
3.15
tor during disassembly
- Locate the existing plastic washer outside the
mounting tool nut.Then pass the tool
through the centre shaft, and screw it into
Always make sure that the the driven shaft to stated depth.
lifting equipment is strong - Screw in the nut of the tool until the Bearing
enough to handle the retainer can be refitted, torque 136 Nm (100
weight of the motor lbf·ft)
- Remove the motor from the driven shaft by
unscrewing the nut of the mounting tool.
- Remove the Bearing retainer and mounting
tool. Finally, refit the removed Bearing retai-
ner, torque 136 Nm (100 lbf·ft) and End cover,
Fig. 3.15 Removal of Compact CB 280...840 torque 80 Nm (59 lbf·ft) as before.
Removing the motor without using the

mounting tool
1 - Slacken the screws of the shaft coupling, see

2 above "Removal of motors by using the
mounting tool".
- Remove end cover and plug to allow air to
enter the space in the hollow shaft of the mo-
tor; see “Mounting the motor without a
mounting tool“. After removal of the motor, refit
3 the removed components as before.
4
- Carefully pull the motor off the driven shaft
supported by an overhead crane or a lifting
truck.
1; Bearing retainer
2; Plastic Washer
3; Nut
4; Mounting tool
22
3.1.6 Mounting the reaction point

Fig. 3.16 Mounting of pivoted attachment
x = ±2 mm (0,079) misalignment in installation.
x ≤ ±15 mm (0,59) movement when in use.
Alternative
Note: The toggle bearing must position
be dismounted during welding.
Steel:
EN 10113S355N
DIN St E39
BS 4360 Grade 50 C
Protected against corrosion, after welding.
Fig. 3.18
DANGER ZONE
Fig. 3.17 In case of failure of
torque arm installation
Make sure that the foundation

can withstand the forces from
the torque arm.
23
Installation Installation and Maintenance Manual, Compact
3.2 Oil connections

When using (heavy wall) piping and in frequent Fig. 3.25a
reversal drives, it is recommended to fit flexible
hoses between the motor and piping to avoid
damage due to vibration and to simplify instal-
lation of the motor. The length of the hoses
should be kept fuirly short.
Fig. 3.25
T4
Table 3.11
Connection Description Remarks
If C is used as the inlet, the motor shaft rotates clockwise,

C1, C2 Main connection
viewed from the motor shaft side.
If A is used as the inlet, the motor shaft rotates counter-
A1, A2 Main connection
clockwise, viewed from the motor shaft side.
D1 Drain outlet Normally plugged at delivery.
D2, D3, D4 Alternative drain outlets Normally plugged at delivery.
F1,F2 Flushing connection For flushing of radial lip seal. Normally plugged.
F3 Flushing connection For flushing of axial bearing and motor case.
Used to measure pressure and/or temperature at the main

T1 Test connection
connections.
T2, T3 Test connection Used to measure pressure and/or temperature in drain oil.
T4 Pressure connection Connection for double ended torque arm.
Table 3.12
D1, D2, F1, T1, y y x x
Motor A** C** D4 F3 T3 T4
1 1/4" 1 1/4" G 1/4" 223 8.78 99 3.90

CB 280...840 G 1 1/4" G 1 1/4" G 1/4" G 1/2 " G 1/4" G 1/2"
1 1/2" 1 1/2" M16 223 8.78 101 3.98
**SAE coupling J 518 C, code 62, 414 bar (6000 psi). 1 1/4" or 1 1/2" can be used.
*** A2-connection and C2-connection is blocked at delivery. They are able to withstand max pressure.
24
Main connection A, C
Fig. 3.25b
Table 3.13
a c
Motor Connection b
mm (in) mm (in)
1 1/4" UNC 1/2" 27 (1.06)

CB 280 - 840 31 (1.22)
1 1/2" UNC 5/8" 35 (1.38)
Drain connection D1, D2, D4 Test connection T

Fig. 3.25c Fig. 3.25d
3/4"
G1 1/4"
∅ 65
(2,56)
G
BSP
25
3.2.1 Direction of rotation of

motor shaft Fig. 3.26
With the inlet pressure supply connected to A

port, the motor shaft rotates in the direction A1
C1
shown by the arrow, anti-clockwise viewed from
the motor shaft side.
With the inlet pressure supply connected to C
port, the motor shaft rotates clockwise viewed
from the motor shaft side.
3.2.2 Draining and venting the motor

Horizontal mounting
When the motor is installed with the shaft in the horizontal plane. The highest of the four drain
outlets D1, D2, D3 or D4 must always be used; see Fig. 3.28.
Drain line must be connected direct to the tank with a minimum of restrictions, to ensure that the
maximum housing pressure is not exceeded.
Vertical mounting
When the motor is mounted vertically, the highest of the four drain outlets D1, D2, D3 or D4 must
be used. Flushing of radial seal from low pressure is necessary.
Motor shaft pointing downwards

The motor must be connected to one of the drain connections in the connection block; see
Figure 3.29. The flushing connection F2 shall be connected to low pressure connection.
Orifice must be installed.
Motor shaft pointing upwards

The motor must be connected to the drain line connection on the shaft end housing; see Figure
3.30.
The flushing connection F1 on the shaft end housing should be connected to the low pressure
connection. With bi-directional drives, use the connection with lowest average pressure. (Connec-
tion to high pressure will increase the motor drain flow). This gives flushing of the radial lip seal. It is
advisable to fit the nipple and the hose to the motor before fitting the torque arm.
Make sure that this

checkvalve is connected
in the correct direction.
26
Fig. 3.28 Fig. 3.29
Drain line
Low pressure
connection
Drain line
connection
Fig. 3.30 G 1/4", Flushing

Fig. 3.31
connection F1

Drain line
connection
G 1/2", Flushing
Low pressure connection F3
3.2.3 Flushing
Flushing of motor case Max. power without flushing

To avoid high temperature in the motor case the CB 280 120 kW (160 hp)
heat must be removed, because high temperature CB 400/560/840 170 kW (227 hp)
gives lower viscosity and that gives reduction in
basic rating life/service life. For calculation of required flushing, please contact
your Hägglunds representative.The flushing oil shall
- For continuous duty in applications with an be drained in the normal drainline. See 3.2.2.
ambient temperature of +20°C (68°F), the motor
case must be flushed when the output power Connect the input line for flushing in F3, see Fig
exceeds the values shown beside. 3.31.
27
4. OPERATING INSTRUCTIONS
4.1 Storage
The motor is delivered with internal protection in the form of an oil film and external protection in the form of an
anti-rust film. This provides sufficient protection for indoor storage in normal temperatures for about 12 months.
Note: the anti-rust protection must be touched-up after transport and handling.
If the motor is stored for more than 3 months in uncontrolled environment or more than 12 months in controlled
environment, it must be filled with oil and positioned as shown in Fig. 3.7.
Place the motor as shown in fig 4.1, fill the motor with filtered oil in the following order: D1, A1, C1. See 2.3,
"Filtration" and table 4.1.
Take extreme care to ensure that no contamination enters the motor.
Seal connections A and C with the cover plate fitted to the connection surface at delivery. Check that the O-
rings or rubber seals are in postion in the cover plate.
Fit the plug to D1, D2, D3 and D4, the table below states the amount of oil needed to fill the various types of
motors.
4.2 Before commissioning

Check the following points before commissioning the motor, i.e. before starting the first time:
- Check that the motor is connected to give the correct direction of rotation (see 3.2 "Oil connections" and
3.2.1 "Direction of rotation of motor shaft").
- Select the hydraulic fluid in accordance with the recommendations (see 2.3 "Choice of hydraulic fluid").
- Fill the motor housing with hydraulic fluid via a filter into the drain outlets D1, D2 or the vent hole (depending
on how the motor is mounted), see table 4.1.
- Check the drain line to ensure that excessive pressure does not build up in the motor housing; see 3.1
"Mounting instructions" and 3.2.2. "Draining and venting the motor".
- Check that the motor is protected from overloads (see 1.1 "Motor data").
- Check that the charge pressure conforms to the
charge pressure curve (see 2.1 "Recommended
Fig. 4.1 charge pressure").
- Check that all hydraulic couplings and plugs are
properly tightened to prevent leakage.
- Make sure that the torque arm is sufficiently faste-
ned, see 3.1.3 and 3.1.6.
Table 4.1
Oil volume approx.
Motor
Litres US gal.
CB 280 15 4.0
CB 400 21 5.6
CB 560 19 5.0
CB 840 25 6.6
28
4.3 Commissioning 4.4 Periodic maintenance

- During initial star ting and the period When a hydraulic system has been in service
immediately after it, any hydraulic installa- for some time, it must undergo periodic
tion must be regularly and carefully checked maintenance and servicing at intervals which
at frequent intervals. depend on the equipment and the type of duty.
- The working pressure and charge pressure This periodic maintenance must include the
must be checked to ensure that they following operations:
correspond to the contracted values. - Check the hydraulic system for leakage.
- The pressure in the drain line measured at Tighten the screws, replace faulty seals and
the motor must be less than 3 bar (43,5 psi). keep the drive clean.
This pressure limit is important for the life of - Inspect and clean all air, oil and magnetic
the motor seals. filters; replace all filter cartridges for which a
- If leakage occurs, correct the fault and carry filter clogged indication has been given;
out new measurements. inspect tank, pump, filters etc. and clean if
necessary.
- Check all lines, connections, screws, etc. and
correct if necessary. - Check the pressure and temperature of the
hydraulic fluid and carry out routine opera-
- Check other possible leakage points and tions. Adjust valves etc. if necessary.
replace faulty parts.
- Check the hydraulic fluid; see the Section
- During the start up period, dirt particles in headed "Oil".
the system are removed by the filters. The
filter cartridges have to be changed after the - Check that no dirt or other contaminations
first 100 working hours and after that enter the system during inspection.Check
according to the maintenance chart. see 4.4 that the outside of the hydraulic motor in an
note to check the "filter clogged" indicators. installation is kept free of dirt; thus leakage
and faults will be detected earlier.
A not run-in motor in combination with dirt
particles in the oil can badly affect the sliding - We recommend that a running log be kept
surfaces in the motor. This is valid during the and that planned inspections are carried out
first 100 working hours. at set intervals.
- Maintenance checks and operations are as
follows:
Maintenance chart
Oil Torque
In operation Oil
filters arm
After the first

100 hours
Rpl. Insp.
After 3
months or Rpl.
500 hours
Once every 6
months
Rpl. Insp. Insp.
Once every
12 months
Rpl = Replacement Insp = Inspection
29
Motor Filters
If the motor is to be stored stationary for a Filters must be changed after the first 100
longer period than about 1 month, it must be working hours and the second change is to be
protected from internal rust. This can be done carried out after 3 months or 500 working hours
as follows: whichever is earlier. They must then be
1. Mix anti-rust additive with the hydraulic changed at regular intervals of 6 months or
fluid of the system. Use 5% of Rust Veto 4000 working hours.
Concentrate (manufactured by E F
Houghton & Co, Philadelphia, USA). This Oil (Se also 2.3)
additive gives rust protection for up to
about 1 year, after which time the motor Analysis
must be turned a few revolutions.
It is recommended that the oil should be analy-
2. If no additives are used, the motor must sed every 6 months. The analysis should cover
be regularly turned a few revolutions. viscosity, oxidation, water content, additives
3. If it is not possible to turn the motor, plug and contamination.
all connections, open drain outlet D1 or D2 Most oil suppliers are equipped to analyse the
on the port end housing (or if the motor is state of the oil and to recommend appropriate
mounted vertically, Flushing connection F1 action. The oil must be replaced immediately if
on the shaft end housing) and fill the motor the analysis shows that it is exhausted.
with hydraulic fluid.(See Fig. 4.3 and Fig.
4.3a). Viscosity
Many hydraulic oils become thinner with
Fig. 4.3
increasing use, and this means poorer
lubrication. The viscosity of the oil in service
must never fall below the minimum recom-
mended viscosity.
Oxidation
Hydraulic oil oxidizes with time of use and
temperature. This is indicated by changes in
colour and smell, increased acidity or the for-
mation of sludge in the tank. The rate of oxida-
Fig. 4.3a tion increases rapidly at surface temperatures
above 60°C (140°F), and the oil should then
be checked more often.
The oxidation process increases the acidity of
the fluid; the acidity is stated in terms of the
"neutralisation number". Typical oxidation is
slow initially and increases rapidly later.
A sharp increase (by a factor of 2 and 3) in the
neutralisation number between inspections is
a signal that the oil has oxidized too much and
should be replaced immediately.
30
Water content
Contamination of the oil by water can be Another method is to install an inline particle
detected by sampling from the bottom of the counter direct in your hydraulic system which
tank. Most hydraulic oils repel the water, which give you the contamination level according to
then collects at the bottom of the tank. This the international rules, the disadvantage with
water must be drained off at regular intervals. this method is that you only get the
Certain types of transmission oils and engine contamination level in the oil.
oils emulsify the water; this can be detected
by coatings on filter cartridges or a change in General
the colour of the oil. Obtain the advice of your The intention is to verify the condition of the oil
oil supplier in such cases. during operation.The motors should be running
Degree of contamination at normal operation while the sample is taken.
The cleanliness is extremely important during
Heavy contamination of the oil causes sampling.
increased wear of the hydraulic system Always use bottles adapted to oil samples,
components. The cause of the contamination they can be ordered from any fluid analysis
must be immediately investigated and re- laboratory.
medied. Never try to clean your own bottle if you want
a true value of the result.
The sample should be taken by using a mini-
mess hose connected to a mini-mess
coupling.
Always clean the connections carefully before
All hydraulic fluids are affected you connect the mini-mess hose to the
differently. Obtain the advice of coupling.
your oil supplier or by nearest Be careful when connecting the mini-mess
Hägglunds representative. hose because the oil beam can be dangerous
and should never point against any person or
other sensible object.
Check and be aware of the pressure you
4.5 Oil inspection mayhave on the connection before you
Purpose connect.
The purpose to take an oil sample is to check
the condition of the oil. How to do
With scheduled oil analysis, wear products can Bottle samples
be identified and corrective action can be taken The sample shall be taken at the mini-mess
before failure occurs. Oil analysis can indicate coupling on the charge pressure side of the
when an oil change is required, point out motor in the closed loop system. Never out of
shortcomings in maintenance and keep repair the tank using the ball valves.
cost to a minimum. Using oil analysis can Clean the coupling and the hose carefully.
create a “window of opportunity”, allowing the Connect the mini-mess hose to the coupling
user to schedule re-fittings or overhauls, but be careful and be aware of the direction of
maintenance or repairs, thus saving money on the oil beam.
equipment repairs and downtime. Let minimum 2 litres (0,6 gallon US) of oil flush
The most used method is to take samples in a into a bucket before you fill the bottle.
special bottle and send it to a fluid laboratory Remove the cap of the bottle as late as
for an analysis and from the laboratory you possible and don’t let any contamination be in
get a repor t, which follow a specific touch with the cap, bottle or the mini-mess hose
international standard. when the sample is taken.
You have to select what analysis the laboratory In dirty air area, use a soft plastic foil (normal
should take, but the most used analysis are as protection in laboratory bottles between
particle count, water content, oxidation and bottle and cap).
viscosity.
31
Fault finding Installation and Maintenance Manual, Compac CB
Do not remove the foil, prick the end of your Inline measure
mini-mess hose through the foil into the bottle The sample shall be taken at the mini-mess
and fill. coupling on the charge pressure side of the
To get a reliable result the system must run motor in of the closed loop system. Clean the
without moving any valves and the mini-mess coupling and the hose carefully.
hose should not touch the bottle. Connect the hoses according to the particle
Only ¾ of the bottle shall be filled because the counters manual.
laboratory has to shake the sample to get a To get a true value the contamination readings
mixed fluid when they analyse it. Minimum have to be stable about 10 min before you stop
200ml are needed for a good analysis. to measure.
When the bottled is filled close the cap as soon
as possible to prevent contamination from the
air that might enter the bottle and give you a
wrong result.
5. FAULT FINDING
Hydraulic motor
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pressure has
risen to the relief valve setting, remove the
load from the drive.
The motor does not deliver Investigate the pressure level in the system
enough torque because the and correct the setting of the pressure limiting
pressure difference across the valve if necessary.
motor is not great enough for
the load.
Insufficient or no oil being Check the hydraulic system. Check the

supplied to motor. external leakage of the motor.
(The D connection)
Motor rotates in wrong Oil supply connections to Connect the oil supply correctly.
direction. motor incorrectly connected.
Motor runs jerkily. Pressure or flow fluctuations Find the cause in the system or in the driven
in the hydraulic system. unit.
Noise in the motor. The motor is being operated Adjust the charge pressure to the correct
with the charge pressure too level. See 2.1 "Recommended charge
low. pressures".
Internal faults in the motor. Investigate the drain oil, if necessary. Put a
magnetic plug in the oil flow and check the
material that sticks to the magnet. Steel
particles indicate damage. Note that fine
material from the castings may be deposited
and does not mean internal damage in the
motor.
External oil leakage on The radial lip seal is worn. Replace the radial lip seal.
the motor.
32
Deklaration of conformity Installation and Maintenance Manual, Compact CB
DECLARATION OF CONFORMITY
Example of the Declaration of Conformity given by Hägglunds Drives AB
178 XXXX-XXX CB 280 XXXXXX
The DECLARATION OF CONFORMITY above, is available on request for deliveries from

Hägglunds Drives AB. Translations into other languages are also available.
33
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
740
4
THROUGH HOLE 110 AVAILABLE

A A
A,A1 C,C1 (29,134)
(0,157)
RO
N TA
ATIO TIO
RO
T N
C1 40 H
A1 (1,575)
(4,331)
(26,772 -0,0062)
45°
-0,0013
A
-0,024
-0,149
H (2:1)
B D1 30 B
C C (1,181)
D4 B B
680
223 (2x)
(8,780)
174 (4x)
(6,850)
(17,008 +0,00078)
C C
+0,00235
)
(29,213 -0,024)
+0,0029
+0,063
432 +0,023
+0,072
+0,023
6x15
742 ±0,6
(17,323)
(0,236)
440
200 0
(7,874 +0
117
(4,606)
D D
D2 T3
E A2 Not 1. E
A
C2 Note 1.
T4 A M20 (34x)
T4 1/2"UNC (16x) 31 (4x)
(1,220)
38
Equ 9° A
ally (1,496)
(1,063)
F F
(1,457)
divi 207 (4x)
27
ded
37
(8,150) 237 425
(9,331) (16,732)
489
782 101 (19,252)
G (30,787) G
B-B (1 : 1) (3,976)
250 224 = = = = A1 C1
25° 55°
(9.843) (8,819)
5/8"UNC (16x) T1 T1
D3 F1 D1 D3
H H
(1,378)
(1,772)
D4
35
45
F2
A F3
D2 F1
(3,346)
(2,874)
85
= = = =
73
T2
C-C (1 : 1)
I T3 I
99 A (1 : 2)
T4 T4
(2,126)
(3,898)
54
MOMENT OF INERTIA = 18.3 Kgm² / 434 lbxft² A2 C2

WEIGHT = 1160 Kg / 2555 lb
(12,047)
306
(13,976)
CONNECTION DECRIPTION PORT CONNECTION

355
J A1 MAIN CONNECTION SAE 1¼" AND 1½" ** J


(17,559)
C1 MAIN CONNECTION SAE 1¼" AND 1½" ** without notice or obligation, unless certified
446
A2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** referring to a certain purchase order.
C2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** Information contained herin should be confirmed
D1 DRAIN CONNECTION BSP 1 ¼"
D2, D4 ALTERNATIVE DRAIN CONNECTION BSP 1 ¼" Measurements within brackets indicates
D3 ALTERNATIVE DRAIN CONNECTION BSP 1" measurements in inches.
K T1, T2 TEST CONNECTION M16 x 2 NOTE 1: For tightening torque see installation manual. K
T3 TEST CONNECTION BSP ¼" Must be verified on actual name plate.
A T4 PRESSURE CONNECTION BSP ½"
T1 T1 FLUSHING CONNECTION BSP ¼"
F1, F2 Item No. Qty Article No. Material, type, etc Dimensions Name of item
Part of
FLUSHING CONNECTION BSP ½"

Weight kg
A F3 Tolerances for length, corner radii,

Reference
according to
SS-ISO 2768-1, class m Scale Presiding drawing no Control code
SS-ISO 965, class 6.
Other not indicated tol. 1:2.5
F2 ** SAE coupling J 518 C, code 62, 414 bar (6000 psi) Cad type
SW
Sheet size
A0
Drawn by
Knight/DVN
Description (English)
HYDRAULIC MOTOR CB 400

Part group
A40P
Prepared both for 1¼" and 1½". Accepted for prod by Iss by Dept. Year Week Description (Own language)
SHRINK DISC VERSION

Type design/group
L
T2 99 A F3 Both UNC 1/2" for SAE 1¼" and UNC 5/8" for SAE 1½" Drawing checked by
D52 01 22 CB400
Rev ind Sheet
Similar drawing No.
1
(3,898) A 620 060 LFN 02 05
D52/BLL
Design checked by
078 5003 A No. of sheets
Rev.Ind. Revision Appd. Year Week D5/BHN 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Bill of Material No.: HK-2005032
Bill Of Material
Issued By: JFD 2275 International Street; Columbus, Ohio 43228, USA - -
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: - Assembly Ref(s) :
HOSE KIT Revised By : -
25 FT. LONG, PBC-200 with 1 x P6S/P7S to 1 x CB-280/400 -
WITH MAINLINE, AND DRAINLINE HOSES Rev. Date : Project No. :
- 2005 032
C
Item O Hägglunds Description Manufacturer Mfg. Part. No. Cost, Each Cost, Total
No. Qty. D Part No.
E
1 2 Hose Assembly, 1-1/2" 5000 PSI Hose with, GATES/MOTION IND. GATES
1-1/2" Code 62 Flange 90° One End, HERSCH PARKER
1-1/2" Code 62 Straight Flange Other End, 25 Ft. Lg.
(Main Lines, Motor to Power Unit)
Gates : 24G5K-24FLH-24FLH90M-300".
Parker: 78C-6N-6A-24-24-24-300"
2 1 Hose Assembly, 1-1/4" Low Pressure Hose with GATES/MOTION IND. GATES
1-1/4" JIC 37° Straight Swivel One End, HERSCH PARKER
1-1/4" JIC 37° Swivel 90° Other End, 25 Ft. Lg.
(Motor Case Drain to Power Unit Drain)
Parker: 381-06-39-20-20-20-300"
3 4 Split Flange Kit, with Bolts/Washers GATES/MOTION IND. GATES

1 1/2" Code 62 HERSCH PARKER
Gates : 24FHHS
Parker: HFHFHK-24
4 1 Hose Assembly, 1/2" Low Pressure Hose with GATES/MOTION IND. GATES
1/2" JIC 37° Straight Swivel One End, HERSCH PARKER
1/2" JIC 37° Swivel 90° Other End, 25 Ft. Lg.
(Motor Case Flushing)
Parker: 381-06-39-08-08-08-300"
NOTE: Clean and cap hoses.
$2,274.00
HK2005032.XLS Form No.: F10203-2 | Release Date: 4/6/2001 | Revision: A

Date Issued: Checked By: Hägglunds Drives, Inc. HAS-10392
5/31/2005 CBH BILL OF MATERIALS
Rev.: Prepared By : Hägglunds Drives, Inc.
A JFDIII 2275 International Street, Columbus, OH. 43228
TITLE: Assembly Reference:
LONG TERM OIL FILLING
COMPACT MOTORS (ALL SIZES) Installation/Project:
Item Qty Part No. Description
1 7 - HYDRUALIC OIL, SHELL TELLUS-68, WITH

5% RUST VETO CONCENTRATE
2 1 - LABOR TO UNCRATE MOTOR AND FILL WITH OIL
NOTES:
Fill up motors all the way with following amount of oil and make
sure all drain and vent ports have metal plugs with o-rings:
Rev. By Date Description
HAS10392a.XLS
Bill of Material No.: HAS-10014
Bill Of Material
Date Issued : 10-Mar-1993 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: CBH 2275 International Street; Columbus, Ohio 43228, USA B
Revised By :
Long Term Storage Flange Kit, 1½" HDR
Used for Goldcup P6, P7, P11, P14 and Hagglunds SP250 and SP355 pumps Rev. Date : Project No. :
11-Apr-2008
C
No. Qty. D Part No.
E
1 2 038-58361-0 1-1/2" CODE 62 PROTECTIVE COVER WITH SEAL
2 NOT USED
3 3 HYDRAULIC OIL, SHELL TELLUS-68 WITH 5% RUST VETO
4 1 LABOR TO UNCRATE PUMP AND INSTALL PROTECTIVE COVERS AND FILL WITH OIL
5 8 306-24180-0 HEX HEAD CAP SCREW, 5/8-11 UNC x 1.25" LONG
NOTE:
Install Items 1, 2 and 5 onto pump and then fill with oil
according to the following chart:
HAS10014c.XLS Form No.: F10203-2 | Release Date: 4/6/2001 | Revision: A

Compact CA & CB AC-3.4
Engineering manual ACB-3.4
Accessories
04-03-30, Replaces 03-06-12
Mounting set SMCB1 for speed encoder

Speed encoder kit for Compact CA50-CA210 and
Compact CB280-CB840 motors where the speed
encoder is enclosed and well protected.
The mounting set can be used for both spline and

shrink disc motors.
The encoder is used for detection of speed by

pulse- frequency or/either direction of rotation by
pulse-train.
CB280-CB840 with SMCB1 CA50-CA210 with SMCB1
AC-3.4
Speed encoder SPDB1:
Digital incremental hollow shaft encoder with torque
arm mounting.
Pulse rates: 1000 and 3600 ppr.

Recommendations:
1000 pulses for speed 6 rpm and above.
3600 pulses for speed below 6 rpm.
- Possibility to read direction of rotation from

encoder.
- Encoder is equipped with zero pulse.

Output signal:
ELECTRICAL SPECIFICATION
Supply voltage + EV DC 24V (9-30V) The output signal contains of two pulse trains with
Polarity protected 1000 or 3600 pulses/rev. and inverted signals to
these. When pulse 1 becomes low, pulse 1-inv.
Current consumption at 65mA @ 24V Max 75mA
no load becomes high same for pulses 2 and 2-inv.
Pulse-train 1 and 2 are displaced 1/4 pulse, (90º
Pule rates 1000, 3600 ppr
el) according to each other so direction can be
Accuracy detected. Direction is measured by detection which
Dividing error ± 50° el pulse comes first (see fig. page 3).
Channel seperation 90° ± 25°el
Outputs Short circuit protected There is a zero-pulse on the turn. This pulse becomes
Load max ± 40mA high (pulse 0) or low (pulse 0-inv), when marking on
Max cable length 200m shaft end (cut in hollow-shaft) is in line with cable
Uhigh (at 10mA load) > +EV -2,0V outlet on speed encoder.
Zero pulse length is 1/4 of ordinary pulse length
Ulow (at 10mA load) < 1,15V
(1/4000 or 1/14400 turn).
Female cable connector HD art.no. 5217 5322-150
EMC approval EN 50081-1, EN 50082-2
MECHANICAL SPECIFICATION
Shaft, Stainless steel Hollow-shaft ø 12mm
Moment of inertia 5,4 x 10-6 kgm2
Load max Same direction as motor
Radial 20 N - clockwise
Axial 10 N
Speed max 6000 rpm
Code disc Unbreakable acrylic glass
Temperature
Operating -25°C...+70°C
Storage -25°C...+70°C
Housing Aluminium, anodized
Weight Approx. 250 g
Protection class IP 65 according to IEC 529
Vibration <100 m/s2 (50...2000 Hz)
Shock <1000 m/s2 (11 ms)
AC-3.4
Clockwise, seen from shaft side
360º el. (1 period)
1 inv
2 inv
90º el. (channel separation)

0
0 inv
Connection:
Encoder must be connected with shielded cable, max 0.5 mm2 which is to be solded in connector-pins.
The shield connects to connector-shell.
Connection female cable connector

1 inv 1 PINNING 12 pin contact
Function Pin
0V 1 8
+EV
+EV 12
10 12 0V 10
0 2 inv 1 8
3 6
1 inv 1
4 5
2 5
0 inv 2 2 inv 6
0 3
0 inv 4
Connector seen from solder side.
T-contact:
To be used for external measuring.
HD art. no: 378 5043-801
AC-3.4
F/A converter:
- Frequence to Analogue converter is available as option.
- Analog output signal 4-20 mA.
- F/A-converter must be mounted externally. Technical data
Supply voltage DC 24 V (12-50 V)
HD art. no: 576 4057-001
Power consumption 3W
Operation temp. -20°C...+60°C
Humidity 0-90% RH, non condens-
ing
Temp. coefficient <0,01%/°C
Accuracy better than 0.3%
Resolution 0.1%
Mounting NS35 DIN rail
Size w45 x d70 d h117 mm
Electrical connections
Pulse input:
- Input high Vin > 15 V
- Input low Vin < 6 V
4-20mA output max. output load 500 Ohms
SW1
EMC approval EN 50081-1, EN 50082-2 SW2-1 on
Safety EN 60730 SW2-2 off
LED1 power on
Settings of SW1 for different type of

encoders and rpm range
Rpm for 4-20mA signal
Settings SW1 1000 ppr 3600 ppr

0 0 - 0,1 rpm 0 - 0,03 rpm
1 0 - 0,2 rpm 0 - 0,06 rpm
2 0 - 0,5 rpm 0 - 0,14 rpm Connection diagram
3 0 - 1,0 rpm 0 - 0,28 rpm
4 0 - 2,0 rpm 0 - 0,56 rpm
5 0 - 5,0 rpm 0 - 1,39 rpm +24 V (15-30 V)
6 0 - 10,0 rpm 0 - 2,78 rpm 0V
7 0 - 20,0 rpm 0 - 5,56 rpm
8 0 - 6,0 rpm 0 - 1,67 rpm
Encoder
9 0- 12,0 rpm 0 - 3,33 rpm

A 0 - 30,0 rpm 0 - 8,33 rpm
4-20 mA out
B 0 - 60,0 rpm 0 - 16,67 rpm
C 0 - 120,0 rpm 0 - 33,33 rpm F/A 4-20 mA ret.
D 0 - 300,0 rpm 0 - 83,33 rpm
E 0 - 600,0 rpm 0 - 166,67 rpm
F 0 - 1200,0 rpm 0 - 333,33 rpm
1 2 3 4 5 6 7 8
+0,009
635 M20 (40x)
68 - 0,021
A +0,00052 (25,000) A
(2,677 -0,00066)
(1,417)
(1,575)
A-A
36
40
1250
(49,213)
1330
(52,362)
1721
(67,756)
B B
R410
(16,142)
(12,070)
C
307
C
A A
19
(0,748) (29 742
,21
3)
D D
B
57 485 429
(2,244) (19,080) (16,890)
(17,717)
(21,457 -0,277)
+0,273

450
without notice or obligation, unless certified

545 ±7
150
E referring to a certain purchase order. E
(5,906)
Information contained herein should be confirmed
Figures within brackets indicate Item No. Qty Article No. Material, type, etc Dimensions Name of item
measurements in inches. Tolerances for length, corner radii,

Part of Weight kg
Reference
according to
SS-ISO 2768-1, class m Scale Preceding drawing no Control code
40
Other not indicated tol. 4 (0,157) SS-ISO 965, class 6.
Other not indicated tol. 1:5
(0,787)
Cad type Sheet size Drawn by Description (English) Prod group

(1,575) TORQUE ARM TCA40
20
210
Weight: 128 kg / 282 lb (arm) SW A2 Knight/DVN A00A
(8,268) Accepted for prod by Iss by Dept. Year Week Description (Own language) Type design/group
135 Weight: 34 kg / 75 lb (Piv.att.) D52 01 24 MOMENTARM DIM.RITN. TCA 40 F

(5,315) Drawing checked by Rev ind Sheet
Similar drawing No.
D522/TKN 1
B-B
Rev.Ind. Revision Appd. Year Week
Design checked by
D52/BLL 278 5016 No. of sheets
1 TCA 40
1 2 3 4 5 6 7 8
PBC POWER UNIT MANUAL
Installation and
Maintenance Manual
PBC
Preface Installation and Maintenance Manual, Power Unit PBC
Preface
Hägglunds Drives is one of the world’s leading manufacturers of low speed,
high torque and heavy-duty hydraulic drive systems. We supply a durable
drive system that will work under the toughest conditions with a minimum
level of maintenance requirements. We have industrial and marine custom-
ers all over the world. They know that when they seek solutions, support or
service, they can trust Hägglunds Drives to be there. The Hägglunds Drives
main office and manufacturing plant is located in Mellansel, Sweden. In
addition, there are sales and service offices in 40 countries worldwide.
Our high quality drive systems are based upon our unique hydraulic piston
motors, which were developed through experience accumulated over 30
years in marine and industrial areas. Today this ongoing development work
has resulted in our PBC power unit product line. This is what powers our
drive systems. New, as well as established technical solutions contribute to
the creation of this product. The most desirable features and operating reli-
ability have been designed into this power unit, PBC.

of the PBC. In order to find particular information, just search for the appli-
cable section as listed in the table of contents. However, changes in the
equipment may occur. Therefore, we reserve the right to introduce amend-
ments in the manual, as we deem necessary without notice or obligations.
Before starting the installation and/or maintenance, the manual must be read
and thoroughly understood in all respects. All involved personnel shall read
and acknowledge the safety precautions that are stated in section 1.1.
The content in this manual is subject to change without notice or

obligation. Therefore, information contained herein should always
be confirmed with Hägglunds Drives or its representatives.
Original AM326-1A 1999
2
Installation and Maintenance Manual, Power Unit PBC Contents
Contents
1. GENERAL ........................................................................................................................ 4
1.1 Safety precautions ........................................................................................................................4
1.2 Operating principle ........................................................................................................................6
2. TECHNICAL DATA .......................................................................................................... 7
2.1 Operating conditions .....................................................................................................................7
2.2 Cooling water ................................................................................................................................7
2.3 Requirements for hydraulic fluid cleanliness .................................................................................7
2.4 Choice of hydraulic fluid ................................................................................................................8
2.5 Power unit monitoring....................................................................................................................9
3. HANDLING OF THE PACKED POWER UNIT .............................................................. 10
3.1 Storage of the packed power unit ................................................................................................10
3.2 Lifting the packed power unit .......................................................................................................10
4. INSTALLATION ............................................................................................................. 11
4.1 Installation directions ................................................................................................................... 11
4.2 Lifting methods and weights ........................................................................................................12
4.3 Positioning the power unit ...........................................................................................................13
4.4 Mounting of the cabinet feet ........................................................................................................14
4.5 Mounting of electric motor ...........................................................................................................14
4.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................15
4.7 Hydraulic connections .................................................................................................................15
4.8 Electric connections ....................................................................................................................16
4.9 Pipe work ....................................................................................................................................16
4.10 Extra filtration prior to start up ...................................................................................................19
4.11 Commissioning......................................................................................................... 20
4.11.1 Prior to commissioning ...........................................................................................................20
4.11.2 Filling up the system with hydraulic fluid .................................................................................20
4.11.3 Initial start up procedure .........................................................................................................22
4.12 Pump settings and adjustments ................................................................................................24
5. PREVENTIVE MAINTENANCE ..................................................................................... 25
5.1 Maintenance log ..........................................................................................................................25
5.2 Maintenance chart .......................................................................................................................25
5.3 Filter change ...............................................................................................................................26
5.4 Inspection of hydraulic fluid .........................................................................................................27
5.5 Lubrication of electric motor ........................................................................................................28
5.6 Air breather change .....................................................................................................................28
5.7 Cleaning of Air-Oil cooler.............................................................................................................29
5.8 Power unit out of service .............................................................................................................29
6. CORRECTIVE MAINTENANCE .................................................................................... 29
6.1 Common ......................................................................................................................................29
6.2 Change of hydraulic pump/electric motor assembly ....................................................................30
6.3 Troubleshooting ...........................................................................................................................31
7. DISPOSING OF POWER UNIT ..................................................................................... 32
3
General Installation and Maintenance Manual, Power Unit PBC
1. GENERAL
It is of extreme importance that the safety precautions are always followed. If you are unsure about
anything, please contact your nearest Hägglunds Drives representative for advice.
Warning signs
In this manual, you will find the following signs, which indicate a potential hazard that can or will cause
personal injury or substantial property damage. There are three levels of hazard classification:
DANGER
! DANGER is used to indicate the presence of a hazard, which will
WARNING
! WARNING is used to indicate the presence of a hazard, which can
!
CAUTION
CAUTION is used to indicate the presence of a hazard, which will or
can cause minor personal injury or property damage if the warning is
ignored.
General
Limit access to the equipment only to authorized personnel. Only perform measures on the PBC when
you are completely familiar with the function of the power unit (including the control system) as well as
the complete drive.
Service and repair of the electrical, hydraulic, and the mechanical functions require professional ser-
vice personnel who are aware of risks involved.
Safety equipment necessary for the prevention of accidents during the mounting and maintenance
must be used in accordance with the regulations prevailing in the local country.
4
Installation and Maintenance Manual, Power Unit PBC General
Prior to troubleshooting
• Use the order code and other attached technical documentation to identify the features of your
unique power unit and system.
• Read the attached technical documentation (this manual included) and make yourself familiar
with the PBC (control system included) as well as the complete drive.
• Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection.
• Always ensure that there is no accumulated energy in the system prior to maintenance.
• Ensure that all electric power is off and locked out.
• Ensure that there is no entrapped pressure in the hydraulic system.
• Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,
for example loads on the shaft or winch drum.
• If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be
secured, or in the rest position (hanging load).
• Ensure that all accumulators are discharged.
Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in accordance with the
regulations prevailing in the local country.
All electrical supply levels shall be within the limits that the equipment is constructed for, see technical
documentation and maximum rating plates.
Mounting
Carefully follow the instructions and be aware of the large weights and forces involved during lifting.
Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause
personal injury or property damage.
Before starting up
Before starting up new, rebuilt or serviced drive systems, all accessories and safety arrangement
functions need to be checked and tested.
Maintenance and service
Follow the maintenance intervals for your specific PBC or the maximum intervals on the maintenance
chart (section 5.2 “Maintenance Chart”) and keep a maintenance log. Regular and correct mainte-
nance is necessary for reliable and safe operation.
Only use spare parts recommended and supplied by the Hägglunds Drives organization.
Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment.
Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain
noxious contaminates. We recommend using the service of a professional oil company for supply and
disposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.
Bell housing
Note that there are rotating parts inside the bell housing during operation. Be careful during inspection
through the inspection hole. Replace inspection cover when finished.
Hot surfaces
Temperatures in the hydraulic system above 158° F (70° C) will create hot surfaces.
Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an emergency situa-
tion. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.
5
Operating Principle Installation and Maintenance Manual, Power Unit PBC
1.2 Operating principle 17
18
Main components
1. Hydraulic pump AIR
FLOW
2. Drain valve 20
3. Sight glass 19
8
4. Charge pressure gauge
5. Servo pressure gauge
6. Main pressure gauge ‘B’ port
7. Main pressure gauge ‘A’ port
8. Air breather 11
11 6
9. Drain filter 7 4
10. Return filter 5 5
4 7
11. Electric motor 6
12. Filter switch 12 3
13. Suction valve limit switch 14

12
14
12
14. Charge pressure switch 15 9
15. Electrohydraulic stroker 10 10

16
16. Oil heater 13
17. Terminal box 15
18. Oil Cooler 1 2

19. Temperature switch D D
20. Level switch
Note: Changes from the picture and

main components table above may
occur.
Function
The function of the power unit is to provide the hydraulic motor(s) (or other hydraulic systems) with the
required flow of oil and pressure at the right time. All included parts are assembled in one (or more)
compact cabinet(s). The PBC has one or more pumps driven by one or more electric motors. The
main pump is an axial piston pump with variable displacement for closed loop systems. The electric
motor is totally enclosed fan cooled. Two different control systems are available.
Control systems available
Spider: A small, compact and configurable con- The PBC is a very flexible product with a wide
trol system. It can health monitor the power unit range of options. This makes it possible to select
and can control one or two pumps with three pre- a standard power unit to fulfill the features needed
programmed functions: in many different applications. This installation and
maintenance manual is intended to cover all stan-
• Basic, for most of our drives can be config-
dard options. It may not cover all details on spe-
ured for speed feedback control and power
cial power units, which differ from the standard PBC
limitation.
concept.
• Shredder, for shredder applications.
• Synchro, for friction and synchronized drives.
It is important to check the
MCA: For special control functions, normally based other attached technical
on PLC and control cards.
Note: It is also possible to control the PBC from
!
CAUTION
documentation to identify
the features of your unique
external control systems provided by the customer. power unit.
6
2. TECHNICAL DATA
2.1 Operating conditions
The standard PBC unit is designed for the conditions listed below. If the requirements are outside of
the conditions listed below, contact your Hägglunds Drives representative with your specific require-
ments for special design considerations.
Ambient temperature: Minimum 32° F (0° C) to a maximum 85° F (30° C).
Altitude: Maximum 3,300 feet (1000 m).
Classified Location: Unit is designed for a standard location. Units can be built for use in
classified hazardous locations. Contact your Hägglunds Drives representative for more details.
2.2 Cooling water

The cooling system is primarily designed to operate with clean water.
When there are particles in the water, larger than 0.02 in. (0.5 mm), a water filter must be used.
It is important to:
• Maintain the water filter (if any) in a correct way, this is to get the required flow of water through
the water oil cooler.
• Ensure you have the required flow, pressure and temperature of the cooling water (see attached
technical documentation).
• Check the temperature in the hydraulic system, according to the maintenance intervals for your
specific power unit or the maximum intervals on the maintenance chart.
• Clean the cooling system if the temperature in the hydraulic system is above the specified limits.
• Clean and empty the cooling system (waterside) before periods of inactivity (especially if the
cooling water is not totally clean).
If cooling capacity is too low, the service life of hydraulic motor, the main
components in power unit, and the hydraulic fluid will be reduced.
2.3 Requirements for hydraulic fluid cleanliness

The PBC is equipped with filters on the drain and return line(s). In order to obtain rated service life it is
important to follow recommendations concerning cleanliness levels and maintenance requirements.
Cleanliness recommendations
• The system must be flushed before start up (section 4.11 “Flushing before start up”).
• When filling the tank with hydraulic fluid it is important to fill through the quick connection (sec-
tion 4.11.2 “Filling up the system with hydraulic fluid”).
• The particle contamination level in the system should not exceed ISO/DIS 4406 16/13 (NAS
1638, class 7).
• The water content shall be <0.1% and in individual applications with high demands for service
life, <0.05%.
• Always use filter elements recommended and supplied by the Hägglunds Drives organization.
• The hydraulic fluid should be analyzed according to the special maintenance intervals for your
specific PBC or the maximum intervals on the maintenance chart (section 5.2 “Maintenance
Chart”). You should be particularly careful when removing equipment for repairs or maintenance
so that dirt cannot enter the system. Components should be cleaned and free of dirt prior to
disassembly.
Do not reuse hydraulic fluid that has leaked out.
7

The power unit is primarily designed to operate on conventional petroleum based hydraulic fluids.
Consultation with a Hägglunds Drives service representative is recommended when choosing your
hydraulic fluid.
The hydraulic fluid has to fulfill the following requirements:
• Have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354).
• Contain inhibitors to prevent oxidation, corrosion and foaming.
• Have a viscosity within the prescribed interval for both PBC (see below) and hydraulic motor at
operating temperature (measured in the motor case).
• Have a water content of <0.1% and in individual applications with high demands for service life,
<0.05%.
For other hydraulic fluids, please contact your Hägglunds Drives representative when:
• You may need other seals within the pump and other components.
• The service life, maximum pressure and maximum speed for the pumps may be reduced.
Viscosity limits RECOMMENDED VISCOSITY at

Recommended 100 VI operating temperature 40-150
Viscosity index VI For operation with large
150 VI cSt (187-720 SSU)
temperature difference
Minimum continuous 40 cSt (187 SSU) At cold start the maximum
Minimum intermittent 20 cSt (98 SSU) permissible viscosity is 1600
Viscosity v cSt (7400 SSU) run with low
Maximum continuous 150 cSt (720 SSU)
Maximum intermittent 1600 cSt (7400 SSU) pressure and low flow.
Temperature ºF (measured in the motor case)

50 100 150 200
1000 Viscosity v SSU
Viscosity v cSt
150 720
100 RECOMMENDED
VISCOSITY
40 187
VG VG
VG 100 150
46
VG
68
10
0 10 20 30 40 50 60 70 80 90 100
Temperature ºC (measured in the motor case)
• Check caution sign on container or consult the supplier.

• Avoid prolonged contact of hydraulic fluid with your skin.
!
WARNING
• Use services of a professional oil supplier for disposal of used fluids,
and filter elements.
• Never dump hydraulic fluid into drainage or water supplies.
• Clean hydraulic fluid spills from floors immediately to prevent injury.
8
2.5 Power unit monitoring

If the monitoring function is not included in a control system supplied with the PBC, the following
function must be fulfilled in the system.
MONITORING SWITCHES EXTERNAL FUNCTIONS
POWER UNIT
Maximum oil
Temperature switch
1
Minimum oil
Temperature switch
1
Minimum oil
level switch
Closed suction
1 1 STOP HYDRAULIC MOTOR
line switch
1
1s 0s STOP ELECTRIC MOTOR
Low charge Time delay off
pressure switch Time delay on
0s 0.5s
1
5s 0s
&
Time delay on
Electric motor started
Warning oil
temperature switch
1
Low oil
level switch
1
Return filter Time delay off
switch
Drain filter
0s 5s
1 1 WARNING INDICATION
Time delay off
switch
0s 5s
1
High pressure Time delay off
switch
0s 5s
1
The monitoring of the power unit switches are grouped in two levels according to the above logic
diagram.
The warning indication is to inform about a problem in the PBC but does not need an immediate action.
The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulic
motor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stop
the electric motor.
The low charge pressure switch must be interlocked during stop and start-up of the electric motor, to
avoid alarm and give the pump time to build up the charge pressure after start.
9
3. HANDLING OF THE PACKED POWER UNIT

3.1 Storage of the packed power unit
At delivery, the hydraulic components are protected internally by an oil film (containing rust preventing
additives). This provides sufficient protection for indoor storage in air conditioned premises for up to
12 months.
The PBC and included parts should be stored indoors, in dry, vibration free and dust free conditions. It
should not be stored for more than three months in non-air conditioned premises. (That also includes
parts belonging to the power unit that are delivered separately).
Place the power unit where it will not be exposed to direct sunlight or extreme cold to avoid condensa-
tion.
If storage time exceeds the above mentioned limits, then the power
unit must be operated so that the hydraulic system is lubricated with
new fluid. (section 5.8 “Power unit out of service”)
3.2 Lifting the packed power unit
The packed power unit is labeled with center of gravity and

weight. Normally the power unit package is designed for forklift
truck handling.
Center of Gravity Label
• Center of gravity is high, see label on the power unit.
!
CAUTION
•
•
Avoid rapid acceleration, deceleration and turns while
moving the equipment.
Position the forks according to the instructions below.

• The minimum distance between the forks is 31.5 in. (800 mm) for a 1 pump PBC and 43.3 in.
(1100 mm) for a 2 pump power unit.
Parts that are delivered separately
• The package is always labeled with the weight.
• Packages on shipping skids are designed for forklift truck handling only.
• Some other packages may be lifted with a lifting crane, always check the label on the package.
• Do not stand underneath hanging load.

!
DANGER
• Use only lifting equipment adapted to the weight on the
label of the package.
10
4. INSTALLATION
4.1 Installation directions
If the PBC is to work properly, it must be installed in accordance with these instructions. The conditions
the unit will operate in must be taken into consideration.
Improper installation, not following the instructions in this manual and in the attached technical docu-
mentation, may affect the function and/or the service life of the power unit. It is important that the
safety precautions mentioned in this manual are always followed.
In order to achieve air circulation requirements, you should never

place the power unit directly against a wall or similar obstruction. If
this is the case then contact your Hägglunds Drives representative.
PAC 100/200/300/400 PAC 200D/400D/600/800
H1
H1
B2 A2 B2
H2
H2
B1 M A1 B1 M
A3 A3
Cabinet Size 1 2 3 4 5
Type PBC 100 PBC 300 PBC 400D
PBC 200D PBC 800
Dimension PBC 200 PBC 400 PBC 600
H1 84 7/8 in. (2156mm) 84 7/8 in. (2156mm) 123 1/2 in. (3138mm) 123 1/2 in. (3138mm) 126 in. (3200mm)
A3 82 in. (2083mm) 111 in. (2820mm) 96 in. (2439mm) 138 in. (3505mm) 154 3/4 in. (3931mm)
11
Placing the power unit

Take into consideration the following when placing the PBC unit:
• Place on a firm level foundation to avoid vibrations.
• Ease of maintenance and service (section 4.3 “Positioning the power unit”).
• Protect from weather, airborne sprays, heavy contamination and radiated heat.
• Ensure proper ventilation for cooling purposes and for the electric motor and air-oil cooler.
• Minimize pipe runs.
Clamp each pipe in the pipe run separately and attach it to a firm foundation to avoid vibration. The
main connections from the PBC must always be fitted to the piping with hoses.
4.2 Lifting methods and weights

Lifting with ropes and/or chains
Lift the PBC with the electric motors removed and the ropes and/or chains at a maximum lifting angle
90°.
• The minimum distance between the forks is 31.5 in. (800 mm) for a 1 pump power unit and 43.3
in. (1100 mm) for a 2 pump power unit.
The total weight of the power

unit is stamped on the rating
plate located on the Junction
box door.
Always use all four lifting points
when lifting the power unit.
MAX
90˚ O

• Use only lifting equipment adapted to the weight of the power unit
! •
(check rating plate).
Do not lift the power unit with hydraulic fluid in the tank, or with the
DANGER front bar disassembled.
12
Electric Motor Denison Pumps Air-Oil Cooler

Power HP (kW) Weight* lb (kg) Model Weight lb (kg) Size Weight lb (kg)
30 (22) 365 (165) P6S 335 (152) AOVH-30 190 (86)
40 (30) 490 (222) P7S 335 (152) AOVH-40 350 (159)
50 (37) 560 (254) P11S 484 (220) AOL-950 221 (100)
60 (45) 800 (363) P14S 484 (220) AOL-1200 296 (134)
75 (56) 840 (380) P24S 753 (342) AOL-1600 355 (161)
100 (75) 1160 (526) P30S 786 (357)
125 (93) 1540 (698)
150 (112) 1730 (785)
200 (149) 1750 (794)
250 (186) 1925 (873)
*This is the weight for a standard electrical
300 (224) 2500 (1134)
motor, more accurate weight for a specific
350 (261) 2650 (1202)
motor can be found on the rating plate.
400 (298) 3500 (1587)
450 (336) 4300 (1950)
4.3 Positioning the power unit

The following minimum space must be left around the PBC, to ensure proper ventilation and provide
sufficient working space for easier maintenance. Heavier maintenance such as changing the pump/
motor assembly will demand larger working space.
It is important that all pipes for both water and hydraulics are mounted properly to allow for sufficient
working space for maintenance.
PBC 100/200/300/400 PBC 200D/400D/600/800


AIR AIR
32 [813mm] FLOW 32 [813mm] FLOW
32 [813mm] 32 [813mm]
12 [305mm] 32 [818mm] 12 [305mm]

32 [820mm]
32 [813mm] 32 [813mm]
FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM
• If air-oil cooler is mounted at a location other than on the power unit,
DANGER
! •
•
beware that the cooler will start without notice and has sharp edges
Beware of airborne particles in the outgoing air flow
If the air-oil cooler becomes loose it can cause severe personal injury.
13
4.4 Mounting of the cabinet feet

The cabinet feet (optional) minimizes the vibrations and makes it easier to level the PBC. They are
delivered separately within the cabinet and have to be mounted according to the following instructions:
1. Mount the cabinet feet before filling hydraulic fluid in the tank.
2. Mount the cabinet feet before installing the electric motor(s), if they are delivered separately or
supplied by the customer.
3. Lift the power unit according to instructions in this manual (section 3.2 “Lifting the packed power
unit”). Be sure to follow the safety precautions.
4. Mount the cabinet feet according to the drawing below.
5. Level the PBC by the adjusting screws.
[25mm-38mm]
1 [13mm]
ADJUSTABLE
Be careful while mounting the
2
2
1
! cabinet feet. Follow the safety
1-1
precautions in section “Lifting
WARNING methods and weights”
4.5 Mounting of electric motor

In certain cases the electric motor(s) are delivered separately. The following instructions are appli-
cable for these cases only.
3. Unpack the electric motor(s)
Unpack the electric motor and check it for external damage. Also, check that all rating plate data is the
same as in the attached technical documentation.
4. Check the shaft coupling(s)
Check that the axial shaft coupling clearance is in conformance with the coupling manufacturer speci-
fications.
5. Lift the electric motor
First, use the top mounted lifting ear and lift to position the electric motor vertically. Then lift with all
lifting ears. Never let the electric motor stand on the shaft coupling.
Two different types of lifting equipment may be needed in order to lift the electric motor.
6. Mount the electric motor in the power unit
Lift the electric motor into the PBC. It is important that it is hanging perpendicular. Fit the shaft
coupling through inspection hole into the nylon star coupling without causing any damage to it. The
connection box on the electric motor must be positioned as shown in the picture on page 6 (section 1.2
“Operating principle”). Lower motor to a position approximately 0.2 in. (5 mm) above bell housing.
Place greased bolts in the holes and tighten by hand.
7. Tighten bolts to the bell housing
Inspect that there is an axial clearance on the shaft coupling through the inspection hole in the bell
housing, and then tighten the attached bolts to the bell housing.
8. Electric motor connections
For connection of electric motor refer to page 18 (section 4.9 “Electric connections”).
14
!
DANGER
•
•
•
Use all lifting ears when the electric motor is hanging free.
Use only lifting equipment adapted to the weight on the rating plate.
No hands/fingers between electric motor and bell housing during assembly.
4.6 Mounting of air-oil cooler and cabinet ventilation

Normally the air-oil cooler is delivered separately and is to be mounted on the power unit. The follow-
ing instructions are applicable for coolers that are shipped loose. (Changes may occur from the draw-
ing and/or technical documentation.)
• Mount brackets with attached screws (in the drilled holes) on the PBC according to the installa-
tion drawing in attached technical documentation.
• Lift up air-oil cooler. Never lift using the electric motor.
• Mount the air-oil cooler on the brackets with the attached screws.
• Check that all screws are properly tightened.
• Connect the attached hydraulic hoses. Note that ‘Oil In’ at the power unit shall be connected to
‘Oil Out’ at the air-oil cooler and vice versa. The coupling protections must be kept on until final
assembly to avoid the entrance of dirt.
• For electric connections, couplings and hoses, see respective section.
• Air-oil cooler must always be connected with flexible hoses.
4.7 Hydraulic connections

During mounting of the hydraulic connections the following points must be kept in mind:
• The coupling protections must be kept on until final assembly.
• It is important that all pipes are properly mounted to allow for sufficient working space for mainte-
nance of the PBC.
• Always use hoses to connect pump with piping.
Professional service personnel aware of risks involved must perform all measurements in the hydrau-
lic system. Be especially cautious when connecting the A and B connections (high pressure).
*SAE-flange J 518, code 62, 414 bar

Denison Pump Main A & B Threaded holes **
(6000 psi) 90° connections have to
Size Connections * Thread Depth be used.
P6/P7
1 1/2" 5/8-11 UNC ** 4 screws needed/connection,
P11/P14 1.06 in. (27 mm) preferably with Grade 8 hex/socket
P24/P30 2" 3/4-10 UNC head cap screws.
Cabinet Dimension connection

size Power Unit
Drain line Flushing
Do not make any measurements 1 PBC 100/200
!
DANGER
or perform maintenance if the
hydraulic system is pressurized.
2
3
4
PBC 200D
PBC 300/400
PBC 400D/600
1 1/4" SAE
code 61 flange
1" SAE female
5 PBC 800
15
4.8 Electric connections

Safety precautions
• All electric equipment is intended to be installed and used by qualified personnel who are familiar
with relevant safety requirements.
• Safety equipment necessary for the prevention of accidents at the mounting and operating site
must be provided in accordance with the regulations prevailing in the local country.
• Grounding shall be carried out according to local regulations before the electric equipment is
connected to the main voltage.
• All electrical supply levels must be within the limits that the equipment is constructed for, see
technical documentation and maximum rating plate.
Junction box
Connect the cables on the screw terminals inside the junction box. Make the connections according to
the electrical drawing in the attached technical documentation.
Air-oil cooler
The voltage and connection are stamped on the rating plate. Connect the electric motor to the electri-
cal supply. Check direction of rotation, see air stream arrow in section 1.2.
Electric motor
Major voltage connection according to designation on the rating plate.
Installation of electrical equipment must in most
4.9 Pipe work DANGER

! countries be installed by licensed electricians
(reference local laws and regulations).
When sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of at
least 4 times the maximum system pressure should be used for the tensile strength. Keep in mind that
the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system
should generally be kept to a minimum but there are exceptions in certain applications. Contact a
Hägglunds Drives service representative for more information.
Hydraulic pipes
The hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.
Pressure test
A pressure test to 1 1/2 times the maximum working pressure should be performed on the main lines to
check for possible leakage.
Pressure tests on the main lines are best carried out using a hydraulic hand pump.
Hoses
To avoid damage caused by vibrations it is important that the PBC and the motor be connected to
pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order to obtain a small compres-
sion volume. Nevertheless, allowance must be made for the minimum permissible bending radius
according to the data provided by the supplier of the hose. Allowance must also be made for the flow
velocities listed under “Pipe sizes.”
Pipe flushing
The piping system must be flushed with an adequately sized flushing pump prior to starting up the PBC
unit to remove contamination introduced during assembly and/or welding. Please contact a Hägglunds
Drives service representative for proper cleaning and flushing procedure.
16
Pipe sizes
It is important that lines between the main connections of the motor and PBC are as short as possible.
This gives the following advantages:
1. Small compression volume in the hydraulic system.
This is particularly important in hydraulic systems with large and rapid load variations, and in
drives, where high speed accuracy is essential.
2. Small power losses in the hydraulic system.
3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.
For a normal hydraulic system, the total pressure drop in the pressure and return line must
not be more than 5 percent of the normal working pressure.
The following flow rates are recommended values and should not be exceeded:
Main lines 15 ft/s (4.5 m/s) Drain lines 5 ft/s (1.0 m/s)
4. Lower noise level.
In certain systems, where very small compression volumes are required, higher flow rates
are acceptable with possible increase in noise. Contact a Hägglunds Drives representative
in these specific cases.
When dimensioning hose and pipe lengths between the drain connections of the motor and the PBC,
keep in mind that the total pressure drop to the drain connections of the motor must not exceed 14.5
PSI (1 bar). The pressure drop through the PBC is 7.25 PSI (0.5 bar).
Pipe couplings
It is essential that a tight and pressure rated coupling is chosen.
The following types of coupling are recommended:
Non-welded couplings are preferred
Non welded couplings provide the most clean piping installation as compared to a welded pipe system.
Welded couplings (socket or butt type)
When using welded couplings, the pipes should be machined, normalized, and pickled. The pipes
must then be brushed, rinsed internally and blown clean before flushing.
Pipe coupling
Type collar coupling as per SAE J 514.
Pipe clamps
Pipes should be clamped with uniformly spaced clamps.
The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between
1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) for
pipes with outside diameters greater than 1 1/2 in. (38 mm).
In addition, the pipes must be clamped immediately before and after a bend. The pipes must be
clamped immediately before transition to a hose as well.
The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.
The pipe clamps must be of a type permitting a certain amount of axial and radial motion in the clamped
joint and have good vibration-absorbing properties.
17
Storage of included components

The included components must be stored in the same way as the power unit (section 3.1 “Storage of
the packed power unit”). Notice that the packing must not be removed during storage.
Do not work on the pipe system if the hydraulic system is pressurized.
DANGER
! Use necessary safety equipment during installation of the pipe system.
Usual safety requirements for each step must be followed.
Handling of fittings
Inspect the sealing surfaces on the couplings visually before mounting. It must be free of any dam-
ages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it has
nicks on it inspect it visually. Check that the seal (if any) is in its right position, free from cracks and that
it is saturated with oil.
The protection and packing on the fittings must be kept on until final assembly.
Flange fittings Clamps

The screws must be tightened crosswise. The normal distance between clamps:
JIC-fittings (SAE J514, ISO 8434) • Pipe diameter less than 1 in. (25.4 mm)
Tighten fittings by hand, then tighten 1/4 to 1/2 turn space clamps 60-80 in. (1524-2032 mm)
more using an appropriate wrench. Do not over apart.
tighten the fittings. • Pipe diameter greater than 1 in. (25.4 mm)
space clamps 80-100 in. (2032-2540 mm)
Use correct size tools, fittings can be damaged apart.
and difficult to remove. The pipes must be clamped immediately before
Be aware that all fittings may expand because of as well as after a bend and immediately before
heat and vibrations. All fittings must be checked transition to a hose.
and retightened. Welded fittings
Contact your Hägglunds Drives representative.
Mounting of hoses
Ensure that hoses are not stressed or twisted on
installation, to prevent premature failure. Bend
radius should conform to manufacturer recommen-
dations.
Pressure tests
Pressure tests should always take place before
flushing in order to release contamination by
stresses introduced by the pressure. The main
lines must be pressure and leakage tested to a
static pressure of 1 1/2 times the maximum ex-
pected system pressure (not above bursting pres-
sure). The hydraulic motor and power unit must
be disconnected or protected by closed valves
Cleaning during the pressure tests.
The pipes and hoses should be pre-cleaned, in-
spected and sealed by the supplier. If the pipes
are field bent and installed the overall system must
be flushed to reach the required cleanliness level.
18
Example of a pipe installation which

is convenient and could easily be
sound insulated
O
4.10 Extra filtration prior to start up
HYDRAULIC MOTOR
A pressure filter and check valve has to be con-
nected to the main line at the power unit. This
filter is connected on the return side of the drive Hoses
pump. connected
together
Recommended filtration degree ß10 = 75 or bet-
ter. Flow Direction
The size of the filter should be matched to that of

the pump concerned, so that the pressure drop
across the filter is not excessive and that the maxi-
Filter
mum pressure/flow ratings for the filter is not ex-
ceeded. Check valve
The main lines should be connected together at

the motor enabling the entire system to be filtered,
see the figure to the right.
The maximum flow from the power unit should be
filtered through the main circuit for at least two
hours on small installations and considerably POWER UNIT
longer on larger ones.
Use extreme caution to ensure pump is stroked in Use a check valve sized for the oil flow.
synchronization with free flow direction of check When using the main pump the maximum
valve. pressure should be reduced.
19
4.11 Commissioning
4.11.1 Prior to commissioning
• Read and understand this complete manual and the other attached technical documentation.
• Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,
and that the degree of filtration of the filters are according to the data in the technical documen-
tation.
• Check that the coupling between the electric motor and pump is properly mounted.
• Check that the pre charge pressure in the accumulator (optional) is in accordance with the
technical documentation.
Cleanliness
• The hydraulic system must be flushed and thoroughly cleaned on the inside.
• If you are uncertain about the cleanliness of the system, it must be checked prior to filling with
oil.
Pipe work
• Are the couplings properly tightened?
• Is the pipe work properly cleaned?
• Is the pipe work mounted free of stress?
• Are the lines in accordance with installation drawing/piping plan?
Electrical System
• Check that electric motor(s) and control system and other electrical components are connected
to the correct voltages.
• Check the function of electrical components and monitoring system manually. Instruments that
cannot be actuated can be checked for correct wiring and possibly operated manually. Level
switch and indication should be checked when filling the tank.
4.11.2 Filling up the system with hydraulic fluid

Before filling
• Check that the correct type and quality of
hydraulic fluid is used. Do not mix different
types of hydraulic fluid without first checking
with manufacturers.
• Check that the barrel with hydraulic fluid and
tank/hoses are not contaminated with water
or other substances.
• Follow instructions for handling of couplings
and hoses (section 4.9 “Pipework”).
• Plug the drain connection D (motor) to pre-
vent non filtered fluid being filled into the
hydraulic motor case, when filling the system
the first time. 'D1' DRAIN
• Fill the pump case with filtered hydraulic oil PORT
through the ‘D1’ port on the pump. When
finished filling the pump case, replace the
plug/hose connected to the ‘D1’ port.
20
Filling
Use a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.
New fluid is normally not filtered and will introduce dirt into the system, the
fluid must therefore always be filled through a filter. Never pour hydraulic
fluid into the tank through the air breather filter.
Always pump the fluid in through the quick connection that is marked appropriately. The quick connec-
tion is a completely rustproof quick release coupling, see figure below. The fluid filled into the system
will be filtered through the drain filter for better results.
The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gauge
on tank before starting for the first time.
Check the function of the level switch and indication during filling up of the tank.
ON FILL HOSE ON POWER UNIT
System is full when

hydraulic fluid is at 5/8 up
into the sight glass
RETURN FILTER
OIL FILL
CONNECTION
PUMP/MOTOR CASE
DRAIN FILTER
OIL HEATER
After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.
• Check caution sign on container and the warnings (section 2.4 “Choice
of hydraulic fluid”).
!
WARNING
•
•
Avoid prolonged contact of hydraulic fluid with your skin.
Clean hydraulic fluid spills from floors immediately to prevent personal
injury.
21
4.11.3 Initial start up procedure

Important Note!
• Make sure the driven system and driven machine is ready to run, warn all personnel in the area
that start up is in progress.
• Follow safety precautions in this manual (section 1.1 “Safety precautions”).
• Never operate the power unit with defective instruments or control elements.
• Keep flammable materials away from the power unit.
• During start-up period, the hydraulic system will be filtered to remove dirt particles, therefore
keep an eye on the filter indicator during the entire start up procedure.
On cold start up, the filters may indicate bypass. After a few minutes of operating, press down the
visual indicator to reset. If the indicators will not reset after system has reached operating tempera-
ture, filter element must be inspected and changed.
STEP 1 Immediately before starting
• Check fluid level in the tank and refill to about 0.79 in. (20 mm) below maximum level at visual
level gauge on tank (section 4.11.2 “Filling up the system with hydraulic fluid”).
• Check if any components need filling with clean hydraulic fluid, such as the pump case and
motor case.
• Check safety equipment.
• Check that all the prescribed steps (section 4.11.1 “Prior to commissioning”) have been carried
out.
• Make sure that all valves on the suction, pressure and inlet side of the pump, as well as any
valves on drain lines, are open.
• Check that cooling water is connected and turned on if a water-oil cooler is used.
For adjustments and settings on the control system (if any) see separate instruction in attached tech-
nical documentation.
STEP 2 Start with unloaded pump at short intervals
Starting of the PBC shall be carried out with a completely unloaded pump in short intervals.
• When the hydraulic fluid is cold, some restarts may be needed in order to raise the charge
pressure.
• Check that the charge pressure corresponds with data and settings on attached technical docu-
mentation.
• If OK, the pump may be allowed to come on stroke and introduce flow into the unloaded hydrau-
lic system.
• Flow and pressure should be limited until lines are purged of air.
Check that the charge pressure is still OK.
Immediately make sure that the ROTATION
pump has the correct direction

of rotation. Otherwise, the
pump will be damaged. The
correct direction of rotation is
evident from a sticker placed
under the electric motor, see
figure to the right.
22
STEP 3 Unloaded pump at longer intervals

Run for a period at no load condition until system is stable and control is established. Checking of the
oil level may be needed due to parts of the system having been filled with fluid.
• Check all interlocks. Check fluid level in the tank
• Check that the specified pressure level for charge pressure at the PBC is maintained in accor-
dance with the values stated on the hydraulic diagram in the attached technical documentation.
These pressure levels are preset at the factory and there is normally no need to readjust.
• Stop the electric motor.
• Correct any faults discovered in the points above.
• Restart when finished.
STEP 4 Loaded hydraulic system
The hydraulic system can be loaded when the hydraulic system function is satisfactory in unloaded
running condition.
• Gradually increase load pressure until proper operation is obtained.
• It may be necessary, at this point, to make adjustments to flow, ramp rates, etc.
• Cycle the system until normal operating temperature is reached.
STEP 5 Checking
• Check the function of the safety equipment.
• Check temperature in tank and closed loop. Check also that the cooler control is stable. If not,
investigate water supply, controls, air cooler, etc.
• Check that the pump compensator pressure control and pressure switches (optional) are set at
levels appropriate to the specific drive. Upon delivery, these pressure levels are set at the levels
specified by the customer and normally no readjustment will be necessary. The values are
stated in the technical documentation. System compensator can easily be checked by closing a
ball valve on the high pressure leg and stroking the pump until the pressure is showing on the
gauge.
• The working pressure must be checked to ensure that they correspond to the specified values.
STEP 6 Stop the electric motor
• Correct any faults discovered while performing the points of Step 5.
• Check the filter indicator. It is not unusual to change elements on commissioning as the system
is cleaning the dirt particles out. When changing filter elements carefully follow the instructions
(section 5.3 “Filter change”) to prevent introduction of dirt into the system. If there is still dirt in
the system, additional flushing is necessary in order to prevent premature failure of system
components.
• Remove waste fluid, scrap cabling, etc. to keep the area in and around the unit clean.
23
4.12 Pump settings and adjustments

Denison Gold Cup pump Working in high pressure areas
DANGER
! could be dangerous in case of
unforeseen failures.
P6S, P7S, P11S & P14S P24S & P30S
CHARGE PRESSURE
ADJUSTMENT
COMPENSATOR
CHARGE PRESSURE VALVE
ADJUSTMENT
View from the back View from the back Front view
Charge pressure and Pump compensator pressure level are set before the PBC leaves the factory and
consequently there is normally no need for readjustment. Always check the pressure levels in techni-
cal documentation. Professional service personnel familiar with the functions and risks involved
with the pump must perform setting of pressures on the pump(s). The pressures shall be set
during operation and with the system at operating temperature. Note that pressures can change with
different viscosity.
1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a
5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (on
the charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &
P11S/P14S & P24S and 261 psi (18 bar) for P30S.
If other charge pressures are to be set, contact a Hägglunds Drives representative for consultation.
2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook or
other technical documentation.
3. If the main pressure levels are to be increased: Make sure that the piping and machine
structure can take higher pressure/higher torque delivered from the hydraulic motor.
4. Compensator pressure adjustment: Dead head the pump, then activate or move the input
signal to the control so that pressure increases in the high pressure closed circuit to the pressure
limiter setting. The pressure limiter setting is reached when the pressure stops increasing and
remains steady at a given pressure level. (As shown on the gauges)
The pressure limiter setting for both A- and B-side is set on the compensator valve.
Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desired
pressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.
5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure
level in logbook or technical documentation.
24
5. PREVENTIVE MAINTENANCE
5.1 Maintenance log
We recommend that a maintenance log be kept to record service/maintenance/repair, addition and
alteration of the equipment. Each note, observation or comment should be dated.
5.2 Maintenance chart

The maintenance of hydraulic systems is designed to prevent failure of the system and to keep the
system running efficiently according to specification. The specific procedures will depend on the na-
ture of the equipment, the environment it is working in and the duty cycle, keeping in mind the conse-
quences of a breakdown. To optimize the maintenance intervals a Life Cycle Cost (LCC) analysis is
recommended. Follow the safety precautions during the checkups (section 1.1 “Safety Precautions”).
Daily checks, first week after Frequent checks

commissioning • Unusual vibrations.
• Fluid leaks. • Unusual noises.
• Fluid level in the tank. • Fluid leaks.
• Operating temperature. • Fluid level in the tank.
• System pressure. • Is the unit relatively clean? Air flow paths
• System performance and general condition. unrestricted?
• Unusual noises. • Pressure levels normal - stable?
• Contamination indicators on the filters. • Actuator speeds normal - stable?
Pre-start checks (also daily) • Operating temperature.
• Fluid leaks. • Is the drive running smoothly?
• Fluid level in the tank. • Contamination indicators on the filters.
• Is the suction valve open?
• Contamination indicator on the filters.
25
Scheduled maintenance
Planned maintenance at specific time intervals, including the following checks and actions:
• All points listed under frequent checks.
• Check all pressure levels.
• Check for stable temperature levels around the system.
• Drain water and sludge from the tank at the drain tap.
• Check the electric motor.
• Check the function of monitoring equipment/switches, etc.
• Clean areas where dirt is building up.
Note: never use a high pressure washing system to clean the power unit.
• Check the cables.
• Check accumulators (optional) for correct pre-charge.
• Check drain line flows and drain line oil condition.
• Check the hoses, couplings and pump(s), with regards to cracks, leaks and condition.
• Check the shaft coupling through the inspection hole. Warning, rotating parts inside the
inspection hole.
• Check the flow of cooling water.
Absolute maximum intervals for major inspection and replacement
Air Oil Air breather Accumulator(s)

Hydraulic fluid
inlet Filters on tank (optional)
After the first 100 working hours ý *
After 3 months or 500 working hours ý *
Once every 6 months þ ý * þ þ
Once every 24 months ý
*If the contamination indicator is tripped out, the filters þ=Inspection
must be changed immediately, and the oil examined. ý=Replacement
5.3 Filter change

Single filter
1. Stop the operation and electric motor.
It is very important during the mounting not to expose the new cartridge to any dirt, therefore
keep it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage, change parts if necessary.
Note! When removing a filter element take some time to inspect and look for unusual contamination
within the pleats. Contact your Hägglunds Drives office for advice.
26
Duplex filter
1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see
figure below.
2. Engage the switching lever and move to the other side.
3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 2-3
turns.
It is very important during the mounting not to expose the cartridge to any dirt, therefore keep
it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage. Change parts if necessary.
6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is
bubble free.
7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.
Vent screws
Pressure
• There are dangers associated equalizer
with hydraulic fluid. lever
• Store used hydraulic fluid
! and contaminated filter ele-
ments for proper disposal.
In this
position
you can Switching
lever
CAUTION • The fluid may be hot if the change
cooling is insufficient. this
element
Different hydraulic fluids are affected differently

- consult the manufacturer.
5.4 Inspection of hydraulic fluid

We recommend that the hydraulic fluid be analyzed once every 6 months. The analysis should cover
viscosity, oxidation, water content, additives and fouling. In the vast majority of cases, your oil supplier
will perform an analysis that will reveal the condition of the hydraulic fluid and can recommend suitable
actions. If the analysis reveals that the properties of the hydraulic fluid are not fulfilling the require-
ments (section 2.3 “Requirements for hydraulic fluid cleanliness”) it should no longer be used, but be
changed or cleaned immediately. Refill fluid according to instructions (section 4.11.2 “Filling up the
system with hydraulic fluid”).
27
5.5 Lubrication of electric motor

Lubricate electric motors larger than 30 HP
1. Clean the grease nipples.
2. Grease the electric motor with a grease gun.
Grease
When re-greasing, use only special ball bearing grease with the following properties:
• Good quality lithium base or lithium complex grease.
• Base oil viscosity 476-667 SSU at 104° F (100-140 cSt at 40° C).
• Consistency NLGI grades 2 or 3.
• Temperature range -22° F - +248° F (-30° C - +120° C), continuously.
Grease with the right properties is available from all the major lubricant manufacturers. If the type of
grease is changed and compatibility is uncertain, lubricate several times at short intervals in order to
displace the old grease.
Air inlet for electrical motor
Check that the air inlets on the cabinet hood and on the electric motor are not clogged by dirt and that
air can easily pass.
!
CAUTION
Check the warning label
on the grease cartridge. Frame
size
Lubrication schedule for electric motor (60 Hz)
Electric motor
HP (kW)
Lubrication
intervals
Volume of
grease
286 30 (22) 1.0 cu. in.

40 (30)
50 (37) 6 to 12 months
324-365 1.5 cu. in.
60 (45)
75 (56)
100 (75)
125 (93)
150 (112)
404-449 200 (149) 6 months 2.5 cu. in.
GREASE 509 250 (186)

NIPPLES
300 (224)
350 (261)
400 (298)
3 months check data
5011 450 (336)
5.6 Air breather change

Refer to maintenance chart (section 5.2 “Maintenance chart”) for recommended replacement inter-
vals.
1. Clean around the area where the air breather is located.
2. Unscrew the breather and make sure no foreign material has entered the tank.
3. Thread on a new air breather.
28
5.7 Cleaning of Air-Oil cooler

Cleaning of air fins
• The easiest way to clean the air fins is by using compressed air or rinsing with water.
• Fouling can be dealt with using a degreasing agent and a high-pressure washing system. When
using a high pressure washing system point the jet carefully parallel to the air fins.
Follow the safety precautions on the container of the cleaning agent used.
! Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.
Make sure that electric power is cut off before cleaning! Cleaning agent
WARNING and waste water from rinsing should be disposed of in accordance to pre-
vailing local regulations.
5.8 Power unit out of service

Periods out of commissioning
Clean and empty the cooling system (water side) before periods of rest (especially if the cooling water
is not totally clean). If the PBC is to be out of service for more than three months, the hydraulic system
must be protected internally against rust.
This can be done in the following manner:
• Use hydraulic fluid that is consistent with fluid types used at your location, which has rust pre-
venting additives.
• Use additives which give protection against rust for up to about a year. After this, the equipment
should be run at intervals to maintain a protective film on the internal surfaces of components
and oil lines, thus providing protection against corrosion.
• If any parts of the system are disconnected, note that open fittings must be protected by plugs or
covers to prevent entrance of any dirt particles.
Re commissioning
Before the drive is restarted after a long idle period, a check should be made as to whether the instruc-
tions supplied for the original commissioning still apply. Moreover, the following measures should be
observed.
• Remove preservative solution and any signs of contamination.
• Follow the procedure for initial start-up (section 4.11.3 “Initial start-up procedure”).
6. CORRECTIVE MAINTENANCE
6.1 Common
Before removing any hydraulic/electric components, disconnect the power unit. Ensure that no energy
is accumulated in the system and the power is disconnected from the electric motor. Follow recom-
mended safety procedures.
Before disassembly
• Troubleshoot the PBC and perform appropriate tests.
• Clean all assemblies and components, take all precautions necessary to prevent dirt entering
the system.
• Disassembly may only be done by professional service personnel.
29
Corrective Maintenance Installation and Maintenance Manual, Power Unit PBC
Disassembly
• Label all parts, and protect precision or machined surfaces.
• Inspect all parts during disassembly for wear or damage.
• If hydraulic fluid is to be drained and reused, make sure that drain containers are clean and
covered when not in use.
• Clean all metal parts using a suitable solvent prior to reassembly, set aside on a clean and lint
free cloth to drain.
Reassembly
• Lubricate with system hydraulic fluid.
• Replace all seals, gaskets and o-rings with new items of the correct size.
• Ensure complete sealing at pipe connections.
• Refill hydraulic fluid according to recommendations (section 4.11.2 “Filling up the system with
hydraulic fluid”).
6.2 Change of hydraulic pump/electric motor assembly

The most common method to change the pump is to lift the complete electric motor/pump unit and then
remove the pump.
The electric motor and pump are assembled into a unit and mounted on the motor support plate
attached to the frame via shock mounts.
1. Release the motor support plate: Release the motor support plate from the frame.
2. Secure lifting equipment: Adapt lifting equipment in the four holes in the corners of the motor
support plate.
3. Lift the electric motor/pump unit: Be careful and take the weight and center of gravity into
consideration. Never let the electric motor/pump stand on the charge pump.
4. Assemble: Assemble in reverse order according to point 1 to 3.
• Always use all four lifting points when lifting the electric
motor/pump unit.
• Never use the lifting ears on the electric motor to lift the
!
DANGER
•
complete electric motor/pump unit.
Use only lifting equipment adapted to the weight (section 4.2
“Lifting methods and weights”).
• Do not stand underneath hanging load
• Take center of gravity into consideration during lifting.
30
Installation and Maintenance Manual, Power Unit PBC Troubleshooting
6.3 Troubleshooting

Main voltage to electric Look for the cause in the electric power
motor lacking supply network
Open suction line valve, verify switch
Suction valve closed function
Verify reservoir oil level and switch
Not enough oil in reservoir function
Power Unit does not start Reservoir temperature
above set limit Verify reservoir temp switch function
Look for the cause in the electric power
supply network
Control voltage lacking Examine the control system in the power
unit. If the control system has tripped,
determine the reason
No control current to electro hydraulic
No servo pressure stroker control. Examine the control
function or electronic control card
Coupling pump/electric Check through the inspection hole in the
Power unit fails to deliver oil motor defect bellhousing
flow Wrong direction of rotation
of hydraulic pump Check direction of rotation
Check that load pressure is not too high
Load is too large so that pressure override reduces pump
delivery
Suction line not open Open suction line valve
Charge pressure too low or
non-existent Check that charge pressure is correct
Pump/Motor baseplate
shipping bolts still installed Remove shipping bolts
Examine the suction line to charge pump

Unwanted noise Air leaks and pump for air leaks. Test by pouring oil over pipe
joints while listening for changes in noise
cavitating in the pump
Air filter in tank clogged Change filter

Worn elastomer element in
the shaft coupling Change elastomer element
Wrong direction of rotation Reverse direction of rotation
High oil temperature in No oil exchange from Check charge pressure and shuttle valve
closed circuit closed loop setting
31
Troubleshooting Installation and Maintenance Manual, Power Unit PBC
Power unit fails to deliver oil Perform previously described actions

Verify input signal to amplifier card and
No command signal to output signal to electrohydraulic pump
pump control
No pressure in system
Verify that pump and electric motor
Pump/Motor coupling not coupling and insert are installed and
installed properly tightened properly
Pump compensator valve is
not closed Replace pump compensator valve
Compare with our oil recommendations
Viscosity too low Check the oil temperature, and the
cooling circuit
Abrasive material Check filters and change if necessary.
circulating through pump Check that changing is performed at
Excessive wear with the hydraulic fluid prescribed intervals
Air in the hydraulic system Locate and remedy the air system leak
and Pump cavitating and purge air from the system
Content of water in
hydraulic fluid too high Inspect hydraulic fluid, change oil
Check flow of cooling water, water
temperature, cooler, water valve and
Poor cooling capacity water filter or air cooler (optional)
If air cooler is clean, inspect cooler fins
and remove any obstructions
High oil temperature Internal leakage in pump Change or repair pump
Too small an amount of
replacement oil in hydraulic Check that charge pump delivers
system sufficient flushing oil
Charge pressure is out of Adjust according to values on hydraulic
adjustment circuit diagram
7. DISPOSING OF POWER UNIT

When the complete PBC or a single component is worn out, it should be disposed of as soon as
possible. Used hydraulic fluid, material exposed to hydraulic fluid and grease may cause damage on
the environment and should be disposed of according to prevailing local regulations.
• Check that the power unit is completely disconnected.
!
DANGER
•
•
•
The components may contain accumulated energy.
Take fire hazards into consideration during dismantling.
The accumulator (optional) must be empty and discharged.
32
AM326-1A Printer : Precision Printing 1999
HÄGGLUNDS DRIVES INC. HÄGGLUNDS DRIVES (CANADA) INC.

2275 INTERNATIONAL STREET 853 Arvin Avenue
COLUMBUS, OHIO 43228 USA Stoney Creek Ontario L8E 5N8
Phone: (614) 527-7400 Fax: (614) 527-7401 Phone: (905) 643-6300 Fax: (905) 643-9933
www.hagglunds.com
GATE VALVE
AMERICAN VALVE OVERSEAS
BRONZE GATE VALVES

P.O. Box 35229
Greensboro, NC 27425
1-800-645-0101
or (336) 668-0554
fax: 1-800-876-0109
or (336) 668-4070
Figure: M300
Threaded Ends Meets ANSI/NSF 61 Section 8
Non-rising Stem (1998)
Solid Wedge Disc and
California Proposition 65
Rating:
125 psi WSP
200 psi WOG
Figure: M300S
Sweat Ends
Non-rising Stem
Solid Wedge Disc Meets ANSI/NSF 61 Section 8
(1998)
Available with Waste and
(specify Fig. M300SW) California Proposition 65
Dimensions:
1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4
A Center of Port to Top 3 3 1/16 3 3 1/2 4 1/16 4 3/4 5 3/16 6 3/16 7 l/2 9 10 1/4
B End to End 1 5/8 1 5/8 1 11/16 1 7/8 2 3/16 2 3/8 2 7/16 2 13/16 3 1/2 4 4 9/16
B1 End to End 1 5/8 1 3/4 2 3/8 2 3/16 3 1/16 3 1/16 4 1/8 4 3/4 4 3/4
C Overall Height 3 1/2 3 1/2 3 9/16 4 1/4 5 5 3/4 6 3/8 7 5/8 9 1/2 11 1/8 13 1/8
D Wheel Diameter 2 1/8 2 1/8 2 1/8 2 1/8 2 3/8 2 7/8 2 7/8 6 3/4 5 4 l/4 3 1/4
Weight lbs. Thd. .55 .53 .56 .81 1.10 1.80 2.l0 3.20 7.00 9.60 17.0
Weight lbs. Swt. .48 .51 .75 1.10 1.70 2.00 3.10 6.80 9.40
CABINET FEET
TF
Features
The TF mounting is installed in minutes by following the
instructions provided. There is no need to fix the machines
to the floor since the rubber base of the mounting keeps
the machine in place. Whenever necessary, the machine
can easily be re-positioned. The level is adjusted with load
applied.
The rubber element of the TF mounting is oil and chemi-

cal resistant. All metal parts are zincplated and chromated
for protection against corrosion.
Models TF 250, TF 600 and TF 1200, also available in

S/S (ISO 2604/11, BS 3605:1).
Novibra® type TF
Novibra® type TF with level adjuster is suitable for a wide
range of free standing workshop machines, e.g.
• Lathes
• Milling machines
• Grinding machines G
• Multiple operation machinery
• Presses
• Plate shears
• Nibbling machines
• Punches and cutters
• Woodworking machines
• Plastic moulding machinery H
Dimensions in mm Overall Thread Weight Max load

Type Art.No. D H min H max bolt length G (kg) (kg)
1)
TF 250 1860740 69 23 100 M 12 0.40 250
TF 250 s/s 2256520 69 23 1)
100 M 12 0.40 250
1)
TF 600 1860780 81 25 100 M 12 0.49 600
TF 600 s/s 2256530 81 25 1)
100 M 12 0.49 600
1)
TF 1200 1860790 108 29 100 M 16 1.0 1200
TF 1200 s/s 2256540 108 29 1)
100 M 16 1.0 1200
1)
TF 3000 1860800 151 35 120 M 20 2.2 3000
1)
TF 4000 1860810 170 39 120 M 20 2.9 4000
1)
TF 6000 1860820 205 44 150 M 24 4.8 6000
1) Levelling of the bolt up to its total length.
TF
Loading range per mounting (kg)
Type of General work- Presses and punches

machinery
shop machines Numbers of strokes per minute
Mounting Max load (kg) 1– 125 126– 175 176– 225 226– 275
TF 250 250 25– 125 20– 100 15– 85 10– 60
TF 600 251– 600 126– 300 101– 240 86– 200 61– 150
TF 1200 601– 1200 301– 600 241– 480 201– 400 151– 300
TF 3000 1201– 3000 601– 2400 481– 1600 401– 1000 301– 750
TF 4000 3001– 4000 2401– 3200 1601– 2100 1001– 1300 751– 1000
TF 6000 4001– 6000 3201– 4800 2101– 3200 1301– 2000 1001– 1500
Mounting instructions
1 2 3
TFE
Mounting TFE is a simpler version of type TF without Both models also available in S/S
level adjuster. It is used for machines which do not require (ISO 2604/11,BS 3605:1 )
height adjustment or where such a feature is already pro-
vided, e.g. by an adjusting screw in the machine.
Dimensions in mm Weight Max load

Type Art.No. D H (kg) (kg)
TFE 601 1861050 80 25 0.375 800
TFE 1201 1861060 109 29 0.925 1600
ISOLATION MOUNTS
Bobbins
Trelleborg Industrial AVS - Bobbins
A supplementary range of cylindrical mountings for a wide Manufactured in natural rubber hardness 40° IRH or
range of applications. They can be loaded either in com- 60° IRH.
pression or shear taking into consideration individual de-
mands for actual applications.
Type A Type B Type C
Type D Type KD Type E
Compression load Shear load
Bobbins
G ØD
L H
Cylindrical mountings type A
40° IRH 60° IRH

Type D/H GxL Art.No. Art.No. Compression Shear load Compression Shear load
40° IRH 60° IRH load load
kcomp Fmax kshear Fmax kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N) (N/mm) (N) (N/mm) (N)
A 10/10 M4x10 1255720 53 77 10 31
A 10/15 M4x10 318600 31 56 6 23
A 15/10 M4x10 318610 135 151 22 52

A 15/15 M4x10 318620 73 133 13 52
A 20/10 M6x15 318630 318640 162 170 19 42 309 324 41 92

A 20/15 M6x15 2255780 1255770 70 123 11 42 145 255 25 92
A 20/20 M6x15 2230950 1255300 45 110 8 42 96 235 18 92
A 20/25 M6x15 318650 1255780 33 105 6 42 72 227 14 92
A 20/30 M6x15 318660 318670 27 102 5 42 58 223 11 92
A 25/10 M6x15 318680 318690 314 330 29 66 574 603 64 144

A 25/15 M6x15 318700 318710 123 215 18 66 247 432 38 144
A 25/20 M6x15 318720 318730 75 184 13 66 157 385 27 144
A 25/25 M6x15 318740 318750 54 171 10 66 116 366 21 144
A 25/30 M6x15 318760 318770 43 164 8 66 93 356 17 144
A 30/15 M8x20 318780 1255830 237 378 28 95 453 723 61 208

A 30/20 M8x20 318790 1255320 129 295 19 95 261 600 42 208
A 30/25 M8x20 318800 318810 88 263 15 95 184 552 32 208
A 30/30 M8x20 1660730 1255840 67 248 12 95 143 529 26 208
A 30/35 117 516 22 208
A 30/40 M8x20 318820 318830 46 233 9 95 100 508 19 208
A 40/20 M8x20 318840 318850 275 632 34 170 534 1226 75 369
A 40/25 359 1076 58 369
A 40/30 M8x20 318860 318870 130 481 21 170 271 1002 47 369
A 40/40 M8x20 318880 318890 86 437 16 170 184 935 34 369
A 50/20 M10x25 318900 318910 564 1248 56 265 1042 2306 122 577
A 50/25 M10x25 318920 318930 335 976 42 265 652 1900 93 577
A 50/30 M10x25 1861540 1255870 234 846 34 265 472 1706 75 577
A 50/35 M10x25 318940 318950 180 774 29 265 371 1598 62 577
A 50/40 M10x25 318960 1255340 146 730 25 265 306 1533 54 577
A 50/45 M10x25 318970 1255880 123 701 22 265 261 1490 47 577
A 50/50 M10x25 318980 1255350 106 681 19 265 228 1460 42 577
A 75/40 M12x35 319000 319010 417 2032 57 596 827 4030 124 1299
A 75/50 M12x35 319020 319030 282 1766 44 596 579 3632 97 1299
A 75/55 M12x35 319040 319050 242 1689 40 596 504 3517 87 1299
A 100/40 M16x45 319060 319070 932 4541 102 1060 1755 8549 221 2309
A 100/55 M16x45 319080 319090 496 3455 71 1060 994 6929 155 2309
Bobbins
S
G ØD
L H
Cylindrical mountings type B

60° IRH
Type D/H GxL (S) Art.No. Compression load Shear load
60° IRH kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N)
B 10/10 M4x10(4) 1255930 58 56 10 23
B 10/15 M4x10(4) 319100 34 52 6 23
B 15/15 M4x10(4) 319110 79 124 13 52
B 20/15 M6x15(6) 1255960 159 238 25 92

B 20/20 M6x15(6) 1255970 105 220 18 92
B 20/25 M6x15(6) 319120 79 213 14 92
B 25/15 M6x15(6) 1255990 269 404 38 144

B 25/20 M6x15(6) 319130 172 360 27 144
B 25/25 M6x15 (6) 319140 127 342 21 144
B 25/30 M6x15(6) 319150 101 333 17 144
B 30/15 M8x20(8) 319160 494 676 61 208

B 30/20 M8x20 (8) 1256040 285 561 42 208
B 30/25 M8x20(8) 319170 201 516 32 208
B 30/30 M8x20 (8) 1256060 156 495 26 208
B 30/40 M8x20(8) 319180 109 475 19 208
B 40/30 M8x20(8) 319190 296 937 47 369

B 40/40 M8x20(8) 319200 200 875 34 369
B 50/30 M10x25(10) 319210 515 1595 75 577
B 50/40 M10x25 (10) 319220 334 1433 54 577
B 50/50 M10x25 (10) 1256120 248 1365 42 577
B 75/50 M12x35(12) 319240 632 3396 97 1299

B 75/55 M12x35 (12) 319250 550 3288 87 1299
B 100/40 M16x45 (16) 319260 1914 7994 221 2309
B 100/55 M16x45(16) 319270 1084 6479 155 2309
Bobbins
S
G ØD
Cylindrical mountings type C
60° IRH
Type D/H G(S) Art.No. Compression load Shear load
60° IRH
kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N)
C 15/15 M4(4) 1256210 86 112 13 52
C 20/20 M6(4) 66522 114 199 18 92

C 20/25 M6(6) 1256220 85 192 14 92
C 20/30 M6(6) 66548 69 189 11 92
C 25/20 M6(6) 1256230 186 325 27 144

C 25/25 M6(6) 319280 137 309 21 144
C 30/25 M8(8) 319300 218 466 32 208

C 30/30 M8(8) 1255410 169 447 26 208
C 30/35 M8(8) 319310 139 436 22 208
C 30/40 M8(8) 319320 118 429 19 208
C 40/30 M 8(8) 1255420 320 846 47 369

C 40/40 M 8(8) 1256260 217 790 34 369
C 50/30 M10(10) 1256270 558 1440 75 577

C 50/35 M10(10) 2255730 438 1349 62 577
C 50/40 M10(10) 1256280 361 1294 54 577
C 50/45 M10(10) 1256290 308 1257 47 577
C 50/50 M10(10) 1256300 269 1232 42 577
C 75/36 M12(12) 66746 1180 3635 141 1299

C 75/40 M12(12) 319330 977 3402 124 1299
C 75/45 M12(12) 319340 805 3202 109 1299
C 75/50 M12(12) 2256670 684 3066 97 1299
C 75/55 M12(12) 1255430 596 2969 87 1299
C 100/40 M16(16) 319350 2074 7217 221 2309

C 100/45 M16(16) 319360 1655 6587 193 2309
C 100/50 M16(16) 319370 1374 6156 172 2309
C 100/55 M16(16) 319380 1174 5849 155 2309
Bobbins
G
Type D Type E
L G
H H
ØD ØD
Cylindrical mountings type D/E/KD
Compression load
Type D/H GxL Art.No. Art.No. 40° IRH 60° IRH
40° IRH 60° IRH Fmax Fmax
(N) (N)
D 10/10 M4x10 319390 59
D 15/15 M4x10 319400 131
D 20/10 M6x15 319410 295

D 20/15 M6x15 319420 248
D 20/20 M6x15 319430 233
D 20/25 M6x15 319440 226
D 25/10 M6x15 319450 532

D 25/15 M6x15 319460 416
D 25/20 M615 319470 379
D 30/15 M8x20 319480 663

D 30/20 M8x20 319490 578
D 30/25 M8x20 1534870 542
D 30/30 M8x20 319500 523
D 40/25 M8x20 319510 1044

D 40/30 M8x20 319520 985
D 40/40 M8x20 319530 928
D 50/20 M10x25 319540 2094
D 50/30 M10x25 319550 1653
D 50/40 M10x25 319560 1512

D 50/45 M10x25 319570 1476
D 75/25 M12x35 319580 5446
D 75/40 M12x35 319590 3895
G(S)
E 30/17 M8(8) 1256930 1661280 225 500
E 50/20 M10(10) 319600 1700
E 50/36 M10(10) 1659990 319610 550 1100
E 50/45 M10(10) 1659870 1000
KD 25/12 M6x16 1534150 300

KD 25/12 M6x18 1533450 250
KD 50/17 M10x28 1256940 1400
P6S, P7S & P8S PUMP MANUAL
DENISON HYDRAULICS
goldcup series
closed circuit piston pumps
P6, P7, P8S
service information
Publ. S1-AM025-A
E-Mail: denison@denisonhydraulics.com Internet: http://www.denisonhydraulics.com

CONTENTS
PAGE
installation 3
typical characteristics 3
fluid connections 4
general 5
description 5
mounting 5
shaft information 5
piping 5
service information 5
recommended fluids 5
viscosity 6
viscosity index 6
temperature 6
alternate fluids 6
maintenance 6
fluid cleanliness for new installation 6
start-up procedure 6
comparison of solid contamination classification system 7
troubleshooting 7
assembly tool drawings, T1, T2, T3, T4, T5 9
disassembly 11
rework of wear parts 12
assembly 13
drive shaft and bearing 13
barrel and auxiliary drive shaft 13
rocker cam 15
pistons and shoes 16
mounting flange, cam & cradle 16
housing 17
housing, end cap, cam and barrel 17
port block 18
mounting port block to housing 18
gerotor and barrel holddown 19
valve block (before 7-93) 20
valve block (after 7-93) 22
valve block for special mounting of servo valve (before 7-93) 26
valve block for special mounting of servo valve (after 7-93) 29
output controls 32
input controls 32
shaft and seal installation 33
mechanical shaft seal assembly procedure 33
counter-balance servo stem 34
rear drive adapter 34
pilot valve 36
shuttle valve 36
shuttle valve mounting 37
important instructions 38
instructions for replenishing circuit isolation plug 38
hydraulic circuit 40
test procedure 41
general requirements 41
basic pump test 41
(refer to manual S1-AM030 for controls service information)
ordering code 43
seal kits
complete S23-15092
valve block S23-00135
HI-IQ valve block S13-04226
shaft seal replacement S23-44302
shaft seal 623-00006
shuttle valve S23-15089
Note: New revisions are shown underlined.

Pages are marked Revised where changes have been made.
2
INSTALLATION
TYPICAL CHARACTERISTICS Specification Term P6 P7 P8
• displacement at max. angle in.3/rev. 6.00 7.25 8.00

cm3/rev (98) (119) (131)
• pressure ports A & B max. psi 5000 5000 3600

continuous bar (345) (345) (248)
max. intermittent psi 6000 6000 4350
bar (414) (414) (300)
• speed, max. continuous rpm 3000 3000 1800


• flow, internal replenishing pump gpm 6.9 6.9 6.9

@ 1800 RPM (theoretical ) L/min. (26.1) (26.1) (26.1)
• flow, auxiliary pump, external gpm 9.3 9.3 9.3

at 1800 RPM (theoretical) L/min. (35.2) (35.2) (35.2)
(see note)
• replenishing pressure psi 200 200 200

bar (14) (14) (14)
• servo pressure psi 335-535 335-535 335-535

bar (23-37) (23-37) (23-37)
• mounting-2 bolt flange SAE C C C
• shaft-spline SAE C C C
keyed
• fluid connection ports A & B in 1-1/2 1-1/2 1-1/2

SAE-4 bolt pad for 6000 mm (38.1) (38.1) (38.1)
split flange
• weight w/rotary servo lbs. 335 335 335

kg. (152) (152) (152)
Note: Any SAE-A or B mount pump may be used with the appropriate external drive
3
INSTALLATION
port size function

A 1 1/2" 4 bolt SAE 6000 psi inlet/outlet
AG, BG SAE - 6 straight thread system pressure gage, ea. side
B 1 1/2" 4 bolt SAE 6000 psi outlet/inlet
C SAE - 16 straight thread internal auxiliary pump inlet
D1, D2 SAE - 12 straight thread case drain
D3 SAE - 16 straight thread replenishing relief drain
DG SAE - 6 straight thread case pressure gage
DS SAE - 4 straight thread shuttle repl. pilot drain (ext.drain)
FA, FB 1/4 - 18 dryseal NPTF control pressure gage, ea. side
G SAE - 8 straight thread int. aux. pump outlet to filter
H SAE - 8 straight thread filter return
I SAE -16 straight thread inlet to optional pump (gear pump)
SAE - 1 1/4 3000 psi, 4-bolt pad optional - vane pump
K SAE -16 straight thread aux. replenishing port
KA SAE - 12 straight thread aux. repl. inlet to shuttle
KG SAE - 6 straight thread replenishing pressure gage
M SAE - 8 straight thread auxiliary servovalve drain
S SAE - 8 straight thread servovalve inlet
VA/VB SAE - 4 straight thread individual compensator vent
Conversion Adapter Kit “A” mount S23-12438-0

“B” mount S23-12669-0
4 Revised
INSTALLATION
GENERAL The DENISON HYDRAULICS Goldcup 6, 7, and 8 axial piston pumps feature advance
design concepts which are time proven and provide for advance pumping and control
concepts. The instructions contained in this manual cover complete disassembly and
reassembly of the unit. Before proceeding with the disassembly or reassembly of any
unit, this manual should be studied in order to become familiar with proper order and
parts nomenclature.
DESCRIPTION The use of a rocker cam to control the pump displacement provides a small package
size, reduces wear, and speeds control response. The control vane actuator eliminates
linkage and backlash inherent in typical stroking cylinder designs.
Standard controls for the Goldcup units are Rotary Servo and Compensator Override.
Additional optional controls are also available.
MOUNTING This pump is designed to operate in any position. The mounting hub and four bolt mount-
ing flange are in full conformance with SAE standard. The pump shaft must be in align-
ment with the shaft of the driven load and should be checked with a dial indicator. The
mounting pad or adaptor into which the fluid pump pilots must be concentric with the pump
shaft to prevent bearing failure. This concentricity is particularly important if the shaft is
rigidly connected to the driven load without a flexible coupling.
SHAFT INFORMATION Splined: The shafts will accept a maximum misalignment of 0.006" TIR (.15 mm).
Angular misalignment at the male and female spline axes must be less than ±.002” per
inch radius (.002 mm per mm radius). The coupling interface must be lubricated. DENI-
SON HYDRAULICS recommends lithium molybdenum disulfide or similar grease. The
female coupling should be hardened to 27-45 Rc and must conform to SAE-J498B
(1971) Class 1 flat root side fit.
Keyed: High strength heat treated keys must be used. Replacement keys must be hard-
ened to 27-34 Rc. The key corners must be chamfered .030"-.040" (.75-1 mm) at 45° to
clear radii that exist in the keyway.
Splined or Keyed: Both types of shafts will accept a side load of 170 lbs. (77 kg) at the
center of the spline or key, with a B10 life of 10,000 hours at 1800 RPM.
PIPING Connect inlet and outlet lines to the port block of the pump.
The maximum case pressure is 75 PSI (5.17 bar) continuous, 125 PSI (8.6 bar) inter-
mittent. Case pressures must never exceed inlet pressure by more than 25 PSI (1.7 bar).
When connecting case drain line make certain that drain plumbing passes above high-
est point of the pump before passing to the reservoir. If not, install a 5 PSI (.3 bar) case
pressure check valve to be certain the case is filled with oil at all times.
The case leakage line must be of sufficient size to prevent back pressure in excess of 75
PSI (5.7 bar) and returned to the reservoir below the surface of the oil as far from the
supply suction as possible. All fluid lines, whether pipe, tubing, or hose must be adequate
size and strength to assure free flow through the pump. An undersized inlet line will pre-
vent the pump from reaching full speed and torque. An undersized outlet line will create
back pressure and cause improper operation. Flexible hose lines are recommended. If
rigid piping is used, the workmanship must be accurate to eliminate strain on the pump
port block or to the fluid connections. Sharp bends in the lines must be eliminated wher-
ever possible. All system piping must be cleaned with solvent or equivalent before
installing pump. Make sure the entire hydraulic system is free of dirt, lint, scale, or other
foreign material.
Caution: Do not use galvanized pipe. Galvanized coating can flake off with
continued use.
SERVICE INFORMATION These hydraulic products are designed to give long dependable service when properly
applied and their systems properly maintained. These general instructions apply to typi-
cal systems. Specific instructions for particular equipment can be developed from them.
RECOMMENDED FLUIDS See DENISON HYDRAULICS bulletin SPO-AM305 for more details.
5 Revised
INSTALLATION
FILLING CASE It is essential to make certain that the case (pump housing) is as full of fluid as possible
and remains full during operation and at rest.
Always fill to the highest available point. Remove a plug or screw and allow the oil to
escape through this point.
Recommended fill points:
Mounting orientation vertical, shaft up. D1 or D2 (drain) port in housing

Vent DG2 port in mounting flange (new units)
or one of the upper screws which attach the
control. See installation drawing.
Vertical, shaft down 1) or horizontal D1 or D2 (drain port in housing.

drain ports to the side 1) Vent DG (case gage) port in port block.
MAINTENANCE This pump is self-lubricating and preventative maintenance is limited to keeping system
fluid clean by changing filters frequently. Keep all fittings and screws tight. Do not oper-
ate at pressures and speeds in excess of the recommended limit. If the pump does not
operate properly, check the Trouble Shooting Chart before attempting to overhaul the
unit. Overhauling is relatively simple and may be accomplished by referring to the
Disassembly, Rework Limits of Wear Parts and Assembly Procedures.
FLUID CLEANLINESS Fluid must be cleaned before and continuously during operation by filters that maintain a
cleanliness level of NAS 1638 Class 8.
START UP PROCEDURE • Read and understand the instruction manual. Identify components and their function.
• Visually inspect components and lines for possible damage.
• Check reservoir for cleanliness and drain and clean as required.
• Check fluid level and fill as required with filtered fluid at least as clean as that recom-
mended. Fill pump case with clean oil prior to starting.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature.
• Reduce pressure settings of relief valve. Make sure accurate pressure readings can be
made at appropriate places.
• If solenoids in system, check for actuation.
• Start pump drive. Make sure pump and motor fill properly.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines especially in
pump and motor inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds, sys-
tem shocks and air in fluid.
• Equipment is operational.
6 Revised
TROUBLESHOOTING
TROUBLESHOOTING Component problems and circuit problems are often inter-related. An improper circuit
may operate with apparent success but will cause failure of a particular component with-
in it. The component failure is the effect, not the cause of the problem.
This general guide is offered to help in locating and eliminating the cause of problems by
studying their effects:
effect of trouble possible cause fault which needs remedy

noisy pump air in fluid leak in suction line
leak at shaft seal
low fluid level
turbulent fluid
return lines above fluid level
gas leak from accumulator
excessive pressure drop in the inlet line from a
pressurized reservoir
suction line strainer acting as air trap
cavitation in fluid too cold
pump or motor fluid too viscous
rotating group fluid too heavy
shaft speed too high
suction line too small
suction line collapsed
suction strainer too small
suction strainer too dirty
operating altitude too high
boost or replenishment pressure too low
replenishment flow too small for dynamic conditions
misaligned shaft faulty installation
distortion in mounting
axial interference
faulty coupling
excessive overhung loads
mechanical fault piston and shoe looseness or failure
in pump bearing failure
incorrect port plate selection or index
eroded or worn parts in the displacement control
erosion on barrel air in fluid see above
ports and port cavitation see above
plate
high wear in excessive loads reduce pressure settings
pump and motor reduce speeds
contaminant improper filter maintenance
particles in fluid filters too coarse
introduction of dirty fluid to system
reservoir openings
improper reservoir breather
improper line replacement
7
TROUBLESHOOTING
TROUBLESHOOTING effect of trouble possible cause fault which needs remedy

(continued) high wear in Improper fluid fluid too thin or thick for operating temperature range
pump and motor breakdown of fluid with time/temperature/shearing
(continued) effects
incorrect additives in new fluid
destruction of additive effectiveness with chemical
aging
improper repair incorrect parts
incorrect procedures, dimensions, finishes
unwanted water condensation
in fluid faulty breather/strainer
heat exchanger leakage
faulty clean-up practice
water in makeup fluid
pressure shocks cogging load mechanical considerations
worn relief valve needed repairs
worn needed repairs
compensator
slow response in replace or relocate
check valves
servo pressure increase pressure and check pressure drop
too low to through servo filter
maintain firm
control
excessive improve decompression control
decompression
energy rates
excessive line reduce line size or lengths
capacitance eliminate hose
(line volume,
line stretch,
accumulator
effects)
barrel blow-off re-check pump hold-down, rotating group, drain
pressure
heating of fluid excessive pump recheck case drain flow and repair as required
or motor fluid too thin
leakage improper assembly, port timing
relief valve set too low (compared to load or to compensator)
instability caused by back pressure, worn parts
compensator set too high (compared to relief)
worn parts
pump too large select smaller pump displacement
for fluid needs
heat exchanger water turned off or too little flow
water too hot
fan clogged or restricted
efficiency reduced by mud or scale deposits
intermittent hydraulic fluid flow
reservoir too little fluid
entrained air in fluid
improper baffles
insulating air blanket that prevents heat rejection
heat pickup from adjacent equipment
8
T-1
MATERIAL
CRS 1" DIA. X 2 5/8"
(25.4mm) (66.68 mm)
T-2
9
T-3
T-4
T-5
Material:
OHTS 5 5/8 x 1 1/4 DIA
(130.17) x (31.75)
Hardened Tip RC 58-62
10
UNIT DISASSEMBLY
INTRODUCTION The instructions contained in this section cover a complete teardown of the subject
pump. Disassemble only as far as necessary to replace or repair any worn parts.
DISASSEMBLY Position pump unit so that valve block assembly is on top. A bench or similar suitable sur-
face capable of supporting unit should be used. Disassembly area should be clean.
VALVE BLOCK See figure 14. Remove the eight hex. head cap screws (17) and lift the entire block
assembly from the port block.
See figure 12/13. Remove the four hex. head cap screws (58) and four soc. hd. screws
(53) and lift the entire block assembly from the port block.
(before 7-93) See figure 10. Remove the four screws (39) to separate the cover (21) from the block
(11). Do not remove the check valves (19).
Remove plugs (43), (36) and pin (40). Remove the 8-32 nut from the bottom of cover (21)
to remove filter assembly (34).
Remove housing (29) and O-ring (28). Remove items (30), (31), (32) and (33) as a unit.
Insert a small brass rod thru the hole in the housing and tap out piston (27) and O-ring
(26).
Remove O-ring (37) and replenishing relief valve (41). Inspect orifices (12) visually to
insure they are open. Do not remove unless damage or clogging is apparent.
Remove springs (16), (17) and (18). Remove retainer (15) and poppets (13) and (14).
Remove the four screws (4) from the plate (6) and (11). Remove gasket (7).
Remove seats (8) and (9). Do not remove roll pins (5) and (10) unless replacements are
needed.
(after 7-93) See figure 11. Remove plugs (20), (23) and pin (21). Remove the 8-32 nut from the bot-
tom of block (1) to remove filter assembly (14). Do not remove the check valves (2).
Remove housing (8), O-ring (9), piston seal (10), O-ring (11), screw (6), nut (7), and
acorn nut (45) as a unit.
Remove plug (25) and replenishing relief valve (36).
Remove O-rings (37), (48) and (47). Remove four screws (43) and remove the retainer
plate (42). Do not remove roll pins (46) unless replacements are needed.
Remove gasket (29) and seats (27) and (28). Remove poppets (30), (31) and springs
(32), (33), (35) and retainer (34).
Inspect orifices (3) visually to insure they are open. Do not remove unless damage or
clogging is apparent.
CONTROLS See figure 14. Remove the four screws (14) from the side cover (16) and remove the
input shear seal valve assembly
Note: The myltite washers (13) should be replaced at assembly.
Remove the four screws (14) from the side cover (15) and remove the counter balance
shear seal assembly.
Remove the two screws (12) and remove the balance stem (9) and balance plate (10)
EXTERNAL PUMP, SHUTTLE See figure 14. Remove two screws (20) and remove external pump (21).
VALVE AND REAR ADAPTER
Remove four screws (23) and remove shuttle valve (24).
Remove four screws (9) fig. 15 and remove adapter (22).
BARREL HOLDDOWN AND See figure 9. Remove retainer ring (16), pin (14), holddown nut (13), insert (15), thrust
GEROTOR ASSEMBLY washers (10), bearing (11) and seal ring (12).
Remove pressure plate (9), Gerotor side plate (5) “O” rings (7) and (8).
Remove Gerotor assembly (3), dowel pin (4), key (2), and side plate (1).
11
UNIT DISASSEMBLY
PORT BLOCK See figure 8. Remove four screws (1) that secure the port block (2) to the housing (6). Use
caution when removing screws on valve block side to prevent marring valve block face.
Remove port block (2) and gasket (5). Remove port plate (4) and port plate pins (3).
Note: port plate will in some instances adhere to port block upon disassembly.
See figure 7. Remove the check valve assemblies (7) from the port block.
Remove needle bearing (2) from the port block.
Remove two screws (5), lockwashers (6), check rings (3), and clamps (4). Only one
check ring assembly in open circuit pumps.
BARREL AND AUXILIARY SHAFT Remove face plate (2, fig. 6) from face of barrel assembly.
BARREL AND AUXILIARY SHAFT
Remove the barrel assembly (1, fig. 4) by grasping the auxiliary shaft and lifting the com-
plete assembly out of the housing.
DRIVE SHAFT See figure 14. Remove the four screws (8) and gaskets (7). Remove seal retainer (6),
and the stationary part of the shaft seal (4). Refer to view of item 4.
Carefully remove the carbon ring and the remainder of the shaft seal from the shaft.
Caution: Do not scratch seal surface of shaft when removing seal.
Remove snap ring (3) and the shaft and bearing assembly (1). Remove shim (2).
HOUSING After shaft assembly has been removed, position the unit on end with the mounting
flange turned down.
Push the ends of the small tube lines away from the housing.
Lift the housing from the mounting flange, remove the gasket, and dowel pins from the
mounting flange.
Do not remove the roll pins and the bearing from the housing unless the bearing is dam-
aged and must be replaced.
ROCKER CAM AND CONTROL See figure 4. Remove the complete assembly (5) from the mounting cap (7) and posi-
STROKING ASSEMBLY tion on a clean flat surface with the two tubes (2) in a horizontal position and located at
the top. Mark the cam (24) and cradle (20) as indicated in Figure 3. These marks will
determine positioning of parts during reassembly.
Carefully remove the small tube lines (3) and (4) from the cradle.
Caution: Do not bend these lines
See figure 3. Position the assembly in an upright position on the flat surface of the cra-
dle (20). Remove the retaining ring (1) and thrust washer (2). Remove the piston and
shoe assembly (4) and the creep plate (5) from the cam (24). Carefully remove the two
set screws (6a) and two screws (6) that secure the servo plate to the cam (24) and
remove the servo input parts (7, 8 and 9).
Remove the four 7/16" screws (10) and eight 1/4" screws (11) and (12) from the control
covers (15R) and (15L). Remove the four dowel pins (16) and remove the two chambers
(17). Remove the two special seals (18) and the four steel balls (19). Remove the two
vane seal cartridge assemblies (23) and the four holddown vanes (22) from the rocker
cam (24).
Note: Some units may have thin shims under the holddown vanes.
Remove the rocker cam (24) from the cradle (20).
Caution: Do not remove the plugs from the rocker cam.
12
UNIT DISASSEMBLY
REWORK LIMITS OF WEAR max. rework

PARTS 6, 7.25 and 8.0 in3 from original min. dimension after rework
port plate face .010” (0,254 mm) .295” (7,49 mm)
shoe retainer face .005” (0,127 mm) .307” (7,8 mm)
piston shoe face .006” (0,152 mm) .008” (0,2 mm)
(pocket)
creep plate face .005” (0,127 mm) .286” (7.13 mm)
face plate none replace
IMPORTANT:
The port plate both faces finish must be 25 microinches (635 mm), flat within .00006
(0015 mm) and parallel within .001(0254 mm) T.I.R.
The creep plate wear face finish must be 10 microinches (254 mm), flat within .0002
(0381 mm) and parallel to the backside within .0005 (0127 mm)T.I.R.
The shoe retainer wear face finish must be 32 microinches (813 mm), and flat within
.0015 (0381 mm) (must not be convex).
The piston shoes wear face finish must be 5 microinches (127 mm), and must be lapped
in a set with the retainer plate, all shoe sole thicknesses to be within .001 (0254 mm) after
lapping. The maximum permissible shoe and piston axial looseness is .010 (254 mm).
The special retaining ring service kit (S23-12461) may be required to control shoe
holddown clearance.
13
ASSEMBLY PROCEDURES
CLEANING AND INSPECTION All parts must be inspected and be free of material defects, dirt, scratches or any foreign
material.
All parts must be cleaned with a suitable cleaning solvent and all holes and passages
blown out with dry, clean, compressed air.
After cleaning and inspection, all parts must be covered with a light film of oil and pro-
tected from dirt and moisture. Excessive handling of internal parts should be avoided
prior to assembly.
During assembly, lapped and ground surfaces must be lubricated with clean oil and pro-
tected from nicks or surface damage.
DRIVE SHAFT AND BEARING See figure 1. Pass one retaining ring (3) over the internal end of drive shaft (1) and install
in the groove near the shaft seal surface.
Caution: Do not pass the ring over the seal surface.
Press the bearing (2) over the same end of the shaft and seat against the ring.
Support only the inner race of the bearing and press on the coupling end of the shaft.
Caution: Do not use excessive force and distort or damage the retaining ring.
Install the other retaining ring (3) in the other retaining ring groove. Be sure that both
rings are fully seated.

S13-41805 DRIVE SHAFT ASSEMBLY (SPLINED)
S13-41806 DRIVE SHAFT ASSEMBLY (W/KEYWAY)
quantity
item description part no. #3 #2
1 #3 (splined shaft) 033-70567 1 -
#2 (keyed shaft) 033-70579 - 1
Figure 1 2 shaft bearing 230-82140 1 1
3 retaining ring 033-70817 2 2
4 square key 5/16 x 1-1/4 033-71348 - 1
BARREL AND AUXILIARY See figure 2. Position the barrel (1) in a press with the large end turned down and insert
DRIVE SHAFT tool figure T-1 in the splined shaft hole in the barrel.
Place stop (3) and spring (4) over shaft (2) in the same sequence as shown.
Insert shaft (2) in barrel (1) and rest on tool figure T-1. Position the spring retainer (5) over
the shaft (2) and against spring (4).
Carefully place tool figure T-2, with the large end of the tapered hole up, over the shaft
(2) and against the barrel face (1). Insert ring (6) around the shaft (2) and in the tool.
Position the ring with the gap within 5/8" (16 mm) of the notch in the barrel for easy
removal.
Place tool figure T-3 over the shaft (2) with the small end against ring (6). Press on the
end of the assembly tool and seat the ring (6) in the groove of the barrel (1).
Remove the assembly tools. Check to be sure that the ring is properly seated. Check bar-
rel face to be certain it is not marred.

quantity
item description part no. P6 P7 P8
1 barrel & sleeve ass’y (P6) S13-43657 1 - -
Figure 2 barrel & sleeve ass’y.(P7) S13-47511 - 1 -
barrel & sleeve ass’y (P8) S23-12718 - - 1
2 auxiliary drive shaft 033-91050 1 1 1
3 stop 033-53944 1 1 1
4 barrel holddown spring 033-70493 1 1 1
5 spring retainer 033-53945 1 1 1
6 retaining ring 033-70494 1 1 1
Consult DENISON HYDRAULICS Service for parts prior to 1983 units.
14
ASSEMBLY PROCEDURES

rocker cam, pistons and retainer
item description part no qty.

1 retaining ring (yellow) .083" (2.11 mm) 033-70484 1
retaining ring (green) .081" (2.06 mm) 033-70488
retaining ring (red) .079" (2.01 mm) 033-70490
retaining ring (white) .087" (2.21 mm) 033-72175
retaining ring (blue) .085" (2.16 mm) 033-72176
retaining ring (black) .077" (1.96 mm) 033-54826
retaining ring service kit S23-12461
3 not used
4 piston & shoe assy. w/retainer See below
5 creep plate 033-71261 1
6 button hd. screw 353-25041 2
6a setscrew, 2 ea. 312-09032 2
7 servo stem 033-71312 2
8 orifice screw 033-70819 2
9 servo plate 033-53874 1
*10 hex. hd. screws 7/16-14 x 2-1/2 306-40183 4
*11 hex. hd. screws 1/4-20 x 1-1/4 306-40188 4
*12 hex. hd. screws 1/4-20 x 2-1/4 306-40187 4
*13 hex socket plug SAE-4 488-35001 2
*14 O-ring 90-6290-4 691-00904 2
*15R right side chamber cover CW rot. 033-70572 1
right side chamber cover CCW rot. 033-70612
*15L left side chamber cover CW rot. 033-70571 1
left side chamber cover CCW rot. 033-70574
*16 dowel pin 1/4 x 1-1/2 324-21624 4
*17 chamber 033-72266 2
*18 seal 606-25036 2
*19 steel ball 3/16 201-06001 4
*20 rocker cradle 033-53951 1
*22 hold down vane 033-70816 4
*23a -seal backup plate 033-70802 4
*23b -vane seal 033-70501 2
*23c -O-ring 90-914-20 691-00120 2
*23d -spacer 033-70519 2
*23e -check valve 033-70803 2
*24 rocker cam S23-12105 1
*Note: Item 10 through 24 can be ordered as a complete rocker cam & control stroking
assembly.
S23-12196 is for RH pumps
S23-12197 is for LH pumps
item description P6S P7S P8S qty.

4 piston & shoe assy. S13-43655 S13-42308 S21-11650 1
w/retainer
4a shoe retainer 033-54290 033-54290 033-57376 1
4b piston & shoe assy. S13-45680 S13-46040 S21-11649 7
15
ASSEMBLY PROCEDURES
ROCKER CAM/PISTONS
AND RETAINER
Marks Designate
Top of Assembly
Figure 3
Note: Install items 6, 7, 8, and 9 on side shown of rocker
cam if pump model number has “B” suffix. Install on
opposite side if “A” suffix.
ROCKER CAM See figure 3. Position the cradle (20) on a clean flat surface with the large flat area down.
Position the rocker cam (24) on the cradle (20). Note marks made earlier to indicate top
of rocker cam & cradle.
Place O-ring (23c) around spacer (23d) and insert in the vane seal (23b).
Insert check valve (23e) inside of spacer (23d) and assemble between the two backup
plates (23a) with the notched V’s exposed.
Install assembled cartridge in slot in cam as indicated in Figure 3. Repeat steps 1, 2 and
3 on other side of cam.
Insert the four holddown vanes (22) in the slots on each side of the control vanes (23).
Position both control chambers (17) on a clean flat surface with seal grooves turned up.
Drop the four steel balls (19) in the four counterbored holes at each end of the seal
grooves.
Lubricate seals (18) and insert in seal grooves in control chamber (17).
The tapered side of the seals must be pushed into the grooves and the ends must cover
the steel balls.
Install the control chamber (17) with seal (18) and steel balls (19) assembled over the
control vane (23). The seal must be against the cam. Rotate the chamber until it passes
over the control vane assembly, then rotate in the opposite direction until the 1/4" dowel
pins (16) can be pushed through the chamber (17) and into the cradle (20). Install cham-
ber in the same manner on the other side of the cam.
Two sets of chamber covers are available. The set marked CW must be installed in the
right hand rotation pump and the set marked CCW must be used in the left hand rota-
tion pump. (Rotation is determined facing the shaft end of pump.) The covers must be
installed with the tubing holes and the tapped holes at the top of the unit. Install cham-
ber covers (15r) and (15l) on the control chambers (17) over the dowel pins (16). The
tapped holes must be at the top. Refer to the “T” marked on the rocker cam (24) and cra-
dle (20).
Install four 1/4-20 screws, two (11) and two (12), in each side and torque to 10 ft.-lbs.
(13.56 Nm)
Install two 7/16-14 screws (10) in each side and torque to 45 ft.-lbs. (61.0 Nm)
Install O-ring (14) and plug (13) in each cover.
16
ASSEMBLY PROCEDURES
ROCKER CAM Install tubes (25) in reamed holes in each cover. These tubes must be a tight fit. If tubes
(continued) are loose, the ends can be expanded with a tapered punch.
Tap the tubes in place with a plastic mallet.
Install two orifice screws (8) in the servo stem (7).
Install servo plate with the end of the screws (6) through the servo stem. The orifice
screw end of the servo stem must be against the servo plate.
Position the stem and plate on the rocker cam input side at 9 o’clock position on “B” suf-
fix or 3 o’clock on “A” suffix models with the screws positioned over the 10-24 tapped
holes. Torque the screws (6) to 40 in. lbs. (4.5 Nm). Install setscrews (6a) and torque to
5 ft.-lbs. (6.8 Nm). Caution: The set screws must not protrude from the servo plate.
Install creep plate (5) over center post on rocker cam with small O.D. of plate turned
toward cam.
PISTONS AND SHOES See figure 3. Insert the seven piston and shoes (4b) in the shoe retainer (4a). Position
the assembly (4) over the center post and against the creep plate.
Install thrust washer (2), over center post.
MOUNTING, FLANGE, CAM & Five different retaining rings (1) are available for the holddown assembly. Each ring is
CRADLE, BARREL marked; white dot .087 (2.21 mm) thick, blue dot .085 (2.16 mm) thick, yellow dot .083
(2.11 mm) thick, green dot .081 (2.06 mm) thick, and red dot .079 (2.01 mm) thick. Install
the thickest ring (1) with the dot up, that will fit in the groove on the center post and allows
a maximum clearance of .002-.004 (.051-.102 mm) between the shoe and creep plate
while grasping one piston and lifting tightly against shoe retainer.
The piston and shoe assembly (4) must be free to rotate easily by hand. The assembly
must be rotated through 360° to confirm there is no binding and that each shoe is always
free in the retainer plate. Oil the assembly thoroughly.
Position the cradle and cam assembly with the piston and shoe assembly attached with
T marked on the cradle turned up.
See figure 4. Insert tube line assemblies (3 and 4) in the holes provided in cradle.
Note: Tube assemblies (3 & 4, fig. 4) must be a snug fit into holes in cradle. Expand end
of tubes with a pointed tool to assure fit.
Position the mounting flange (7) with the large open end up, and install two dowel pins
(6) in the cradle mounting surface of the flange and two dowel pins (6) in the outer edge
of the flange.
See
Fig. 3 Install rocker cam and cradle assembly over the two dowel pins (6) in the mounting
flange. Be certain that cradle is seated over the pins and against the flange with the tube
lines (3) and (4) in the grooves in the flange.
Position the mounting flange with the rocker cam assembly installed on the top or bottom
side and install two or more 1/4-20 x 1-1/4" screws through the seal retainer area into the
cradle. Be certain the cradle is fully seated in flange. These screws are required to hold
the rocker cam assembly in place and will be removed later.
Return the assembly to an upright position with the mounting flange down.
Tilt the rocker cam to either extreme position in the cradle.
Position the Barrel Assembly with Auxiliary Shaft (1) directly over the pistons. Start with
the uppermost piston and guide them one at a time into the barrel. Return the rocker cam
to a level position in the cradle.

1 barrel and auxiliary shaft assy. See fig. 2 1
3 tubing assy. (right side) S13-42402 1
4 tubing assy. (left side) S13-42403 1
5 rocker cam and stroking assy. See fig. 3 1
6 dowel pin 3/8" X 3/4" 324-22412 4
7 mounting flange 033-70604 1
Figure 4
17
ASSEMBLY PROCEDURES
HOUSING See figure 5. Position housing (1) on a clean flat surface with the large open end up.
S13-42335
lubricated with clear oil and protected from nicks or surface damage.
2
Clean housing, item #1, and barrel bearing, item #2. Apply loctite primer grade "T" & loc-
tite retaining compound #609 to bearing O.D. & bearing bore of housing. Rest housing
on mounting flange end.
Position notch on bearing (2) with hole in housing bore. Insert Pressing Plug tool (figure
Drive 1
T-4) in the bearing. With smooth and steady force, press the bearing into the housing
Shaft Right bore until seated. DO NOT HAMMER OR BEAT INTO PLACE.
End Side
Install bearing retainer (7) with O-ring (8). Torque to 50 lb.-ft. (68 Nm).
Bottom
3
Turn housing (1) on side and install roll pin (4) in the 1/4" through hole in the control cover
4 pad. The pin must be 3/8" below the pad surface. THE PIN END MUST NOT INTER-
FERE WITH THE INTERNAL BEARING CAGE. Install two dowel pins (3) in the blind
Left
holes in the same pad.
Repeat the above step on the opposite side of the housing.

Port Block End
Place O-ring (5) on plug (6) and install in bottom of housing (1). (Roll pins (4) are in bot-
Figure 5 tom of housing.)

1 housing 033-91108 1
2 bearing 033-91107 1
3 dowel pin 324-21608 4
4 roll pin 325-16280 2
5 O-ring 90-6290-12 691-00912 1
7 retainer-bearing 033-91106 1
8 O-ring, 90 S-1 ARP 908 691-00908 1
HOUSING, END CAP, CAM See figure 6. Insert the three face plate pins (1) in the holes provided in the barrel face.
AND BARREL
Apply heavy grease to the face of the barrel and install the face plate (2) over the pins
(1) in the barrel.
Make certain the face plate is properly seated on the barrel and pins with the steel
side towards the barrel face. The face plates have only one side bronzed and this
should be toward the port plate. If necessary, remove coating from edge of face plate
to determine bronze side.
Install gasket (3) over the two dowel pins (item 6 on Fig. 4) in the mounting flange.
Position the Housing Assembly (4) over the Barrel and Auxiliary Shaft Assembly and
carefully guide the pressure tubes and tube lines (items 2, 3 and 4 on Fig. 4) through the
Housing Assembly (4).

1 face plate pins 033-49825 3
*2 barrel face plate 6 in3 only 033-71530 1
barrel face plate 7.25 and 8.0 in3 033-72532 1
4 housing assembly See fig. 4 1
*Note: item 2: (Ref. only) Arcuate port width: 6 in3 is 13/32" (10,3 mm), 8.0 & 7.25 in3 is
1/2" (12.7 mm)
See
Fig. 4
Figure 6
18
ASSEMBLY PROCEDURES
PORT BLOCK See figure 7. Position the port block (1) on a clean flat surface with the two open ports up.
THE OPPOSITE FACE MUST NOT BE SCRATCHED OR DAMAGED. Position needle
bearing (2) on tool (Figure T-5) with the marked end of the bearing against the shoulder on
the tool and press the bearing (2) into the port block. The bearing must be .010-.025" (.254-
.635 mm) below the surface.
Slip check ring (3) into the two 1.50" (38 mm) ports and align holes in the ring with the
side holes in the port wall.
Place lock washers (6) on special screws (5). Insert (5) through port wall and drilled holes
in checks (3) and thread into clamps (4). Torque to 10 ft. lbs. (13.56 Nm).
Thread socket pipe plugs (8) into port block.
Thread two check valve assemblies (7) into valve face of port block.
Figure 7 Place O-ring (10) on hollow hex plug (9) and thread into tapped hole in top of the port
block.

1 port block 033-71296 1
2 needle bearing 230-82146 1
3 check ring 033-70502 2
4 clamp 033-70489 2
5 special screw 033-70908 2
6 no. 10 lock washer 348-10016 2
8 1/4 soc. pipe plugs 431-90404 2
10 O-ring 90-6290-6 691-00906 1
MOUNTING PORT See figure 8 on next page. Position the pump with the unplugged hole (top drainport) in
BLOCK TO HOUSING the housing assembly at 12 o'clock position.
Install gasket (5) on the housing assembly (6).
Install the two special pins (3) in the face of the port block assembly. Apply petroleum jelly
or heavy grease to the plate (4) and position port plate over the pins (3) on the port block.
Port plate must be fully seated and indexed towards direction of rotation. (See port plate
view in figure 8.)
Slide the port block assembly and port plate over the end of the auxiliary shaft. Be cer-
tain that tubes 2, 3 and 4 shown on Fig. 4 are engaged and that the port plate (4) is still
on the pins (3).
When the pump is properly assembled, the valve mounting surface will be at the top of
the unit.
Install the four bolts (1), and torque to 225 ft.-lbs. (305 Nm). Caution: Use care to prevent
damage to the valve mounting surface while installing and torquing the two top bolts.

1 hex head cap screw 5/8-11 x 9 306-40182 4
2 port block assy. See Fig. 7 1
3 port plate pins 033-49825 2
4 RH port plate 6 in3 033-71526 1
LH port plate 6 in3 033-71525 1
RH port plate 7.25 in3 033-72811 1
LH port plate 7.25 in3 033-53776 1
RH port plate 8.0 in3 033-91252 1
LH port plate 8.0 in3 033-91553 1
6 housing Assy. S13-42335 1
7 mounting flange See Fig. 4 1
19
ASSEMBLY PROCEDURES
MOUNTING PORT
BLOCK TO HOUSING
(continued)
Rear View –
Width of Arcuate Ports
6 in.3 is 13/32" (10,3 mm)
7.25 and 8.0 in.3 is 1/2 (12,7 mm)
Figure 8
15
16 13
14
GEROTOR IN POSITION FOR RH ROTATION
Figure 9
GEROTOR AND BARREL See figure 9. Position the unit with the shaft in a horizontal position and the valve block
HOLDDOWN mounting surface turned up. Rotate the shaft until the small keyway in the auxiliary shaft
is at 12 o’clock.
If pump is being assembled for right hand rotation install dowel pin (4) in hole in port
block at the 9 o’clock position; if left hand pump, install at 3 o’clock position when view-
ing from port block end of unit.
Install side plate (1), steel side first, over dowel pin. Insert key (2) in shaft keyway. Install
the inner gear of the gerotor assembly (3b) on the shaft and over the key (2). Install the
eccentric ring (3a) on the dowel pin (4). Install the large outer gear of the gerotor assem-
bly (3b) inside the eccentric ring (3a) and over the inner gear.
Note: When changing pump rotation consult parts list for proper side plate.
Place O-rings (7) and (8) on side plate assembly. Lubricate the O-rings and slip the pres-
sure plate (9) over the O-rings on the side plate assembly. Slip the two plates over the
auxiliary shaft and position the gerotor side plate over the dowel pin (4).
Place seal ring (12) on auxiliary shaft. Position bearing (11) between the two thrust wash-
ers (10) and install around the seal ring (12). Install insert (15) over spline on shaft.
Thread holddown nut (13) on the shaft and tighten no more than 10 ft. lbs. (13.56 Nm)
max. Back off the nut (13) until second slot is aligned with pin hole in the shaft. Insert pin
(14) through nut and shaft and secure with ring (16).
Check the main shaft for smooth rotation. If not smooth, check the gerotor parts for posi-
tion and hold down nut for proper adjustment.
20
ASSEMBLY PROCEDURES

1 side plate 033-71492 1
2 square key 1/8 x 9/16 211-22034 1
3 gerotor and eccentric ring assy. S13-43334 1
3a eccentric ring 033-72256 1
3b inner and outer gerotor 033-71500 1
4 dowel pin 3/16 x 1-9/16 324-21225 1
*5 gerotor sideplate and bearing assy See below 1.
7 O-ring 70-914-44 671-00144 1
8 O-ring 70-914-29 671-00129 1
9 pressure plate 033-70531 1
11 bearing 230-82164 1
12 seal ring 033-72101 1
13 holddown nut 033-91052 1
14 pin 033-53921 1
15 insert 033-91051 1
* for RH pumps use S13-46762

* for LH pumps use S13-46763

(before 7-93)
Note: Prior to assembly of reconditioned parts, check finish of gasket surface on
valve block and retainer. Must have 60 rms finish with no grinding marks which might
carry oil to outside surface. If lapping is necessary, check depth of pockets for valve
seats after lapping. Must be .085" (2.16 mm) minimum after lapping, to provide clear-
ance for valve seats.
Lubricate the four orifice plugs (12) and insert in the top of valve block (11).
Check the pilot valve assembly (41) to be certain that approximately 1-1/2 threads are
exposed from this small nut on the bottom of the valve assembly. This setting will allow
the valve to function at about 200 PSI (14 bar). Each complete right hand turn of this
screw will increase the pressure about 50 PSI (3.4 bar). Torque hex lock nut to 20-25 in.
lbs. (2.26 to 2.82 Nm). Thread the check valve (41) into the 3/8-24 tapped hole into the
valve block (11) as shown.
Press the two dowel pins (10) into the holes provided in the bottom of the valve block
(11). The pins (10) must be .12" (.3 mm) below the surface.
Place the two sequence seats (8) in the sequence ports (SB, SA). Place the four valve
seats (9) in the ports marked RB, RA, RV and servo. Position the gasket (7) and retain-
er plate (6) over the seats and insert the four screws (4) in the block (11). Torque to 10
in.-lbs. (1.1 Nm).
Position the valve block and the attached parts with four orifices (12) turned up. Insert the
two 1-7/16 long springs (17) in the two sequence poppets (13) and install (13) and(17)
in the block and over the sequence seats (18) in ports SB and SA. Install the four valve
poppets (14) in the ports marked RB, RA,RV and servo. Servo and RV seats to seated
with grooved side down. Insert spring retainer (15), large end first, in the servo poppet.
Insert the light weight spring (18) 1-9/16" (39.7 mm) long in the RV poppet. Insert the
three 1" (25.4 mm) long springs (16) in poppets RB, RA and servo.
Lubricate the two check valves (19) and install in sides of cover (21).
Lubricate O-ring (22) and place on seat (23) and install in valve cover (21). Use a 1/2" 6
point 1/4" drive socket and torque to 15 ft-lbs. ((20.4 Nm). Do not use impact wrench.
Lubricate O-rings (26) and (28) and place on parts (27) and (29). Assemble parts 30, and
33 on (31) and start (31) into housing (29). Push seal piston (27) and O-ring (26) into
housing (29) with the small end of the piston exposed. Place spring (25) on cone (24) and
insert all these parts in the valve cover (21). Be certain that cone (24) enters seat (23).
a. Install the orifice screw of the strainer assembly into valve cover. Thread elastic stop
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in. (1.47 Nm).
21 Revised
ASSEMBLY PROCEDURES
VALVE BLOCK Lubricate O-rings 37. Install (37) in the block (11).
before 7-93 (continued)
Position the cover (21) over the springs and poppets and install the four screws (39). BE
CERTAIN THAT THE SPRINGS ARE IN THE RIGHT POSITION BEFORE TIGHTENING
THE SCREWS.
Install dowel pin or roller pin (40) in the hole over the servo poppet. Lubricate the four
O-rings (42) and place on the four plugs (43). Install the four plugs. Lubricate O-ring (35)
and place on plug (36) and install.
Caution: Use of other than SAE plugs will result in malfunction and possible pump
damage
Invert the complete assembly and install roll pins (5) thru plate (6) and into the valve
block. Install O-rings (2) and (3) in the plate (6).

1 not used
2 O-ring 70-914-2 671-00014 2
3 O-ring 70-914-1 671-00013 2
4 10-24 x 1/2 button hd screw 353-25023 4
5 1/8 x 3/4 roll pin 325-08120 2
7 lower gasket 033-91193 1
8 sequence seat 033-70507 2
9 valve seat 033-70500 4
10 3/16 x 3/4 roll pin 325-12120 2
11 valve block 033-72377 1
12 .047 orifice plug 033-25528 4
13 sequence poppet 033-72378 2
14 valve poppet 033-72379 4
16 spring (1 OAL) 033-71086 3
17 spring (1-7/16 OAL) 033-70512 2
18 spring (light weight) 033-22141 1
20 not used
21 valve cover 033-72376 1
22 O-ring 6290-3 691-00903 1
23 seat 033-70508 1
24 cone 033-12288 1
25 spring 033-12289 1
26 O-ring 70-6227-7 671-00012 1
27 seal piston 033-21767 1
28 O-ring 90-6290-10 691-00910 1
29 housing 033-70545 1
30 5/16-24 hex nut 335-13100 1
31 5/16-24 x 1-1/2 soc set screw 312-13160 1
32 not used
33 acorn nut 327-25006 1
34 servo strainer assy. S13-43240 1
35 O-ring 90-6290-6 691-00906 1
36 hex plug SAE-6 488-35003 1
37 O-ring 671-00050 2
38 not used
39 hex hd cap screw 10-24 x 1-3/4 306-40167 4
40 dowel pin 1/8 x 5/8 324-20810 1
41 pilot relief assy S23-12813 1
42 O-ring 90-6290-4 691-00904 5
22
ASSEMBLY PROCEDURES
Valve Block
(Before 7-93)
S23-00904
Figure 10

(after 7-93)
cap screw, 6-32 x 1/4" long. Torque #6-32 screw to 13 lb-in (1.47 Nm).
23
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
after 7-93 (continued) Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
Place spring (32) 1.56" long (39.6 mm) into bore next to compensator valve side of block.
over poppet.
Insert spring (35) 1.09" long (27.7 mm) into the remaining bore. Place spring retainer (34)
in spring. Place servo poppet (31) over the retainer and spring. Position seat (28) with
the groove side facing down, over poppet.
Lubricate O-ring (11) install in groove of piston (10) and insert end into spring (12).
Lubricate O-ring (9) and install on housing guide (8) and thread into valve block. Tighten
in place.
Repeat step 18, on other end of valve block.
Install pin (21). Lubricate O-ring (22) and install over plug (23) and tighten plug in place.
Lubricate two O-rings (22) and install over two plugs (25) and tighten in place.
block.
24
ASSEMBLY PROCEDURES
Valve Block
(After 7-93)
S23-12770
Seal Kit
S23-00135
Figure 11
25
ASSEMBLY PROCEDURES

2 check valve S13-40266 2
3 orifice plug (.0465 dia.)
(1.18 mm) 033-91249 4
4 gasket, O-ring 691-00903 3
5 seat 033-70508 1
6 screw, socket head 5/16-24 x 1 312-13160 1
7 nut, hex jam 5/16-24 335-13100 1
8 housing guide 033-70545 1
9 gasket, O-ring 691-00910 1
10 piston 033-21767 1
11 gasket, O-ring 671-00012 1
12 spring 036-12289 1
13 cone 036-12288 1
14 assy servo strainer S13-43240 1
19 gasket, O-ring 691-00906 1
20 plug 488-35003 1
21 pin, 1/8 x 5/8 324-20810 1
22 gasket, O-ring 691-00904 5
23 plug 488-35001 5
25 plug 488-35049 2
26 pin, roll 3/16 x 3/4 325-12120 2
27 seat, sequence 033-70507 2
28 replenish & servo seat 033-70500 4
29 gasket, valve block 033-91193 1
30 poppet, sequence 033-72378 2
31 poppet, dual & replenish 033-72379 4
32 spring, replenish 033-22141 1
33 spring, sequence & servo 033-70512 2
35 spring, dual relief 033-71086 3
36 pilot valve, replenish relief S23-12813 1
37 gasket, O-ring 671-00050 1
43 screw, button head
#10-24 x 3/4 LG 353-25078 4
45 nut, acorn 5/16-24 327-25006 1
46 pin, roll 1/8 x 3/4 325-08120 2
47 gasket, O-ring 671-00013 2
48 gasket, O-ring 671-00014 2
26
ASSEMBLY PROCEDURES
VALVE BLOCK
(before 7-93)
S23-11433
Figure 12
See figure 12.
Note: Prior to assembly of reconditioned parts, check finish of gasket surface on valve
block and retainer. Must have 60 rms finish with no grinding marks which might carry oil
to outside surface. If lapping is necessary, check depth of pockets for valve seats after
lapping. Must be .085" (2.16 mm) minimum after lapping, to provide clearance for valve
seats.
Place valve block (25) with O-ring groove down and horizontal in order to press two roll
pins (26) in position. (Roll pins need to be .12" (3.05 mm) below surface of valve block).
Apply a liberal amount of vaseline or grease to the six counterbores in the face of the valve
block (25). Install two valve seats (27) tapered bore side first, into counterbores and
against roll pin (26), one required each end, (outer-most counterbores in block). Insert the
valve seats (28) and valve seat (44) in remaining counterbores as shown.
Press two roll pins (46) into retainer plate (42). Each roll pin should stick out approximately
.25" (6.35 mm) from each face of the retainer plate.
27
ASSEMBLY PROCEDURES
VALVE BLOCK Position valve block gasket (29) on valve block. Take care that none of the gasket is cov-
for special mounting of servo valve ering the valve seats.
before 7-93 (continued) a. Position retainer plate (42) with O-ring grooves facing up, over valve block gasket.
Install four button-head cap screws (43), torque to 30 in.-lbs. (3.39 Nm).
b.Turn the assembly over so that it is resting with the retainer plate O-ring side down-
ward.
Place spring (33) (1.43" long) (36.3 mm) into poppet (30) and insert small hole end first
into outer-most bores at each end of the valve block (25).
Insert three poppets (31) and one poppet (34) in remaining bores as shown, small diam-
eter end first.
Slip springs (33) into poppets (34) and (30) as shown.
Insert two springs (35) (1.09" long) (27.7 mm) into remaining outer poppets (31).
Install spring (32) 1.56" long (39.6 mm) into remaining poppet located in center of valve
block.
Install four orifice plugs (3) in valve block (25) and tighten in place.
Thread pilot replenishing relief valve (36) into block (25). Valve must not extend below
lower surface of retainer plate.
Place O-ring (4) onto seat (5) and install in valve block cover (1). (Be careful not to dam-
age bore in seat.) Torque (5) to 15 ft.-lbs. (20.4 Nm). (Do not use impact wrench).
Lubricate O-ring (11) and insert into groove of seal piston (10) and slip spring (12) onto
end of seal piston and press into bore of housing guide (8).
a. Lubricate O-ring (9) and install on housing guide (8).
b. Place shank of cone (13) into spring (12).
c. Align cone with seat in valve cover and thread housing guide into bore and tighten
in place.
Thread nut (7) on soc. setscrew (6) and thread into housing guide (8) until it starts to
compress spring. Thread acorn nut (45) on soc. setscrew (6).
Coat check valve (2) threads with loctite removable thread locker #242 and thread into
end of valve cover (1). (Be sure check valve is properly installed and does not block pas-
sages from orifice plug (3). Lubricate O-ring (22) and install on plug (23) and tighten.
Repeat above step at the opposite end of the valve cover (1).
Disassemble the strainer assembly (14) in valve block and reassemble per the following:
a. Install the orifice screw of strainer assembly (14) into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 in.-lbs. (2.6 Nm).
b. Install the strainer support, filter screen and #6-32 x 1/4 lg. screw. Torque #6-32
screw to 13 in.-lbs. (1.47 Nm).
Place O-ring (37) and two (2) O-rings (47) into the grooves on the upper surface of the
valve block and secure with vaseline or grease.
Place valve cover (1) over valve block (25) positioning over springs (33), (32) and (35)
and secure in place with four (4) socket hd. cap screws (41).
Lubricate O-ring (19) and install over plug (20) and tighten plug in place.
towards the left side of the manifold (15) when viewing from the top rear.
Install temporary plugs (49) and (50) in 1/2" tube and 1/4" tube ports, front and back and
side. Insert O-ring (19) and plug (20) in alternate drain port.
28
ASSEMBLY PROCEDURES

(before 7-93)

1 valve cover 033-54391 1
3 orifice #56 (.0465) 1/16 pt 033-25528 5
4 O-ring, 90 S-1 ARP 903 691-00903 1
5 seat 033-70508 1
6 set screw, 5/16-24 x 1 cup pt 312-13160 1
7 hex jam nut 335-13100 1
9 O-ring, 90 S-1 ARP 910 691-00910 1
10 piston 033-21767 1
11 O-ring, 70 S-1 ARP 012 671-00012 1
12 spring 036-12289 1
13 cone 036-12288 1
15 manifold 033-54389 1
16 spring (Lee #LC-038C-19) 225-92083 1
19 O-ring, 90 S-1 ARP 906 691-00906 3
20 plug 6HP5N- PL 488-35041 3
21 gasket 035-47851 1
22 O-ring, 90 S-1 ARP 904 691-00904 10
23 plug, 4HP5N-S w/o PL 488-35001 9
25 valve block 033-54390 1
26 roll pin 3/16 x 3/4 325-12120 2
27 seat sys relief 033-70507 2
28 servo seat 033-70500 3
29 gasket 033-91193 1
30 poppet 033-72378 2
31 poppet 033-72379 3
32 spring 033-22141 1
33 spring 033-70512 3
35 spring 033-71086 2
36 valve, repl S23-12699 1
37 O-ring, 70 S-1 ARP 050 671-00050 1
38 spool 033-54392 1
39 O-ring, 90 S-1 ARP 008 691-00008 1
41 screw, soc hd 10-24 x 2-3/4 358-10300 4
43 screw 353-25023 4
45 acorn nut 327-25006 1
46 rollpin 1/8 x 3/4 325-08120 2
47 O-ring, 70 S-1 ARP 013 671-00013 6
48 O-ring, 70 S-1 ARP 014 671-00014 2
49 plug 3/4-16 449-00016 2
50 plug 7/16-20 449-00013 1
51 cover, gasket 035-47852 1
52 screw, soc hd 10-32 x 1/2 359-09080 4
53 screw, soc hd 3/8-16 x 4 358-16360 4
54 plug 035-54400 1
55 screw, hex hd 306-40132 4
seal kit S23-04226
29
ASSEMBLY PROCEDURES
VALVE BLOCK
(after 7-93)
S23-12776
Figure 13
See figure 13.
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in (1.47 Nm).
Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
30
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
for special mounting of servo valve step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
after 7-93 (continued)
Place spring (32) 1.56" (39.6 mm) into bore next to com-pensator valve side of block.
over poppet.
Insert spring (33) 1.43" (36.3 mm) into the remaining bore. Place servo poppet (37) over
the retainer and spring. Position seat (44) with the tapered bore facing down, over poppet.
Lubricate O-ring (11) install in groove of piston (10) and insert end of piston into spring
(12).Lubricate O-ring (9) and install on housing guide (8) and thread into valve block.
Tighten in place.
Lubricate O-ring (22) install on plug (23) and tighten in place.
Repeat above step on other end of valve block.
Lubricate O-rings (22) install over plugs (23) and tighten plugs in place.
Lubricate O-rings (4) install on plugs (25) and tighten in place.
Lubricate O-ring (19) install over plug (20) and tighten in place.
towards the left side of the manifold (15) when viewing from the top rear. Install orifice
plug (61) in manifold (15).
Install temporary plug, (50) in 1/4" tube port. Insert O-ring (19) and plug (20) in alternate
drain port.
block.
31
ASSEMBLY PROCEDURES

(after 7-93)

3 orifice #56 (.0465) 033-91249 4
4 O-ring, 90 S-1 ARP 903 691-00903 3
5 seat 033-70508 1
6 set screw, 5/16-24 x 1 cup pt. 312-13160 1
7 hex jam nut 335-13100 1
9 O-ring, 90 S-1 ARP 910 691-00910 1
10 piston 033-21767 1
11 O-ring, 70 S-1 ARP 012 671-00012 1
12 spring 036-12289 1
13 cone 036-12288 1
15 manifold 033-54389 1
16 spring (Lee #LC-038C-19) 225-92083 1
19 O-ring, 90 S-1 ARP 906 691-00906 3
20 plug 6HP5N-PL 488-35041 3
22 O-ring, 90 S-1 ARP 904 691-00904 10
23 plug, 4HP5N-S w/o PL 488-35001 9
25 plug (3HP5N-S) 488-35049 2
26 pin, roll 3/16 x 3/4 325-12120 2
27 seat, sys relief 033-70507 2
28 servo seat 033-70500 3
29 gasket 033-91193 1
30 poppet 033-72378 2
31 poppet 033-72379 3
32 spring, (light weight) 033-22141 1
33 spring (1.47 (36.5 mm) O.A.L.) 033-70512 3
35 spring (1" (25.4 mm) O.A.L.) 033-71086 2
36 valve, repl. S23-12699 1
37 O-ring, 70 S-1 ARP 050 671-00050 1
38 spool 033-54392 1
39 O-ring, 90 S-1 ARP 008 691-00008 1
41 screw, soc hd 10-24 x 1 1/4 358-10180 4
43 screw 353-25078 4
45 acorn nut 327-25006 1
46 roll pin 1/8 x 3/4 325-08120 2
47 O-ring, 70 S-1 ARP 013 671-00013 6
48 O-ring, 70 S-1 ARP 014 671-00014 2
50 plug 7/16-20 449-00013 1
53 screw, soc hd 3/8-16 x 4 358-16360 4
54 plug 035-54400 1
58 screw, hex hd 306-40132 4
61 orifice #56 (.0465) 033-25528 1
seal kit S23-04226
32
ASSEMBLY PROCEDURES

1 no. 3 splined shaft assy. (see fig. 1) S13-41805 1
no. 2 keyed shaft assy. (see fig. 1) S15-41806
2 shim .008 (.203 mm) (use only 1) 033-53948 1
shim .007 (.178 mm) 033-53949
3 ret. ring .066/.068 (1.68/1.73 mm) (use only 1) 033-53901 1
ret. ring .070/.072 (1.78/1.83 mm) 033-53902
ret. ring .074/.076 (1.88/1.93 mm) 033-53903
4 shaft seal 623-00006 1
5 O-ring 671-00043 1
6 seal retainer 033-57892 1
7 nyltite gasket 631-45003 4
8 screw 306-40144 4
9 servo stem 033-71312 1
10 balance plate 033-70546 1
11 spacer 033-71247 2
12 soc. hd. cap screw 10-24 x 2-3/4 358-10300 2
13 nyltite washer 631-45007 8
14 hex washer hd. screw 3/8-16 x 1-1/4 353-25018 8
15 output control assy. see below 1
16 input control assy. see below 1
17 hex. hd. cap screw 3/8-16 x 3-1/4 306-40184 8
*18 O-ring 671-00017 1
*19 O-ring 671-00048 1
20 hex hd screw 306-40025 2
21 optional - gear pump C.W.(see note) 512-42023 1
- gear pump C.C.W. 512-42024
- vane pump TB006 (CW) 024-51095-0/01
- vane pump TB006 (CCW) 024-51096-0/01
22 rear adapter, SAE-A for shuttle valve (Std.) S23-12362
rear adapter, SAE-B for shuttle valve (Std.) S23-12670
23 hex screw 306-40224 4
24 shuttle valve-external drain (see fig. 16) S23-11966 1
shuttle valve-internal drain (Std.) S23-12007
*Some controls use gasket 033-91058 in lieu of O-rings (cast iron covers).
Powder metal covers have groove for O-rings 671-00048, 671-00017.
Note: Any pump with SAE-A or SAE-B mounting may be used, with the corresponding
adapter assembly (22).
OUTPUT CONTROLS output controls part no.

standard, with volume indicator S13-42064
torque limiter S23-12299
INPUT CONTROLS input controls part no.

10 “B” mtg. CW, “A” mtg. CCW S23-12327
10 “B” mtg. CCW, “A” mtg. CW S23-12328
2H S23-12328
40 S23-12344
4A S23-12325
4B S23-12343
4C S23-12324
5A '0' deadband S23-12413
5C S23-12414
60 S13-48944
6B S23-12424
8A S23-12268
9A S23-12667
33 Revised
ASSEMBLY PROCEDURES
Valve Block
See Fig.
10, 11,
12, 13
21
20
22
24
23 Figure 14
SHAFT AND SEAL INSTALLATION See figure 14. Stand the pump in an upright position with the port block inlet and outlet
pads turned down.
Install the shaft and bearing (1) assembly in the mounting flange and cradle. Be certain
that there are no burrs or sharp edges on shaft seal area of the shaft.
For a rigid shaft application use the shim (2) that results in least clearance around the
shaft bearing. Do not use a shim with a floating shaft.
Install the snap ring (3) in the mounting flange to retain the Shaft Assembly. Be certain
that the ring is fully seated in the groove. Use the ring that results in the tightest fit.
MECHANICAL SHAFT SEAL

ASSEMBLY PROCEDURE
Warning: When installing a new mechanical shaft seal, exercise care to insure that
all of the parts fit together properly. This is particularly important if the seal was once
assembled and disassembled for some reason. If the rubber boot, item 4, grips the
shaft and doesn't slide on the shaft, as it is disassembled, then the spring, item 7, can
disengage the shell, item 5, from the band, item 6, so that they do not re-engage
properly when reassembled. Be sure the shell and the band are properly engaged
before reassembling the seal, and stays engaged during assembly.
Note: Lubricate seal and shaft with clean hydraulic fluid of the same type that will be
used in the system.
34
ASSEMBLY PROCEDURES
See figure 14. The seal assembly (4) is available as a complete unit only.
Caution: Before installing the seal assembly examine all the parts. The lapped seal
seat and the carbon ring have a precision finish that must be handled with care. Be
certain that both parts are free of scratches, marks and cracks.
Place the spring retainer (e) over the shaft and against the retaining ring on the shaft
assembly. Place the spring (d) against the retainer (e). Apply grease to the inner surface
of the rubber friction ring (f) and position the shell containing the rubber friction ring (f)
and carbon ring (c) over the shaft with the carbon ring exposed. Apply grease to the
square section rubber seal (a) and install on the ceramic seat (b). Insert the seat and seal
in the seal retainer (6) with the lapped side of the seat in position to contact the carbon
ring. Place the seal retainer assembly and O-ring (5) over the shaft with the lapped sur-
face against the carbon face. Place the four gaskets (7) on the four screws (8) and insert
the seal retainer (6). Depress the seal retainer only far enough to start the four screws
and tighten evenly. Torque to 10 ft.-lbs. (13.56 Nm).
Note: Seal installation must be completed quickly to avoid the rubber friction ring from
seizing on the shaft.
COUNTER-BALANCE SERVO Place the two spacers (11) on the two screws (12) and insert through the balance plate
STEM (10) and servo stem (9).
Insert these parts through the opening in the side of the housing assembly and position
the screws over the two #10-24 tapped holes in the rocker cam.
Hold these parts against the cam and alternately tighten the screws (12) to hold the
assembly firmly in place. Torque screws to 5 ft.-lbs. (6.78 Nm)
REAR DRIVE ADAPTER See figure 15. Place wave spring, (8) over isolation tube (4). Lube O-ring (7) and assem-
ble to isolation tube. Place isolation tube against pressure plate, item (9) Fig. 9.
Lube O-ring (5) and assemble to adapter (1).
Lube tetraseals (10). Insert into adapter block and carefully assemble adapter block to
port block. Using screws (9) and washers (12) to hold adapter block in place, torque to
150 ft-lbs. (203 Nm).
Insert retaining ring (6) into groove of coupling insert (3).
Coupling (2) with coupling insert (3) and retaining ring (6) may be installed to end of aux-
iliary shaft when external pump is mounted.
Adapter
Figure 15
35
ASSEMBLY PROCEDURES

1 adapter — SAE-A with shuttle pad 033-91015 1
adapter — SAE-B with shuttle pad 033-57967
adapter — SAE-A no shuttle 033-57958
adapter — SAE B no shuttle 033-57957
2 coupling 033-57963 1
3 insert — SAE-A 033-57965 1
insert — SAE-B 033-57964
4 tube — Isolation 033-57966 1
5 gasket — O-ring 671-00147 1
7 gasket — O-ring 671-00033 1
8 spring — wave 225-92093 1
9 screw — HHC 306-40088 4
10 gasket — Square 691-10131 2
11 gasket — O-ring (with SAE-A) 671-00152 1
gasket — O-ring (with SAE-B) 671-00155
12 washer 350-10136 4
PARTS LIST FOR FIGURE 16 SHUTTLE VALVE ext. int.

drain drain
1 blk-shuttle 033-57752 1 1
2 pilot valve ext. drain S23-22865 1 —
pilot valve int. drain S26-22867 — 1
3 spool 033-57180 1 1
4 spring stop washer 033-57182 2 2
5 sleeve 036-27549 1 1
6 piston 036-32902 1 1
7 spring 036-27547 1 1
8 spring 033-57181 2 2
9 O-ring 691-00125 2 2
10 O-ring 691-00026 1 1
11 tetraseal 691-10221 2 2
12 plug 488-35024 2 2
13 screw, HHC 1/2-13 x 3 1/2 306-40224 4 4
14 screw, SHC 3/8-24 x 1 3/4 359-15220 3 3
15 O-ring 691-00916 2 2
16 plug 488-35014 1 1
17 O-ring 691-00912 1 1
shuttle valve w/external drain S23-11966
shuttle valve w/internal drain S23-12007
PARTS LIST FOR FIGURE 16 PILOT VALVE ext. int.

drain drain
2-1 orifice 036-25528 1 1
2-2 O-ring 695-00013 2 2
2-3 cap 036-38910 1 1
2-4 set screw 312-35051 1 1
2-5 spacer 036-27548 1 1
2-6 piston 036-11694 1 1
2-7 block 036-11710 1 1
2-8 seat 036-11692 1 1
2-9 cone 036-12288 1 1
2-10 spring 036-32465 1 1
2-11 spring 036-85514 1 1
2-12 screw SHC 3/8-24 x 1-3/4 (w/hole) 036-36749 1 1
2-13 piston 036-21767 1 1
2-14 O-ring 675-00012 1 1
2-15 plug 036-21765 1 1
2-16 nut hex 5/16-24 333-13001 1 1
2-17 screw S.S. 5/16-24 x 1-5/8 312-13200 1 1
2-18 nut acorn 036-33474 1 1
2-19 plug hex soc. (external drain) 431-90104 1 —
2-20 plug-SAE-4 488-35001 — 1
2-21 O-ring 691-00904 — 1
seal kit, shuttle valve 523-15089
36 Revised
ASSEMBLY PROCEDURES
Exploded View of Shuttle

Valve Exploded View of
Pilot Valve
Figure 16
PILOT VALVE See figure 16. Insert seat (2-8) into cap (2-3) and seat in bottom of bore.
Install small end first of block (2-7) into bore and against seat.
Install small end first of piston (2-6) into block (2-7).
Install spacer (2-5) and secure in place with set screw (2-4).
Install spring (2-11) onto cone (2-9) . Install spring (2-10) over spring (2-11), and insert into
cap (2-3) and seat (2-8).
Install O-ring (2-14) in piston (2-13) and insert small end into springs.
Install plug (2-15), screw (2-17) & nut (2-16). Set per requirement and cover with acorn
nut. (2-18).
Insert orifice plug (2-1) in center hole of cap.
Grease and install O-rings (2-2).
If externally drained, insert plug (2-19) into hole on spring end of cap.
If internally drained, insert plug (2-20) and O-ring (2-19) in cap drain port.
SHUTTLE VALVE See figure 16. Lube spool (3) and insert it into valve body (1). When the spool is fully
engaged, move the spool back and forth a few times to check for smooth operation. Spool
must move freely in body bore.
Install spring stop (4) into one end of valve body (1). Make sure it is seated properly.
Insert spring (8) into valve body (1) over the spool (3). Install plug (12) & O-ring (15) into
the valve body (1).
Repeat step #2 on other end of valve body.
Lube O-ring (9) and install into valve body (1). Make sure it fits exactly.
Lube O-ring (9) and place over the sleeve (5) and install into bore of valve body (1). Be
careful not to jam sleeve in bore.
37
ASSEMBLY PROCEDURES
SHUTTLE VALVE Insert piston (6) into sleeve (5) and place spring (7) into piston (6).
(continued)
Lube O-ring (10) and place onto the sleeve (5).
Lube O-rings which come on pilot valve sub-assembly (2).
Mount pilot valve cap sub-assembly (2) onto shuttle block (1). Use three S.H.C. screws
(14) and the one screw which comes with the pilot valve sub-assembly. Make sure that
the screw that comes with the valve cap sub-assembly is positioned on end closest to
acorn nut. Torque to 50 ft-lbs. (68 Nm) Run lead wire which comes with valve cap sub-
assembly through holes in special screw and acorn nut. Twist ends together.
SHUTTLE VALVE MOUNTING Lubricate tetraseals (11) figure 16 and place in C' bores of shuttle valve mounting surface.
Carefully attach shuttle valve to adapter (22) fig. 14, using hex hd. screws (13) figure 16.
Torque to 75 lb-ft. (102 Nm).
38
IMPORTANT INSTRUCTIONS
Without Filter No Plug
External Filter With Plug
INSTRUCTIONS FOR CAUTION: The isolation plug enclosed is to be used ONLY if an external filter circuit
REPLENISHING CIRCUIT is provided. DO NOT operate this unit with the isolation plug installed unless an exter-
ISOLATION PLUG nal line has been provided.
When the external filter circuit IS NOT used discard the isolation plug.
When the external filter circuit IS used install the isolation plug between port G and H
(refer to appropriate installation drawing): use a 3/16 Hex. wrench by 4" minimum length
INSERTING THE ISOLATION PLUG INTO PORT H and tighten to 80 - 120 in.-lb. torque.
(9.04-13.56 Nm)
Isolation plug: Part No. 311-45032 (3/8-16 x 1/2 UNC Flat point set screw).
39
HYDRAULIC CIRCUIT
40 Revised
HYDRAULIC CIRCUIT
41 Revised
TEST PROCEDURES
GENERAL REQUIREMENTS 1. Maximum runout between pump shaft and electric motor shaft .003 (.076 mm) T.I.R.
A floating shaft must have a support in mounting bracket. A fixed shaft should not have
a support bearing in mounting bracket.
2. Electric motor speed - 1800 RPM.
3. Inlet temperature - 130° ± 10°F. (54°C ± 4°C)
4. Inlet condition Main Pump 100 to 150 PSI. (6.9 to 10.3 bar)
Gerotor 10" HG to 5 PSI. (25.4 mm HG to .34 bar)
5. Case pressure 65 PSI ± 10 PSI. (4.5 ± .69 bar).
6. Fluid - 200SSU @ 100°F. (37.8°C)
BASIC PUMP TEST 1. Mount pump on test stand. Connect system lines and gerotor inlet line to pump.
Connect case drain line to flowmeter. Connect shuttle return line to reservoir. If shuttle
pilot valve is externally drained, connect drain to max. 5 PSI (.34 bar) return line. If an
auxiliary pump is mounted, connect auxiliary pump inlet to reservoir. If auxiliary pump is
not mounted, remove coupling and seal auxiliary unit mounting surface.
2. Start electric motor.
3. Rotate pump input control shaft. The servo control should control pump displacement
through its full range. Set pump displacement for full volume, and adjust system pressure
for 1000 PSI (69 bar). Check and record system flow and case drain flow above and below
center.
6.0 in3 7.25 in3 8.0 in3

Maximum 47 GPM 57 GPM 63 GPM
System Flow (177.9 l/m) (215.7 l/m) (238 l/m)
4. Back out compensator adjusting screw until unit is fully compensated (count number
of turns). Observe volume indicator and stroke rotary servo input shaft from full to full
position on each side of center. Indicator should remain on or very near zero position
("O"). If compensator functions normally, return compensator adjusting screw to its orig-
inal position and proceed with Step 5.
Caution: Do not over-tighten adjusting screw.
5. Cycle pump at 10 sec. intervals-full volume above center to full volume below
center*—as follows:
6. Adjust system pressure to 5000 PSI (345 bar) and set pump displacement for full vol-
ume. Check and record system flow and case drain flow above and below center.
*Pumps with screw adjustment controls do not need to be cycled.
6.0 in3 7.25 in3 8.0 in3

Minimum 41 GPM 50.0 GPM 55 GPM
System Flow (155.9 l/m) (189 l/m) (208 l/m)
7. Set pump to compensate at 5000 PSI (345 bar). Servo pressure should be at least
650 PSI (45.5 bar). Check and record replenishing flow. (Case leakage flow).
Maximum flow-14.6 GPM (55.3 l/m) with Barnes auxiliary pump. 6.5 GPM (24.6 l/m)
without auxiliary pump.
8. Set pump to compensate at minimum PSI. Check and record replenishing and servo
pressure.
Servo pressure-Minus Case Pressure 455 to 570 PSI (31.3 to 39.3 bar).
Repl. pressure-Minus Case Pressure 350 PSI ± 20 PSI (24.1 ± 1.4 bar).
42
TEST PROCEDURES
BASIC PUMP TEST If pressures are incorrect, remove replenishing relief valve pilot and increase or decrease
pressure as required. (One full turn on adj. screw will cause pressure to change approx-
(continued)
imately 50 PSI) (3.4 bar). Re-torque locknut to 20-25 in-lbs. (2.3-2.8 Nm).
Note: There is no servo relief valve adjustment. Increasing or decreasing repl. pres-
sure will cause both servo and repl. pressure to change by the same amount.
9. Set pump to full displacement and set the test stand relief valve at approx. 2000 PSI
(138 bar). Set the pump compensator at 1000 PSI (69 bar). Set the shuttle relief valve
pilot cap to 220 ± 20 PSI (15.2 ± 1.4 bar) above case pressure and secure with locknut
and acorn nut.
10. Stroke pump to center position and observe repl. pressure. It should rise to the value
in step 8 above.
11. Slowly cycle the pump across center several times while observing repl. pressure
drops to 220 ± 20 PSI (15.2 ±1.4 bar) while on stroke, and rises to 350 ± 20 PSI (24.1 ±
1.4 bar) at zero stroke, to verify shuttle operation.
12. Set pump to compensate at 5000 PSI (345 bar). Record repl. and servo pressure.
Servo Pressure-Minus Case Pressure-660 to 770 PSI (45.5 to 53.1 bar).

Repl. Pressure-Minus Case Pressure-350 ± 20 PSI (24.1 ± 1.4 bar).
13. Set pump to compensate at minumum PSI. Servo pressure should return to 455 to
570 PSI (3.3 to 39.3 bar).
Note: After completing step 13, proceed with pump control test and adjustment. Refer
to the goldcup control manual #S1-AM030 for your control type. Continue with step
14 after testing controls.
14. Adjust pump displacement for full volume and adjust system pressure to 6000 PSI
(413.8 bar).**Adjust compensator from 6000 PSI to 3000 PSI (413.8 to 206.9 bar) to min-
imum pressure. At each pressure, stroke rotary servo input shaft to the full position on
each side of center. Cam indicator should remain on or very near the zero position with
no oscillation. System pressure should not vary from Port "A" to Port "B" more than 150
PSI (10.3 bar) and not oscillate.
Minimum compensator pressure should be under 500 PSI (34.5 bar)
**Caution: DO NOT hold pump at 6000 PSI (413.8 bar) for longer than one minute at
any time. This is only an intermittent pressure rating.
15. Set compensator for 1000 PSI (69 bar) when fully compensated, UNLESS OTHER-
WISE SPECIFIED. Increase and decrease system pressure above and below compensa-
tor setting. When system pressure is above compensator setting, the pump should de-
stroke and not oscillate. When the system pressure is below the compensator setting, the
pump should stroke to full volume.
16. Check pump for external leaks. No external leaks permitted.
Note: Refer to Manual S1-AM030 for Control Service information.
43
ORDERING CODE
Model Number P 6 S -2 R 1 * -4 A 2 - A - 00 -0 -B 0- M2-XXXXX
Pump series
Displacements, Max.
6 = 6.0 in3/rev., 98 cc/rev.
7 = 7.25 in3/rev., 119 cc/rev.
8 = 8.0 in3/rev., 131 cc/rev.
Pump type
S = closed circuit, with shuttle valve
Shaft
SAE = C
2 = keyed
3 = spline
Rotation, shaft
R = clockwise
L = counter-clockwise
Fluid class
1 = compatible w/Buna N
4 = compatible w/EPR
5 = compatible w/Viton
Design letter - P6 Design C, P7 & 8 Design A

Primary controls
1 = screw adjustment
2 = cylinder control
4 = rotary servo-spring centered w/trimmer
5 = electrohydraulic stroker
7 = servovalve & feedback device
9 = electric stroker
(All include rotary servo, pressure compensator override & displ. indicator)
Primary controls, options
0 = none
A = adjustable maximum volume stops
B = automatic brake control
C = A & B combined
D = 10 gpm servovalve w/feedback potentiometer
E = 10 gpm servovalve w/feedback RVDT
F = 10 gpm servovalve w/pot. & man. override -w/4A2 control
G = 10 gpm servovalve w/2/RVDT & man.override -w/4A2 control
H = 3 position 2A control
Secondary controls
2 = auxiliary replenishment port on centerline - STD
4 = torque limiter and auxiliary replenishing port
Control location
A = command on port A side, displ. ind. on opp. side
B = command on port B side, displ. ind. on opp. side
500 control 600 control 700 control 8A control
00 = w/deadband 00 = 75-350 psi, 00 = w/o man. override shut-off 00 = 75-350 psi, (5-24 bar)
(5-24 bar)
01 = w/o deadband 01 = 75-435 psi, 01 = w/man. override shut-off 01 = 75-435 psi, (5-30 bar)
(5-30 bar)
02 = N/A 02 = 100-380 psi, 02 = N/A 02 = 110-375 psi, (7.6 bar)
(7-26 bar)
03 = 150-400 psi, (10-28 bar)
04 = 75-250 psi, (5-17.2 bar)
For all other controls use 00
Internal pump
0 = 1.07 in3/rev., 17.7 cc/rev.
x = none
External drive A = SAE-A B = SAE-B P Pumps only

External mounting 0 = pump not mounted 1 = pump mounted, - must be separately specified
Designates special
Allowable Controls: 102, 104, 2A2, 2A4, 2H2, 2H4,402, 4A2,4A4,

4B2, 4B4, 4C2, 4C4, 5A2, 5A4, 5C2, 5C4,
602, 604, 6B2, 6B4, 7D2, 7E2, 7F2, 7G2,
8A2, 8A4, 9A2, 9A4
44 Revised
NOTES
45
NOTES
46
NOTES
47
International Distributors Australia France Mexico, Central America, South

In Europe: DENISON HYDRAULICS Pty. Ltd. DENISON HYDRAULICS America and Caribbean
Cyprus 41-43 St. Hillers Road FRANCE SA Countries Contact
Eastern Europe P.O. Box 192 14, route du Bois Blanc DENISON HYDRAULICS Inc.
The Faroe Islands Auburn, N.S.W. 2144 BP 539 6167 NW 181 Terrace Circle North
Finland Tel. (612) 9646 5200 18105 Vierzon Miami, FL 33015, USA
Greece Fax (612) 9643 1305 Tel. (33) 2 48 53 01 20 Tel. (305) 362 2246
Iceland Other sales offices: Fax (33) 2 48 75 02 91 Fax (305) 362 6220
Norway Queensland Other sales offices:
Portugal South Wantirna Victoria Bordeaux Other European, Middle East
Switzerland Western Australia Lyon and African Countries Contact
Turkey Paris DENISON HYDRAULICS
Austria FRANCE SA
In Africa: DENISON HYDRAULIK GmbH Germany 14, route du Bois Blanc
Algeria Zweigniederlassung Linz DENISON HYDRAULIK GmbH BP 539
Egypt Haidbachstraße 69 Herderstrasse 26 18105 Vierzon Cedex
Ivory Coast A-4061 Pasching D-40721 Hilden France
Morocco Tel. (43) 7229 4887 Tel. (49) 2103 940-6 Tel. (33) 2 48 53 01 45
Nigeria Fax (43) 7229 63092 Fax (49) 2103 940-880 Fax (33) 2 48 53 01 46
South Africa Other sales offices:
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BENELUX B. V. Stuttgart Pte. Ltd.
In Middle East: Pascalstraat 100 No. 11 Lorong Tukang Dua
Iran 3316 Dordrecht Great Britain 2261 Singapore
Israel Holland DENISON HYDRAULICS U.K. Tel. (65) 2687840
Lebanon Tel. (31) 786179 900 Ltd. Fax (65) 2687847
Pakistan Fax (31) 786175 755 Kenmore Road
Qatar Wakefield 41, Industrial Estate Spain
Saudi Arabia Canada Wakefield, WF20XE DENISON HYDRAULICS, S.A.
Syria DENISON HYDRAULICS West Yorkshire Gomis, 1
United Arab Emirates CANADA Inc. England 08023 Barcelona
2320 Bristol Circle, Unit 1 Tel. (44) 19 24 826 021 Tel. (34) 3418 46 87
In Far East: Oakville, ON L6H 5S2 Fax (44) 19 24 826 146 Fax (34) 3211 65 07
Indonesia Tel. (905) 829 5800 Other sales offices: Other sales offices:
Korea Fax (905) 829 5805 Burgess Hill San Sebastian
Malaysia Other sales offices:
New Zealand Montreal, QC Hong Kong, N. T. Sweden
Philippines Calgary, AB DENISON HYDRAULICS Ltd. DENISON HYDRAULICS
Thailand Unit 3, 25/F Wharf Cable Tower SVENSKA AB
China, P.R. 9 Hoi Shing Road Sporregatan 13
DENISON HYDRAULICS Ltd. Tsuen Wan 213 77 - Malmö
3F, No. 1, Mao Jia Zhai, Bai Lian Jing Tel. (852) 24988381 Tel. (46) 40 21 04 40
Pudong New Area Fax (852) 24991522 Fax (46) 40 21 47 26
Shanghai 200126, Other sales offices:
Tel. (86) 21 5886 8991 Italy Spånga
Fax (86) 21 5886 1978 DENISON HYDRAULICS S.r.l.
Viale Europa 68 Taiwan, R.O.C.
Denmark 20090 Cusago DENISON HYDRAULICS Ltd.
DENISON HYDRAULIK Tel. (39) 2 90 33 01 6F-10, No. 79, Sec. 2, Roosevelt Road
DENMARK A/S Fax (39) 2 90 39 06 94 Taipei,
Industrikrogen 2 Tel. (886) 2 3645101 / 3645102
DK-2635 Ishöj Japan Fax (886) 2 3639025
Tel. (45) 4371 15 00 DENISON JAPAN Inc.
Fax (45) 4371 15 16 4-2-1 Tsujido-Shinmachi USA
Fujisawa 251, DENISON HYDRAULICS Inc.
Finland Tel. (81) 466 35 3257 14249 Industrial Parkway
DENISON HYDRAULICS Fax (81) 466 35 2029 Marysville, OH 43040
P.O. Box 36 Other sales office: Tel. 937 644 3915
FIN-08101 Lohja Osaka Fax 937 642 3738
Tel. (358) 208 33 045 For nearest Distributor:
Fax (358) 207 33 045 Call toll free 1 800 551 5956
Other sales offices:
Fulton, CA
Mulberry, FL
Moline, IL
Rock Island, IL
Kentwood, MI
Portland, OR
Collierville, TN
Arlington, TX
Houston, TX

Printed in U.S.A. 6-98
Internet: http://www.denisonhydraulics.com
E-mail: denison@denisonhydraulics.com
900 PUMP CONTROL
DENISON HYDRAULICS
controls for
goldcup pumps & motors series 6. . .30
service information
valve block
"B" side
control
mounting
"A" side
control
mounting
rotation
Publ. S1-AM030-A replaces S1-AM030 11-96

GOLDCUP CONTROLS ORDERING CODE
P 6 P -2 R 1 C -4 A 2 -A -00 -B 1 -M-XXXXX
Pump series Control Feature
500 Control
Primary Controls 00-with deadband
1-Screw Adjustment 01-without deadband
2-Cylinder Control
4-Rotary Servo (spring centered w/trimmer) 600 Control
5-Electrohydraulic Stroker 00-75-350 PSI (5-24 bar)
6-Hydraulic Stroker 01-75-435 PSI (5-30 bar)
7-Servovalve & Feedback Device 02-100-380 PSI (7-26 bar)
8-Proportional Hydraulic Stroker 03-150-400 PSI (10.3-27.6 bar)
9-Electrohydraulic Stroker
(All include rotary servo, pressure compensator 700 Control
override & displ. indicator) 00-w/o manual override shut-off
01-w/manual override shut-off
Primary Control Options
0-None 800 Control
B-Automatic brake control 01-75-435 PSI (5-30 bar)
C-A & B above, together 02-100-380 PSI (7-26 bar)
D-10 GPM Servovalve w/feedback potentiometer 03-150-400 PSI (10.3-27.6 bar)
E-10 GPM Servovalve w/feedback RVDT 04-75-250 PSI (5-17 bar)
F-10 GPM Servovalve w/pot. & manual override
w/4A2 Control 900 Control
G-10 GPM Servovalve w/RVDT & manual override 00-24 VDC
w/4A2 Control 01-12 VDC
H-3 pos (Spring centered w/trimmer) ALL OTHER CONTROLS USE 00
Secondary Controls Control Location

2-Auxiliary Replenishment Port on Centerline A-Command on Port A side
4-Torque Limiter and Auxiliary Replenishment Port B-Command on Port B side
(Displ. indicator on opposite side)
Allowable Controls, P_P: Allowable Controls, P_V:*

102,104,2A2,2A4,2H2,2H4,402,404,4A2,4A4,4B2,4B4, 102,104,2A2,2A4,4A2,4A4,4C2,4C4,5A2,5A4,
4C2,4C4,5A2,5A4,5C2,5C4,602,604,6B2,6B4,7D2, 5C2,5C4,6A2,6A4,6C2,6C4,7D2,7E2,7F2,7G2,
7E2,7F2,7G2,8A2,8A4,8C2,8C4,9A2,9A4,9C2,9C4, 8A2,8A4,8C2,8C4,9A2,9A4,9C2,9C4
*P_V not available on 24 & 30 Series
M 6 H -2 N 1 C -2 A 0 -A -00 -M-XXXXX
Motor series Control Feature
500 Control
Primary Controls 1-without deadband
2-Cylinder with adjustable maximum & minimum stops
5-Electrohydraulic Stroker 600 Control
6-Hydraulic Stroker 0-170-350 PSI (11.7-24.1 bar)
8-Proportional Hydraulic Stroker 1-200-450 PSI (17.2-31 bar)
9-Electrohydraulic Stroker (without deadband) 2-150-380 PSI (10.3-26.2 bar)
(All include rotary servo stem and displacement indicator) 3-75-250 PSI (5-17 bar)
Primary Control Options 800 Control

0-None 0-75-250 PSI (5-17 bar)
Secondary Control options 900 Control

0-None 0-24 VDC
5-Reverse compensator (not available on 24 & 30 series) 0-12 VDC
Control Location
A-Command on Port A side
B-Command on Port B side
Allowable Controls: M*V,M*H: 2A0,2A5,5A0,5A5,6A0,6A5,8A0,8A5,9A0,9A5
4
TABLE 1 TYPICAL CHARACTERISTICS

Control stop adjustment, 0 to full volume
1A, 2A, 4A, 4C 6.72 Turns
5A, 5C 8.48 Turns
6A, 6C 6.06 Turns
8A, 8C, 9A, 9C 5.04 Turns
Servo response time, 0 to full volume
Compensator off stroke response, full to 0 volume.
Servo shaft rotation, 0 to full volume 19 degrees
Fluid connections:
Signal ports, 2A 1/8 Dryseal NPTF
Signal ports, 2H, 60, 6A, 6B, 6C, 8A, 8C SAE -4 St. Thd. O-ring seal
Brake port, 4B, 4C, 5C, 6B, 6C, 8C, 9C SAE -6 St. Thd. O-ring seal
Bypass port to system pressure, 4B, 4C, 5C, 6B, 6C SAE -4 St. Thd. O-ring seal
Bypass port to system pressure, 8C, 9C SAE -6 St. Thd. O-ring seal
Bypass port to replenishing, 4B, 4C, 5C, 6B, 6C, 8C, 9C SAE -6 St. Thd. O-ring seal
*5A, 5C CONTROLS

Hysteresis Less than 5%
Linearity Within 5%
Response 0.5 seconds, zero to full. (control response)
Temperature null shift Less than 2% per 100° F (38°C)
Deadband 0% or 10%
Input pressure 400 psi (28 bar) nominal, range 200-1000 psi (14-70 bar)
Coil resistance 24 to 30 Ohms
Electrical input Full stroke .275 ma. typ., 400 ma. max., Max. current 600 ma.
Torque for manual operation 20 in.-lb (2.25 Nm) with control pressure shut off.
*Note: If the driver uses Pulse Width Modulation, (PWM) the frequency must be 2000 Hz. or higher to avoid erratic operation.
Water Glycol, Phosphate Ester (including Skydrol), and Invert emulsions cannot be used with 5A and 5C controls.
60, 6A, 6B, 6C PUMP CONTROLS

00 60-90 (4.1-6.2) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
01 60-90 (4.1-6.2) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
02 100-120 (6.9-8.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
03 135-165 (9.3-11.4) 375-425 (25.9-29.3) 30 (2.1) 50 (3.4)
5
6A MOTOR CONTROLS
max. displacement min. displacement max. displacement min. displacement
0- 155-185 (10.7-12.7) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
1- 185-215 (12.8-14.8) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
2- 135-165 (9.3-11.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
3- 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
700 FEEDBACK CONTROLS

Input voltage +/- 15 Volts
Input Amperes
Potentiometer 3 ma
D.C. RVDT 30 ma
* Output Volts @ max displacement, 19° CW rotation facing control
Potentiometer +3.1 Volts
D.C. RVDT -2.3 Volts
Output impedance
Potentiometer 2.5 K Ohms
D.C. RVDT <1 Ohm
*With connector terminal B at +15 Volts, terminal D at - 15 Volts. This polarity must be maintained for D.C. RVDT, Polarity is optional
for potentiometer.
8A, 8C PUMP CONTROL
00 60-90 (4.1-6.2) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
01 60-90 (4.1-6.2) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
02 100-120 (6.9-8.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
03 135-165 (9.3-11.4) 375-425 (25.9-29.3) 30 (2.1) 50 (3.4)
04 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
8A MOTOR CONTROL
0* 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
1* 235-265 (16.2-18.3) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
Signal ports SAE - 4
9A, 9C PUMP CONTROL 9A MOTOR CONTROL

Code mA @min. mA @max. Code mA @max. mA @min. Coil Nom.
displacement displacement displacement displacement voltage resist.
00 360 +/- 60 650 +/- 110 0* 360 +/- 60 580 +/- 100 12 Volt 10 Ohm
01 180 +/- 30 325 +/- 55 1* 180 +/- 30 290 +/- 50 24 Volt 41 Ohm
* Hysteresis- percent of full displacement 5% typ. 8% max.
* Linearity - percent of full displacement within 8%
Manual override 3/16"(4.8 mm) internal hex
Torque to override (no signal current) 30 in.-lb (3.4 N•m) typ.
Mating connector (supplied) DIN 43650 type AF
*Specifications above are based on using a Jupiter 900 Driver with a 24 VDC supply and set at 120 Hz pulse width modulation.
Performance will vary when other controls are used. 100 to 200 Hz pulse width modulation is recommended.
6
9A ELECTRIC STROKER
S23-12940 Feature 00 cross ctr.

P6R,P7R,P8R
S23-12734 Feature 00 CW-A,CCW-B-

Pump)
S23-12733 Feature 00 CCW-A,CW-B-

Pump)
S23-15050 Feature 0* A Mtg. Motor)
S23-15051 Feature 0* B Mtg. Motor)
DESCRIPTION The 9A consists of one or two electric proportional pressure control valves mounted on
the 8A cover to provide the pilot pressure signal. It is a simple electrohydraulic control
with comparable performance to the 5A in most applications. Refer to 8A for stroker
description.
The Jupiter 900 Driver Card has been developed to accompany the 9A control with
24V coil.
DISASSEMBLY 1. Disconnect connector (46) from coil (52).

See Figure 9A 2. Remove proportional valve or valves from block (39). Do not attempt disassembly
of the valve, other than replacement of the coil, (52) and external O-rings, (38-a), (38-
b) and (38-c).
3. Remove screws (2) from control. Remove proportional valve block (39) from con-
trol. Remove control from pump.
4. Examine orifices (37) for plugging or contamination. Examine servo plate for exces-
sive scratching on surface. Note if orifices in stem are open. If servo plate is
scratched or orifices appear to be plugged, remove plate and servo stem by removing
two soc. setscrews from plate, then alternately loosening the two button hd. screws
under the setscrews.
5. Remove retaining ring (4) and press the shaft assembly through the valve body
(10).
6. Examine shoes (8) and (18) for contamination in balance pads and excessive
scratching on shoe faces. Note the two shoes are not identical and must be installed
in the proper position upon reassembly.
7. Remove the plug (13) with the stop assembly intact.
8. Remove the centering adjustment screw (23) with the spool assembly and stop
assembly intact. Note: positive centering and control starting current are determined
by the spring preload. Do not disassemble or change unless setting is incorrect.
9. Clean and examine all parts for breakage or evidence of abnormal wear.
REWORK OF WEAR PARTS Description Rework

Servo plate face Fine stone to remove raised burrs & dings
Shear seal Fine stone to remove raised burrs & dings. Note:
grooves to supply balance pads must be present
and adequate.
Control cover Stone or lap inside face to remove raised burrs &
dings.
Spool Break sharp edges or dings.
ASSEMBLY All parts are to be inspected and be free of material defects, dirt, scratches, or any for-
eign material.
All parts are to be cleaned with a suitable cleaning solvent and all cores and passages
blown out with clean dry compressed air.
After cleaning and inspection, all parts are to be covered with a light film of oil and
should be protected from dirt and excessive handling until assembled onto the unit.
During assembly, lapped and ground surfaces should be kept lubricated and protected
from nicks or surface damage.
1. Apply pipe sealant to the 1/8” pipe plug (12) and install in the cover plate. Torque to
100 lbs-in. (11.3 Nm).
87
2. Thread trimmer locknut (22) all the way onto trimmer screw (23). Slip back-up
washer (21), small dia. first, onto trimmer screw and against locknut. Using a 3/4-16
hex nut with a 1.030” (26.2mm) dia. x .030/.035” (0.76/0.89mm) deep c’bore, crimp the
washer onto the stop. Washer must be free to rotate slightly. Remove crimping nut.
See Figure 8A-1 3. Compress spring (4) solid in order to remove spring set. This may be safely
accomplished using a 1/4” (6.35 mm) dia. bolt, nut and washers.
4. Assemble retaining ring (2), guide (3), spring (4) and guide (3) onto spool (1).
5. Tighten nut (7) till it just starts to load the spring, then tighten 2-5/6 additional turns.
6. Install locknut (5) onto spool and lock against nut (7) without changing adjustment.
See Figure 9A 7. Insert spool assembly (11), spring end first, into trimmer screw (23). Compress
snap ring on the spool assembly until it snaps into internal groove inside trimmer
screw. See that it is securely seated.
8. Thread spring stop locknut (24) all the way onto adjusting spring stop (25). Slip
back-up washer (26), small diameter first, onto stop and against locknut. Using a 9/16-
18 hex nut with a .810/.815” (20.6/20.7mm) dia. x .030-.035” (0.76-0.89mm) dp. c’bore,
crimp washer onto stop. Washer must be free to rotate slightly. Remove the crimping
nut.
9. Install O-ring (35) on plug (34) and insert into spring stop (25). Install O-ring (27)
onto stop (25) and against washer (26).
10. Thread adjusting spring stop (25) into trimmer screw (23) until it just touches the
spool assembly. Be sure spool assembly is against snap ring.
11. Determine the correct position of the spool assembly in the valve body. For 9A
standard pump controls, and for 9A motor controls mounted on the “B” port side, the
spool assembly is installed in the side of the control cap containing the 1/8” pipe plug
(12). For controls used on P*R pumps, and motor controls mounted on the “A” port
side, the spool assembly is installed on the side opposite the 1/8” pipe plug (12).
CONTROL SPOOL POS.

MODEL LOCATION REF. FIG. 9A
P*P, P*V, P*S “A” OR “B” OPPOSITE
P*R “A” OR “B” AS SHOWN
M*H, M*V “A” AS SHOWN
M*H, M*V “B” OPPOSITE
12. Place O-ring (14) on trimmer screw (23) and thread assembly into the cover plate,
as noted above.
13. Install adjusting screw (15) in plug (13). Install O-ring (14) on plug. Thread adjust-
ing screw in until it protrudes approximately 1/2” from top of plug (13). For motor con-
trols, install two nuts (36) on the inner end.
14. Thread cover nut (16) with O-ring (31) onto adjusting screw.
15. Install plug (28) and O-ring (29) into cover nut (16).
16. Install this assembly in body on the opposite side from the spool assembly (11).
17. Install nut (36) on adjusting screw (6). Thread adjusting screw into stop (25).
18. Install roll pins (30) into drilled holes in surface of cover, being careful not to dam-
age surface.
19. Install 0-ring (7) in groove of shear seal (8).
20. Install shear seal with o-ring in large hole on the servo link, on the servo shaft
side. Be certain that the shear seal is sitting with the flange flush against the servo
link surface.
Note: The shear seal will fit in one position only, otherwise one side will be held up
by the lip of the servo link. Shear seal (8) must be installed to face against the cover
plate (10). This shear seal (8) differs from shear seal (18) in that the face surface is
machined with two .094” (2.4mm) radius scallops.
21. Install thrust bearing (9) over servo shaft and seat against the servo link.
22. Slip washer (33) over the servo shaft and against the thrust bearing.
23. Using installation tool T-1, install O-ring (5) in the second groove from the end of
the shaft (1). Warm glyd ring (20) to make it pliable, and install over O-ring (5).
24. Install the servo shaft assembly in the cover plate (10). Pin must engage slot in
spool assembly (11).
25. Install retaining ring (4) into the groove of the servo shaft extending thru the cover
plate.
26. Apply loctite® 271 on threads of screw (43), and on threads of shaft assembly (1).
Assemble nut (44) on screw, insert screw into shaft assembly and turn in snugly. Hold
screw and arm. Torque nut to 14 lb.-ft. (19 Nm).
27. Place two spring washers (17), nested with the bent sections matching each other,
into the large hole in the servo link.
88
28. Place washer (32) against the spring washers.

29. Install O-ring (7) into groove in the remaining shear seal (18). Note: This shear
seal does not contain the two .094” (2.4mm) radius scallops in the face. Place on top
of washer, (32). Position shear seal to match the lip on the servo link.
30. Install four orifices (37) in two tapped holes in stroker block (39) closest to the
valve opening. Insert one orifice, then another on top of the first. Torque to 70 lbs-in.
(7.9 Nm).
31. Install proportional pressure valve(s) in block (39). Torque to 20 lb.-ft. (27 Nm).
Cross-center pumps use two valves. One side of center pumps and motors use one
valve. See chart for location of single valve:
CONT. LOCATION VALVE LOCATION

PUMP, CW-A, CCW-B VALVE “B”, FIG. 9A
PUMP, CW-B, CCW-A VALVE “A”, FIG. 9A
MOTOR, B MTG. VALVE “B”, FIG. 9A
MOTOR, A MTG. VALVE “A”, FIG. 9A
32. For controls with single valve, install soc. setscrew (54) in the tapped hole furthest
in from the unused opening. Torque to 70 in.-lb. (7.9 Nm). Install plug (53) and O-ring
(55) in the unused opening. Torque to 20 lb.-ft. (27 Nm).
33. Install coil(s) (52) on proportional valve (38). CAUTION! Torque to 20-25 in.-lb.
(2.2-2.8 Nm) max.
34. Install remaining parts.
35. If control is to be tested on unit, install stroker block assembly and control on
pump control pad with O-rings (3, 31, and 45), gasket (19), washers (49) and screws
(2). Torque to 30 Lb.-ft. (40.8 Nm).
9A CONTROL TEST SETUP Remove plug over input shaft. Insert T handle 3/16” Allen wrench into opening.
Connect proportional control driver to proportional valve. Connect pressure gage on
SAE-4 port adjacent to proportional valve or valves.
Rotate wrench handle to check for free play. Turn spring stop adjustment in or out till
it just contacts the spring and there is no free play. Lock in place. Note: this adjust-
ment is critical to accurate neutral adjustment!
9A PUMP TEST 1. Turn trimmer screw to place input shaft on the zero stroke position. Check for posi-
tive centering. Lock in place. For cross-center pumps, set max. volume stops so that
servo shaft link touches stop pins when handle is stroked each side of center. For one
side of center pumps, set max. stop so that servo shaft link touches the stop pin. Set
min stop to prevent crossing over center. Lock stops in place.
2. Apply signal current to one proportional valve. Adjust current from minimum to
maximum. Note the pressure and current value at which pump just starts to stroke,
and at which the pump reaches full stroke These must be within the following values:

Min. Disp. Disp. Max. Disp. Max. Disp.
12 Volt 75 ±15psi 360 ± 60 250±25psi 650 ± 110
(5.17±1bar) (17.2±1.7bar)
24 Volt 75±15psi 180 ± 30 250±25psi 325 ± 55
(5.17±1bar) (17.2±1.7bar)
6. With minimum signal, pump shall return to zero stroke within 200 psi. (13.8 bar)
max.
7. For cross-center pumps, repeat test on opposite side of center.
Pump stroke should follow control pressure smoothly and proportionally. Full to zero or
zero to full stroke should be achieved in no more than two seconds. Adjust stroke up
to approximately 50% stroke from zero stroke, then adjust down from full stroke to the
same current value. The flow at the two settings shall not vary more than 25%.
9A MOTOR TEST 1. Turn trimmer screw to place input shaft on the full stroke position. Lock in position.
2. Rotate input handle to reduce motor displacement to minimum. CAUTION! do not
exceed motor rated speed! Adjust minimum stop screw to set minimum displacement
at 25% of full displacement. (4 times the rpm at maximum displacement.)
89
3. Lock screw in this position.

4. Apply signal current to proportional valve. Adjust current from minimum to maxi-
mum. Note the pressure and current value at which motor just starts to reduce stroke,
and at which the motor reaches minimum stroke. These must be within the following
values:
Max. Disp. Disp. Min. Disp. Min. Disp.
12 Volt 75 ±15psi 360 ± 60 205±25psi 580 ± 100
(5.17±1bar) (14.1±1.7bar)
24 Volt 75±15psi 180 ± 30 205±25psi 290 ± 50
(5.17±1bar) (14.1±1.7bar)
8. With minimum signal, motor shall return to full stroke.
Motor stroke should follow control pressure smoothly and proportionally. Full to min. or
min. to full stroke should be achieved in no more than two seconds. Adjust stroke
down to approximately 50% stroke from full stroke, then adjust up from 25% stroke to
the same signal. The speed at the two settings shall vary no more than 25%.
10. When control has satisfactorily passed test, remove stop assembly, set and lock
the two nuts on the inside to prevent adjustment below 25% stroke. Re-install stop.
90
PARTS LIST
Feature ➔ 00 00 01 00 0*
S23-12733 S23-15051
1 Servo shaft S23-12267 1 1 1 1 1
2 HHCS 3/8-16 X 3.25” 306-40184 4 4 4 4 4
3 O-ring, 70- S-5 ARP 013 675 00013 9 9 9 9 9
4 Ring, Truarc #5144-50 356-65070 1 1 1 1 1
5 O-ring, 70 S-5 ARP 012 675-00012 5 5 5 5 5
6 HHCS, 5/16-24 X 1” 307-13160 1 1 1 1 -
Setscrew, 5/16-24 X 1.25” 312-13180 - - - - 1
7 O-ring, 70 S-5 ARP 017 675-00017 2 2 2 2 2
8 Shear Seal 033-71371 1 1 1 1 1
9 Bearing 230-82141 1 1 1 1 1
10 Cover-9A 033-91220 1 1 1 1 1
11 Spool Assy (Fig. 8A-1) S23-12956 1 1 1 1 1
12 Flush plug 1/8” 431-90204 1 1 1 1 1
13 SAE plug 033-91027 1 1 1 1 1
14 O-ring, 90 S-5 ARP 908 695-00908 3 3 3 3 3
15 Soc. setscrew, 5/16-24 X 2” 312-35062 1 1 1 1 -
Setscrew, 5/16-24 X 2.50” 312-35063 - - - - 1
16 Nut 033-91033 1 1 1 1 1
17 Finger Spring 350-10067 2 2 2 2 2
18 Shear seal 033-70525 1 1 1 1 1
19 Gasket 033-91058 1 1 1 1 1
20 Glyd ring 679-00004 1 1 1 1 1
21 Washer 350-10139 1 1 1 1 1
22 Nut 033-91115 1 1 1 1 1
23 Center trimmer 033-91028 1 1 1 1 1
24 Locknut 492-15353 1 1 1 1 1
25 Stop 033-91026 1 1 1 1 1
26 Washer 350-10126 1 1 1 1 1
27 O-ring, 90 S-5 ARP 906 695-00906 1 1 1 1 1
28 Plug, Parker 2P5N-S 488-35029 1 1 1 1 1
29 O-ring, 90 S-5 ARP 902 695-00902 1 1 1 1 1
30 Rollpin 3/16 X .75” 325-12120 2 2 2 2 2
31 O-ring, 70 S-5 ARP 014 675-00014 2 2 2 2 2
32 Washer 350-10064 1 1 1 1 1
33 Washer 350-10141 1 1 1 1 1
34 Piston 033-91099 1 1 1 1 1
35 O-ring, 70 S-5 ARP 010 675-00010 1 1 1 1 1
36 Nut, 5/16-24 335-13100 1 1 1 1 3
37 Orifice, .025” 033-91225 4 4 4 4 4
38 Valve- proportional 517-00085 2 2 2 1 1
38-a O-ring, 70 S-5 ARP 015 675-00015 2 2 2 1 1
38-b O-ring, 90 S-5 ARP 016 695-00016 2 2 2 1 1
91
PARTS LIST
Feature ➔ 00 00 01 00 0*
S23-12733 S23-15051
38-c O-ring, 90 S-5 ARP 116 695-00116 2 2 2 1 1
39 Stroker Block 033-54991 1 1 1 1 1
40 Plug, SAE-4 488-35061 2 2 2 2 2
41 O-ring, 90 S-5 ARP 904 695-00904 2 2 2 2 2
42 Plug. Parker 8HP N-S 488-35018 1 1 1 1 1
43 SHCS, 1/4-20 X 2.25” 358-12100 1 1 1 1 1
44 Nut, 1/4-20 333-12001 1 1 1 1 1
45 O-ring, 70 S-5 ARP 121 675-00121 1 1 1 1 1
46 Connector 167-01008 2 2 2 1 1
47 Guard 033-54994 1 1 1 1 1
48 SHCS, 1/4-20 X 2.25” 306-12260 2 2 2 2 2
49 Washer 350-10144 4 4 4 4 4
50 Plate 030-55002 1 - - - -
Plate 030-55003 - 1 1 1 1
51 Drive screw 320-10203 2 2 2 2 2
52 Coil, 24 VDC. 517-00086 2 2 - 1 1
Coil, 12 VDC 517-00087 - - 2 - -
53 Plug, Parker 10 P50N-S 488-35016 - - - 1 1
54 SHCS, 10-32 X .19” 312-09030 - - - 1 1
55 O-ring, 90 S-5 ARP 910 695-00910 - - - 1 1
56 Washer 345-10016 2 2 2 2 2
92
ELECTRIC STROKER
FIGURE 9A
93
NOTES
115
International Distributors Australia Germany Spain

In Europe: DENISON HYDRAULICS Pty. Ltd. DENISON HYDRAULIK GmbH DENISON HYDRAULICS, S.A.
Cyprus 41-43 St. Hillers Road Gerresheimer Straße 93 Gomis, 1
Eastern Europe P.O. Box 192 D-40721 Hilden 08023 Barcelona
The Faroe Islands Auburn, N.S.W. 2144 Germany Spain
Finland Australia Tel. (49) 2103 3090 Tel. (34) 3418 46 87
Greece Tel. (612) 9646 5200 Fax (49) 2103 309211 Fax (34) 3211 65 07
Iceland Fax (612) 9643 1305
Norway Other sales offices: Other sales offices:
Portugal Other sales offices: Dresden San Sebastian
Switzerland Queensland Hanover
Turkey South Wantirna Victoria Stuttgart Sweden
Western Australia DENISON HYDRAULICS
In Africa: Great Britain SVENSKA AB
Algeria Austria DENISON HYDRAULICS U.K. Sporregatan 13
Egypt DENISON HYDRAULIK GmbH Ltd. 213 77 - Malmö
Ivory Coast Zweigniederlassung Linz Kenmore Road Sweden
Morrocco Haidbachstraße 69 Wakefield 41, Industrial Estate Tel. (46) 40 21 04 40
Nigeria A-4061 Pasching Wakefield, WF20XE Fax (46) 40 21 47 26
South Africa Austria West Yorkshire
Togo Tel. (43) 7229 4887 England Other sales offices:
Tunisia Fax (43) 7229 63092 Tel. (44) 19 24 826 021 Spånga
Fax (44) 19 24 826 146
In Middle East: Benelux USA
Iran DENISON HYDRAULICS Other sales offices: DENISON HYDRAULICS Inc.
Israel BENELUX B. V. Burgess Hill 14249 Industrial Parkway
Lebanon Pascalstraat 100 Marysville, OH 43040
Pakistan 3316 Dordrecht Hong Kong & P. R. China USA
Qatar Holland DENISON HYDRAULICS Ltd. Tel. 937 644 3915
Saudi Arabia Tel. (31) 786179 900 Unit 2, 25/F Wharf Cable Tower Fax 937 642 3738
Syria Fax (31) 786175 755 9 Hoi Shing Road For nearest Distributor:
United Arab Emirates Tsuen Wan Call toll free 1 800 551 5956
Canada N.T., Hong Kong E-Mail address:
In Far East: DENISON HYDRAULICS Tel. (852) 24988381 DENISONHYD@AOL.COM
China CANADA Inc. Fax (852) 24991522 WWW address-
Indonesia 2320 Bristol Circle, Unit 1 http://www.DenisonHydraulics.com
Korea Oakville, ON L6H 5S2 Italy
Malaysia Canada DENISON HYDRAULICS ITALY S.r.l. Other sales offices:
New Zealand Tel. (905) 829 5800 Viale Europa 68 Trabuco Canyon, CA
Philippines Fax (905) 829 5805 20090 Cusago Mulberry, FL
Taiwan Milano, Moline, IL
Thailand Other sales offices: Italy Rock Island, IL
Montreal, QC Tel. (39) 2 90330 1 Medina, OH
Richmond, BC Fax (39) 2 90390 695 Portland, OR
Arlington, TX
Denmark Japan Houston, TX
DENISON HYDRAULIK DENISON JAPAN Inc.
DENMARK A/S 4-2-1 Tsujido-Shinmachi Other European, Middle East
Industrikrogen 2 Fujisawa 251, and African Countries Contact
DK-2635 Ishöj Japan DENISON HYDRAULICS
Denmark Tel. (81) 466 35 3257 FRANCE SA
Tel. (45) 4371 15 00 Fax (81) 466 35 2029 14, route du Bois Blanc
Fax (45) 4371 15 16 BP 539
Other sales office: 18105 Vierzon Cedex
Finland Osaka France
DENISON HYDRAULICS Tel. (33) 2/48 53 01 20
P.O. Box 1096 Mexico, Central America, South Fax (33) 2/48 75 02 91
Alhotie 24 America and Caribbean
FIN-04431 Järvenpää Countries Contact
Finland DENISON HYDRAULICS Inc.
Tel./Fax (358) 0 2710 588 6167 NW 181 Terrace Circle North
Miami, FL 33015
France USA
DENISON HYDRAULICS Tel. (305) 362 2246
FRANCE SA Fax (305) 362 6220
14, route du Bois Blanc
BP 539 Singapore
18105 Vierzon DENISON HYDRAULICS S.E.A. Pte.
France Ltd.
Tel. (33) 2/48 53 01 20 No. 11 Lorong Tukang Dua
Fax (33) 2/48 75 02 91 Singapore 2261
Tel. (65) 2687840
Other sales offices: Fax (65) 2687847
Bordeaux
Lyon
Paris 10-96
Printed in U.S.A.
OPI 2M 10203
TB VANE PUMP
Vane Pumps
TB Series - Single Pumps

.5 - 2.4 in3/rev. - 2755 psi
2
P S
Performance @ 1500 rpm (fluid 25 cSt)
Output Flow (gpm) Input Power (hp)

in3
SIZE / 0 1450 2538 7 1450 2538 SIZE
rev
psi psi psi psi psi psi
003 0.54 3.5 2.7 2.4 0.5 3.2 4.4 003

004 0.78 5.1 4.3 3.8 0.7 4.6 7.8 004
005 0.98 6.3 5.6 5.0 0.7 5.6 9.7 005
006 1.26 8.2 7.4 6.9 0.8 7.2 12.3 006
008 1.59 10.3 9.6 9.0 0.9 9.0 15.4 008
009 1.92 12.5 11.7 11.1 1.1 10.9 18.6 009
011 2.17 14.1 13.3 12.8 1.1 12.2 21.1 011
012 2.42 15.7 15.0 14.4 1.2 13.5 23.5 012
Key sheet (Example: TB-011-1R00-A100)
1. TB-011-1R00-A100 .....................................Series
6. TB-011-1R00-A100 ....................................Design
2. TB-011-1R00-A100 ................................ Cam size
Size.........in3/rev Size.........in3/rev Size.........in3/rev
7. TB-011-1R00-A100 ..............................Seal Class
003..........0.54 006 ......... 1.26 011 ......... 2.17 Buna N : mineral oil 1
004..........0.78 008 ......... 1.59 012 ......... 2.42
005..........0.98 009 ......... 1.92
8. TB-011-1R00-A100 ................... Port Connections
3. TB-011-1R00-A100 .....................................Shafts Pressure port P Threaded SAE, 4 bolts
Suction port S SAE-12 ¾” NPTF ¾”
4. TB-011-1R00-A100 ..................................Rotation
SAE-20 00
CW R Threaded
1” ¼ NPTF 03 0X
CCW L
SAE, 4 bolts 1” ¼ 01
5. TB-011-1R00-A100 ....................................Porting
P & S : same side / opposite side 01 / 00

TB Series – Medium Duty, Single Pump
TB
E 1.22
F 3.39
G 5.72
J1 3.250
2
J2 3.248
N 4.19
O 5.13
P ∅ .44
Torque
Shafts in-lb
TB L1 L2 DIAMETER K1 x K2 H1 M1
1 Key : No SAE (∅.75) - ● 2.66 1.25 .750 - .749 .188 x.186 0.83 -
3 Spline : No SAE - ● 1.50 0.75 Class 1-J498b, 16/32 d.p. - 11 teeth

4 Spline : SAE A - ● 1.23 0.59 Class 1-J498b, 16/32 d.p. - 9 teeth
Dimensions (i n)
Ports Options Threads T1
A1 B1 C1 D1
P Threaded, SAE SAE - 12 (1” 1/16 - 12UNF) 2.75 -

00 5
S Threaded, SAE SAE - 20 (1” /8 - 12UNF) 2.75 -
3
P SAE - 1 ¼” 0.87 1.87 ∅.75 2.75 /8”-16UNC x .87
01
7
S SAE - ¾” 1.19 2.31 ∅1.25 2.75 /16”-14UNC x .87
1
P Threaded, SAE SAE - 12 (1” /16 - 12UNF) 2.75 -
03
P Threaded, NPTF NPTF - ¾” 2.75 -
0X

CHECK VALVE
6C/3C Inline Check Valves
◆ Poppet style – soft seat

◆ Steel or stainless steel construction; other materials
available
◆ Flow rates to 175 gpm (662 l/min)
◆ SAE, NPSF, NPT, BS 2779 & ORS end fittings available
1/4”, 3/8”, 1/2”, 3/4” & 1”
1-1/4”, 1-1/2” & 2”
Features
These soft seat (virtual zero leak), with guided poppet valves offer a wide variety of end fitting configurations and elastomers
and the option of 316 stainless steel construction. These options enable a valve to be configured to meet the needs of any
system. Snap-tite’s versatile 6C/3C Inline Check Valves are designed with a 4:1 safety factor at a maximum working
pressure of 6000 psi (415 bar) making them ideal for any application.
*Dimensions and Specifications

Size 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
In. .75 1.12 1.25 1.62 1.88 2.00 2.50 3.25
Hex
mm 19.05 28.45 31.75 41.15 47.75 50.80 63.50 82.55
In. 2.82 3.38 3.73 4.91 6.07 5.76 6.51 7.28
Length
mm 71.60 85.85 94.75 124.70 154.20 146.30 165.35 184.90
Cv .45 1.80 3.40 7.40 9.50 12.30 16.15 21.80
lbs. .29 .81 1.20 2.05 3.40 3.75 7.80 13.00
Weight
kg. .13 .37 .54 .93 1.54 1.70 3.54 5.90
gpm 3.00 8.00 12.00 20.00 30.00 90.00 125.00 175.00
Flow
l/min. 11.40 30.30 45.45 75.70 113.55 340.65 473.15 662.40
FLOW, I/min FLOW, I/min

HYDRAULIC OIL AT 38° C, FULLY OPEN HYDRAULIC OIL AT 38° C, FULLY OPEN
37.85
75.70
113.55
151.40
189.25
378.50
757.00
113.55
378.50
1892.50
11.36
15.14
18.93
37.85
75.70
1.36
1.51
1.89
3.79
7.57
.38
.76
100 6.90
3.45
PRESSURE DROP, bar
PRESSURE DROP, bar

PRESSURE DROP, psi
PRESSURE DROP, psi
2.76 500 34.48

30 2.07 400 27.59
20 1.38
300 20.69
10 .69 200
/4"
13.79
"
1-1
1/4
"
3/8
5.0 .35
"
1/2
4.0 .28
/2"
"
100 6.90
3/4
3.0 .21
1-1
1"
2.0 .14
50 3.45
1.0 .07
40 2.76
.5 .034 30 2.07
.4 .028
2"
.3 .021 20 1.38
.2 .014
.1 .007 10 .69
.1
.2
.3
.4
.5
1.0
2.0
3.0
4.0
5.0
10
20
30
100
10
20
30
40
50
100
200
500
FLOW, gpm FLOW, gpm

HYDRAULIC OIL AT 100° F, FULLY OPEN HYDRAULIC OIL AT 100° F, FULLY OPEN
Note: Gallons shown are in U.S. gallons. *Dimensions shown are for NPTF ported valves; for other end fitting configurations consult factory.
Ordering Information
Inline Check Valves - 5,000 psi (345 bar) rated

CPI F F - 4 P - 15
Series Inlet Outlet Port Size Thread Type Spring Pressure Seal
CPI - F- F- NPSF or BSP SAE RP - 05 - 5 psi (.35 bar) No letter for
Inline Female Female 2 - 1/4” Female 15 - 15 psi (1 bar) Viton (std.)
Check 3 - 3/8” British Parallel 25 - 25 psi (1.75 bar) A - Buna
Valve 4 - 1/2” 8 - 1/2” BS 2779 65 - 65 psi (4.50 bar) E - Ethylene
Poppet 6 - 3/4” 12 - 3/4” P - Female NPSF Propylene
Style 8 - 1” 16 - 1” S - Female SAE
Inline Check Valves - Up to 6,000 psi (415 bar) rated•

S 6C 4 F - F 5
Material Check Size Inlet Outlet Spring Seal

No letter Valve 4 - 1/4” M - Male NPT M - Male NPT Pressure No letter for
Steel 6C - 6 - 3/8” F - Female NPTF F - Female NPTF 5 - 5 psi Viton (std.)
Zinc Clear 6,000 psi* 8 - 1/2” EF - Female SAE EF - Female SAE (.35 bar) M - Military
Dichromate (415 bar) 12 - 3/4” EM - Male 37° Flare EM - Male SAE 37° Flare 25 - 25 psi variation of
Plated operating 16 - 1” ORS - Male Face ORS - Male Face (1.75 bar) Buna N for
(standard) pressure Seal Seal 65 - 65 psi MIL-H-5606
S - 316 3C - 20 - 1-1/4” RP - Female British RP - Female British (4.5 bar) fluids
Stainless Parallel BS 2779 Parallel BS 2779 A - Buna
3,000 psi 24 - 1-1/2”
Steel (210 bar) 32 - 2” E - Ethylene
operating
pressure CAC 10 - 15 - A -1
Series Rated Flow Cracking Pressure Seal Air Pilot* Current

CAC - Poppet 10 - 10 gpm (38 l/min) 15 - 15 psi (1 bar) No letter Option Design
Cartridge Pilot 25 - 25 gpm (95 l/min) 25 - 25 psi (1.7 bar) for Viton P - O-ring on -1
Check Valve 50 - 50 gpm (189 l/min) 60 - 60 psi (4 bar) A - Buna N Pilot Piston
CPC - Poppet (60 psi spring is
Cartridge Check recommended)
Valve *CAC only
CAV 10 - 3P - 15 A
Series Rated Flow Port Size Cracking Air Pilot Seal

CAV - Single Pilot 10 - 10 gpm (38 l/min) NPT SAE Pressure P - O-ring on No letter for
Operated Check 1/4”, 3/8”, 1/2” ports 2P - 1/4” 4S - 1/4” 15 - 15 psi (1 bar) Pilot Piston Viton
Valve 25 - 25 gpm (95 l/min) 3P - 3/8” 6S - 3/8” 25 - 25 psi (1.7 bar) (60 psi spring is A - Buna N
CAD - Dual Pilot 3/8”, 1/2”, 3/4” ports 4P - 1/2” 8S - 1/2” 60 - 60 psi (4 bar) recommended)
Operated Check 50 - 50 gpm (189 l/min) 6P - 3/4” 12S - 3/4”
Valve 3/4”, 1” ports 8P - 1” 16S - 1”
*3/4” 6C SST working pressure - 5000 psi (345 bar), 1” 6C SST working pressure - 4000 psi (275 bar)
! WARNING !
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH,
PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Snap-tite, Inc., its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having
technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to
the variety of operation conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of
the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Snap-tite, Inc. and its subsidiaries
at any time without notice.
Distributed by:
Quick Disconnect & Valve Division Industrial Estate

201 Titusville Road Whitemill - Wexford
Union City, Pennsylvania 16438-8699 USA Republic of Ireland
PH: 814-438-3821 FAX: 814-438-3069 PH: 353-53-41566 FAX: 353-53-41582
e-mail: qd&v_sales@snap-tite.com e-mail: snaptite@snap-tite.iol.ie
www.snap-tite.com www.snap-tite.com ISO-9001 Certified
qd/icv.799
FLEXIBLE JAW COUPLING
ROTEX® is a torsionally flexible jaw coupling. It is able to compensate for shaft displacement
caused by, as an example, inaccuracies in production, heat expansion, etc.
Table of Contents
1 Technical Data
2 Hints
2.1 General Hints
2.3 General Hints to Danger
2.4 Proper Use
3 Storage
4 Assembly
5 Enclosure A


5.5 Starting
5.6 Breakdowns, causes and elimination
5.7 Certificate of Conformity according to the EG Standards 94/9/EG
dated 23 March 1994

1 Technical Data
® ®
picture 1: ROTEX (material: Al-D) picture 2: ROTEX (material: GG 25 / GGG 40)
Table 1: material Al-D

1)
®
size nent screws
14 1a 7,5 12,5 - 6 - 16 35 11 13 10 1,5 30 10 30 - M4 5
1 6 - 19 32
19 10 17 - 66 25 16 12 2 41 18 20 M5 10
1a 19 - 24 41
1 9 - 24 40
24 35 60 - 78 30 18 14 2 56 27 24 M5 10
1a 22 - 28 56
1 10 - 28 48
28 95 160 - 90 35 20 15 2,5 67 30 28 M8 15
1a 28 - 38 67
Table 2: material GG 25 / GGG 40

1)
®
size nent screws
1 12 - 38 66
114 45 37
38 1a 190 325 405 24 18 3 80 38 M8 15
38 - 45 78
1b 164 70 62
1 14 - 42 75
126 50 40
42 1a 265 450 560 26 20 3 95 46 M8 20
42 - 55 94
1b 176 75 65
1 15 - 48 85
140 56 45
48 1a 310 525 655 28 21 3,5 105 51 M8 20
48 - 60 104
1b 188 80 69
1 20 - 55 98
55 410 685 825 160 65 30 22 4 120 60 52 M10 20
1b 55 - 70 118
65 1 625 940 1175 22 - 65 185 75 35 26 4,5 135 68 115 61 M10 20
75 1 1280 1920 2400 30 - 75 210 85 40 30 5 160 80 135 69 M10 25
90 1 2400 3600 4500 40 - 90 245 100 45 34 5,5 200 100 160 81 M12 30
100 1 3300 4950 6185 50 - 115 270 110 50 38 6 225 113 180 89 M12 30
110 1 4800 7200 9000 60 - 125 295 120 55 42 6,5 255 127 200 96 M16 35
125 1 6650 10000 12500 60 - 145 340 140 60 46 7 290 147 230 112 M16 40
140 1 8550 12800 16000 60 - 160 375 155 65 50 7,5 320 165 255 124 M20 45
160 1 12800 19200 24000 80 - 185 425 175 75 57 9 370 190 290 140 M20 50
180 1 18650 28000 35000 85 - 200 475 185 85 64 10,5 420 220 325 156 M20 50
1) Maximum torque of the coupling TKmax. = nominal torque of the coupling TK Nenn. x 2.
2) Threads for set screws are opposite the keyway in case of material Al-D and on the keyway in case of material GG 25 / GGG 40.
3) From size 125 thread for set screws on request.

1 Technical Data
® ®
picture 3: ROTEX (material: steel) picture 4: ROTEX design DKM
Table 3: material steel

1)
®
size nent screws
92 Sh A 98 Sh A 64 Sh D d (min-max)
L l1; l2 E b s DH dH D N G t
1a 66 25
19 10 17 21 0 - 25 16 12 2 40 18 40 - M5 10
1b 90 37
1a 78 30
24 35 60 75 0 - 35 18 14 2 55 27 55 - M5 10
1b 118 50
1a 90 35
28 95 160 200 0 - 40 20 15 2,5 65 30 65 - M8 15
1b 140 60
1 114 45 70 27
38 190 325 405 0 - 48 24 18 3 80 38 M8 15
1b 164 70 80 -
1 126 50 85 28
42 265 450 560 0 - 55 26 20 3 95 46 M8 20
1b 176 75 95 -
1 140 56 95 32
48 310 525 655 0 - 62 28 21 3,5 105 51 M8 20
1b 188 80 105 -
1 160 65 110 37
55 410 685 825 0 - 74 30 22 4 120 60 M10 20
1b 210 90 120 -
1 185 75 115 47
65 625 940 1175 0 - 80 35 26 4,5 135 68 M10 20
1b 235 100 135 -
1 210 85 135 53
75 1280 1920 2400 0 - 95 40 30 5 160 80 M10 25
1b 260 110 160 -
1 245 100 160 62
90 2400 3600 4500 0 - 110 45 34 5,5 200 100 M12 30
1b 295 125 200 -
Table 4: design DKM

1)
®
ROTEX nominal torque [Nm] meas- set
general 2)
size ure d, screws
92 Sh A 98 Sh A 64 Sh D
D, D1LDKM l1; l2 E b s DH dH l11 l12 G t
19 10 17 - 92 25 16 12 2 40 18 10 42 M5 10
24 35 60 - 112 30 18 14 2 55 27 16 52 M5 10
28 95 160 - 128 35 20 15 2,5 65 30 18 58 M8 15
see table 1 to 3
38 190 325 - 158 45 24 18 3 80 38 20 68 M8 15

42 265 450 - 174 50 26 20 3 95 46 22 74 M8 20
48 310 525 - 192 56 28 21 3,5 105 51 24 80 M8 20
55 410 685 - 218 65 30 22 4 120 60 28 88 M10 20
65 625 940 - 252 75 35 26 4,5 135 68 32 102 M10 20
75 1280 1920 - 286 85 40 30 5 160 80 36 116 M10 25
90 2400 3600 - 330 100 45 34 5,5 200 100 40 130 M12 30

1 Technical Data
®
picture 5: ROTEX design Taper-Lock
Table 5: design Taper-Lock

1)
® Taper-
ROTEX compo- nominal torque [Nm]
finish bore general Lock-
size nent
92 Sh A 98 Sh A 64 Sh D d (min-max) sleeve
L l1; l2 E b s DH dH D1 N
24 1a 35 60 - 10 - 22 64 23 18 14 2 55 27 - - 1008
28 1a 95 160 - 10 - 25 66 23 20 15 2,5 65 30 - - 1108
38 1a 190 325 - 10 - 25 70 23 24 18 3 80 38 78 15 1108
42 1a 265 450 - 14 - 40 78 26 26 20 3 95 46 94 16 1610
48 1a 310 525 - 14 - 40 106 39 28 21 3,5 105 51 104 28 1615
55 1a 410 685 - 14 - 50 96 33 30 22 4 120 60 118 20 2012
65 1 625 940 - 14 - 50 101 33 35 26 4,5 135 68 115 5 2012
75 1 1280 1920 - 16 - 60 130 52 40 30 5 160 80 158 36 2517
90 1 2400 3600 - 25 - 75 149 52 45 34 5,5 200 100 160 14 3020
CAUTION !
For a continuous and troublefree operation of the coupling it must be designed according
! to the selection instructions (according to DIN 740 part 2) for the particular application
®
(see ROTEX catalogue).
If the operating conditions (performance, speed, changes at engine and machine) change,
the coupling selection must be checked again.
2 Hints
2.1 General Hints
Please read through these mounting instructions carefully before you set the coupling into operation. Please pay
special attention to the safety instructions!
The ROTEX® coupling is approved for the use in hazardous areas.
When using the coupling in hazardous areas please observe the special hints and instructions
regarding safety in enclosure A.
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.

2 Hints
STOP DANGER ! Danger of injury to persons.
CAUTION ! Damages on the machine possible.

!
F ATTENTION ! Pointing to important items.
PRECAUTION ! Hints concerning explosion protection.
2.3 General Hints of Danger
DANGER !
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Please make sure to disengage the power pack before you perform your work.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
• Do not touch the operation area of the coupling as long as it is in operation.
• Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
2.4 Proper Use
You may only assemble, operate and maintain the coupling if you
• carefully read through the mounting instructions and understood them
• had technical training
• are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 5 in chapter 1).
Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting
damages. To further develop the product we reserve the right for technical modifications.
The ROTEX® described in here corresponds to the technical status at the time of printing of these mounting
instructions.

3 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years in case of favourable stock
conditions.
CAUTION !
The storage rooms may not include any ozone-generating devices, like e. g. fluorescent
! light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is under
65%.
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
Components of ROTEX®, shaft coupling design No. 001
Compo-
nent
1 2 hub
2 1 spider
3 2 setscrew
®
picture 6: ROTEX
Components of ROTEX®, DKM design No. 018
Compo-
nent
1 2 hub
2 2 spider
3 1 DKM - spacer
4 2 setscrew
®
picture 7: ROTEX DKM

4 Assembly
Components of ROTEX®, Taper Lock Clamping Sleeve
Compo-
nent
hub for taper
1 2
clamping sleeve
taper lock clamping
2 2
sleeve
3 1 spider
4 4 setscrew
®
picture 8: ROTEX Taper-Lock-clamping sleeve
Features of the standard spiders
spider hardness
marking (colour)
(Shore)
92 Sh A yellow
95/98 Sh A red
natural white with green
64 Sh D-F
marking of teeth
DANGER !
STOP Valid for all materials !
The maximum permissible bore diameters d (see
table 1 to 5 in chapter 1 - Technical Data) must not be
exceeded. If these figures are disregarded, the
coupling may tear. Rotating particles may cause
serious danger.
• Hub bores machined by the customer have to observe

concentric running or axial running, respectively (see
picture 9).
• Please make absolutely sure to observe the figures for
dmax.
• Carefully align the hubs when the finish bores are
brought in.
• Please provide for a setscrew or an end plate for the picture 9: concentric running and axial running
axial fastening of the hubs.
Table 6: Setscrews
ROTEX® size 14 19 24 28 38 42 48 55 65
dimension G M4 M5 M5 M6 M8 M8 M8 M10 M10
tightening torque TA [Nm] 1,5 2 2 4,8 10 10 10 17 17
®
ROTEX size 75 90 100 110 125 140 160 180
dimension G M10 M12 M12 M16 M16 M20 M20 M20
tightening torque TA [Nm] 17 40 40 80 80 140 140 140

4 Assembly
Assembly of the taper lock-clamping sleeve:

The taper lock clamping sleeve has cylindrical and even pocket holes parallel to the axis. Only half to these
holes are in the material of the sleeve. The other half located at the hub has convolutions.
Push the coupling hub and the taper lock clamping sleeve into each other, make holes onto the cover and
tighten the grub screws slightly.
Disassembly of the taper lock clamping sleeve:

By removing the grub screws you can detach the taper lock clamping sleeve. Afterwards, one of the grub screws
is screwed into the thread of the sleeve as forcing screw and tightened.
The detached coupling hub can be manually taken off the shaft with the taper lock clamping sleeve.
Table 7:
taper lock screw dimension
clamping G L SW TA quantity spanner
sleeve [inch] [inch] [mm] [Nm]
1008 1/4 1/2 3 5,7 2 SW 3
1108 1/4 1/2 3 5,7 2 SW 3
1610 3/8 5/8 5 20 2 SW 5
1615 3/8 5/8 5 20 2 SW 5
2012 7/16 7/8 6 31 2 SW 6
2517 1/2 7/8 6 49 2 SW 6
3020 5/8 1 1/4 8 92 2 SW 8 picture 10: withworth grub screw (BSW)
F
ATTENTION !
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION !
Please pay attention to the danger of ignition in hazardous areas.
DANGER !
STOP Touching the heated hubs causes burns.
We would recommend to wear safety gloves.
CAUTION !
For the assembly please make sure that the distance dimension E (see table 1 to 5) is kept
! to ensure that the spider can be moved axially.
Disregarding this hint may cause damage on the coupling.
• Assemble the hubs onto the shaft of driving and driven side.
• Move the power packs in axial direction until the dimension E is achieved.
• If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for
adjusting the dimension E.
• Fasten the hubs by tightening the setscrews DIN 916 with cup point.

4 Assembly
F
ATTENTION !
If the shaft diameters with inserted feather key are smaller than the dimension dH (see
table 1 to 5) of the spider, one or two shaft ends may protude into the spider.
The displacement figures shown in tables 8 and 9 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion or lowering of foundation.
CAUTION !
In case of a use in hazardous areas for the explosion group IIC (marking II 2G c IIC T4),
only the half displacement figures (see tables 8 and 9) are permissible.
Please note:
• The displacement figures mentioned in tables 8 and 9 are maximum figures which must not arise in parallel.
If radial and angular displacement arises at the same time, the permissible displacement values may only be
used in part (see picture 12).
• Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 8 and 9
can be observed.
angular displacements radial displacements axial displacements
∆KW = L1max. - L1min. [mm] Lmax = L + ∆KA [mm]

picture 11: displacements

4 Assembly
Example for the misalignment

combinations given in picture 12:
Example 1:
∆KR = 30%
∆KW = 70%
Example 2:
∆KR = 60%
∆KW = 40%
∆Ktotal = ∆KR + ∆KW ≤ 100 % picture 12: combinations of displacement
Table 8: Displacement figures for type 001 (standard coupling)

ROTEX® size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
1,0 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0 3,4 3,8 4,2 4,6 5,0 5,7 6,4
∆Ka [mm]
0,17 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48 0,50 0,52 0,55 0,60 0,62 0,64 0,68
n=1500 1/min ∆Kr [mm]
0,11 0,13 0,15 0,17 0,19 0,21 0,25 0,26 0,28 0,32 0,34 0,36 0,38 - - - -
n=3000 1/min ∆Kr [mm]
∆Kw [degree]
1,2 1,2 0,9 0,9 1,0 1,0 1,1 1,1 1,2 1,2 1,2 1,2 1,3 1,3 1,2 1,2 1,2
with n=1500 1/min
0,67 0,82 0,85 1,05 1,35 1,70 2,00 2,30 2,70 3,30 4,30 4,80 5,60 6,50 6,60 7,60 9,00
∆Kw [mm]
∆Kw [degree]
1,1 1,1 0,8 0,8 0,8 0,8 0,9 1,0 1,0 1,0 1,1 1,1 1,1 - - - -
with n=3000 1/min
0,62 0,70 0,75 0,84 1,10 1,40 1,60 2,00 2,30 2,90 3,80 4,20 5,00 - - - -
∆Kw [mm]
Table 9: Displacement figures for type 018

ROTEX® size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
- 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0 3,4 - - - - - -
∆Ka [mm]
- 0,54 0,53 0,60 0,77 0,84 1,00 1,11 1,40 1,59 1,78 - - - - - -
n=1500 1/min ∆Kr [mm]
- 0,50 0,47 0,53 0,61 0,67 0,82 1,01 1,17 1,33 1,63 - - - - - -
n=3000 1/min ∆Kr [mm]
∆Kw [degree]
with n=1500 1/min
∆Kw [degree]
with n=3000 1/min

5 Enclosure A
design 001: hub / spider / hub

design 018: hub / spider / DKM spacer / spider / hub
ROTEX® DKM and ROTEX® ZS-DKM only with spacer made from steel.
explosion group control intervals

II 2G c IIB T4
far as possible.
parameters.
II 2G c IIC T4
far as possible.
parameters.
ROTEX® Coupling
® ®
picture 13: ROTEX coupling picture 14: ROTEX spider
Here the backlash between coupling cams and the flexible spider must be checked by a feeler gauge.
When reaching the limit of wear of max. friction, the spider must be exchanged immediately, independent of the
inspection intervals.

5 Enclosure A
In case of a backlash of more than x mm, the flexible spider must be exchanged.
The reaching of the exchange values depends on the operating conditions and the existing operating
parameters.
CAUTION !
picture 15: checking of the limit of wear picture 16: wear of spider
Table 10:
ROTEX® limits of wear (friction) ROTEX® limits of wear (friction)
size Xmax. [mm] size Xmax. [mm]
9 2 65 5
14 2 75 6
19 3 90 8
24 3 100 9
28 3 110 9
38 3 125 10
42 4 140 12
48 4 160 14
55 5 180 14
In the explosion groups IIB and IIC only the following material combinations may be used:
GG 25 - GG 25
GGG 40 - GGG 40
steel - steel
stainless steel - stainless steel
Aluminium as coupling material is generally excluded for the explosion area.

5 Enclosure A
Couplings for the use in hazardous areas are marked for the respectively permissible conditions of use.
Explosion group IIC: e. g. II 2G c IIC T4
In the marking II 2G c IIC T4 the explosion group IIB is included.
5.5 Starting
Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and
the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated
tightening torques dependent on the type of coupling.
If used in hazardous areas, the setscrews must be additionally secured against self-loosening to fix
the hub, e. g. with Loctite (medium strength).
Last but not least, the coupling protection against unintended contact must be fixed.
Coupling protection in the hazardous area.

Covering of the coupling
The couplings must be provided with firm coverings (if possible, made from stainless steel)
protecting the couplings against falling objects. There can be regular openings in the coverings
which may not exceed the following dimensions:
circular openings rectangular openings

diameter in mm side length in mm
top surface of the covering 4 4
side parts of the covering 8 8
The distance between the cover and the rotating parts must be at least 5 mm.
The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings made from
aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor if the
magnesium part is below 7,5 %. The cover may only be taken off after having stopped the unit.
During operation, please pay attention to

• strange running noises
• occurring vibrations.
CAUTION !
If you note any irregularities at the coupling during operation, the drive unit must be turned
! off immediately. The cause of the breakdown must be found out with the table
„Breakdowns“ and, if possible, be eliminated according to the proposals. The possible
breakdowns mentioned can be hints only. To find out the cause all operating factors and
machine components must be considered.

5 Enclosure A
danger hints for

hazardous areas
the the spider surface;
danger of ignition by
hot surfaces
coupling)
Control
change of the 1) put the unit out of operation
running noises 2) disassemble the coupling and remove
and / or occurring wear of spider,
rests of the spider
vibrations short-term torque danger of ignition due
transmission due to to sparking
metal contact
2) check alignment of coupling
loose screws for danger of ignition due
3) tighten the screws to secure the hubs
axial securement of to hot surfaces and
and secure against self-loosening
hubs sparking
Control
wear of spider, 1) put the unit out of operation
danger of ignition due
torque transmission 2) change complete coupling
to sparking
due to metal contact 3) check alignment
break of the cams
danger of ignition due 2) change complete coupling
due to high shock
to sparking 3) check alignment
energy / overload
4) find out the reason of overload
break of cam operating
2) check the operating parameters and
parameters do not
danger of ignition due select a larger coupling (consider
correspond to the
to sparking installation space)
performance of the
3) assemble new coupling size
coupling
4) check alignment
mistake in service of danger of ignition due 2) change complete coupling
the unit to sparking 3) check alignment
4) instruct and train the service staff
premature wear of the the spider surface;
spider danger of ignition by
hot surfaces
coupling)
Control

5 Enclosure A
danger hints for

hazardous areas
e. g. contact with
aggressive liquids /
rests of the spider
oils, ozone- danger of ignition due
influence, too high to sparking in case of
ambient metallic contact of the
temperatures etc. cams
effecting a physical
6) make sure that further physical changes
change of the spider
of the spider are excluded
premature wear of 1) put the unit out of operation
spider 2) disassemble the coupling and remove
rests of the spider
ambient / contact
temperatures which danger of ignition due
are too high for the to sparking in case of
spider, max. metallic contact of the
permissible cams
6) check and regulate ambient / contact
-20 °C / +80 °C
temperature (eventually even
elimination by using other spider
materials)
rests of the spider
premature wear of danger of ignition due 3) check coupling parts and exchange
spider (liquefaction to sparking in case of damaged coupling parts
drive vibrations
of material inside metallic contact of the 4) insert spider, assemble coupling parts
the spider cam) cams 5) check alignment, correct if necessary
6) find out the reason for the vibrations
(eventually elimination by spider with
lower or higher shore hardness)
F
ATTENTION !
KTR does not assume any liabilities or guarantees regarding the use of spare parts and
accessories which are not provided by KTR and for the damages resulting herefrom.

5 Enclosure A
5.7 Certificate of Conformity
Certificate of Conformity
corresponding to EG Standard 94/9/EG dated 23 March 1994
and to the legal regulations
The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the
flexible ROTEX® couplings

described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b)
of Standard 94/9/EG and comply with the general Safety and Health Requirements according to
enclosure II of Standard 94/9/EG.
The couplings are certified according to Type Examination Certificate IBExU02ATEXB001 X.
According to article 8 (1) of Standard 94/9/EG the technical documentation is deposited with the:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
Rheine, 06.06.02 ppa. i. V.

Date Dr. Norbert Partmann Bernd Tenfelde
Engineering Manager Product Manager

TOSHIBA ELECTRIC MOTOR INSTALLATION & MAINTENANCE MANUAL
SINGLE OIL FILTER
Series FLN
In-Line Filter
Pressures 360 psi (25 bar) • Flows to 100 gpm (400 l/min)
GENERAL
The FLN filter consists of a filter
head and screw-in filter bowl. The
standard model is supplied with
bypass valve, vent and drain
screws, and a connection for dif-
ferential clogging indicator.
• Mounting
Inline filter
• Temperature Range
-20°F to 210°F (-30°C to 100°C)
• Trip pressure of the differential
pressure clogging indicator
∆pa = 72 psi (5 bar) -10%
• Cracking pressure of the
bypass valve
43 psi (3 bar) - (standard)
No bypass - (consult factory)
FILTER ELEMENTS
HYDAC filters are tested according
to the following ISO test standards:
• ISO 3724, Verification of fatigue
characteristics
• ISO 4572, Filtration Efficiency
FLN In-Line Simplex Filter
• ISO 4572, Multi-pass method for
evaluating filtration performance Fluid Compatibility:
• ISO 3968, Evaluation of pressure Suitable for mineral oils,
drop versus flow characteristics lubrication oils, non-flammable
• ISO 2942, Bubble point test fluids, synthetic and rapidly
biodegradable oils. For use with
• ISO 2941, Verification of water, please contact our
collapse / burst resistance
technical sales department.
Reliable filter operation is only
• Clogging Indicator:
guaranteed with the original
For further types of clogging
HYDAC filter elements.
indicators and further details
The filter elements are also on indicators, please see
suitable for use in dynamic brochure no.: 02070327.
applications due to their high
• Seals:
pressure stability; maximum
FKM (Viton)
permissable ∆p across the element:
Betamicron® (BN/HC):
435 psi (30 bar)
Wire Mesh (W/HC):
435 psi (30 bar)
Model Code: Filter
FLN BN/HC 250 D E 10 A 1 . X / 12 - V - B3 .
Filter Type
FLN
Filter Material Element
BN/HC = Betamicron® (BN3HC)
W/HC = Stainless Steel Wire Mesh
Size
160, 250, 400
Operating Pressure
D = 360 psi (25 bar)
Type and Size of Port
E = SAE-20 (1 1/4”)
3 = 3µm
6 = 6µm
BN/HC
10 = 10µm
25 = 25µm
25 = 25µm
50 = 50µm
W/HC
100 = 100µm
200 = 200µm
Type of Clogging Indicator
A = no clogging indicator
B = with visual clogging indicator VM2B.0 for other
C = with electrical clogging indicator VM2C.0 clogging
D = with visual and electrical clogging indicator VM2D.0 indicators
see brochure
LE = visual-mechanical/electrical indicator VD2LE.0 # 02070327
LZ = visual-mechanical/electrical indicator with VD2LZ.0
75% and 100% switching contact
Type Code
1
Modification Number
X the latest version is always supplied
Port Configuration
12 = SAE straight thread inlet/outlet connections
Seals
V = Fluoro Rubber (FKM) (standard)
Bypass Valve
B3 = 43 psid (3 bar) (standard)
(omit) = no bypass (optional - consult factory)
L48 = Lamp for 48 volt D-type clogging
L115 = Lamp for 110 volt indicator only
W = suitable for oil-water emulsions (HFA, HFC), NBR seals,
(refers exclusively to the type of clogging indicator)
EV = knurled air bleed valve (replaces standard socket head plug)
A2.2 = 32 psi (2.2 bar) Indicator trip setting
30C = 30°C Indicator thermal lockout
2
Model Code: Replacement Element
0250 DN 010 BN/HC / - V
Size
0160 = size 160
0250 = size 250
0400 = size 400
Type
DN
003 = 3µm
006 = 6µm
BN/HC
010 = 10µm
025 = 25µm
025 = 25µm
050 = 50µm
W/HC
100 = 100µm
200 = 200µm
Filter Material
BN/HC = Betamicron®
W/HC = Stainless Steel wire mesh
Seals
V = FKM - Fluoro Rubber (standard)
Filtration Efficiency:
Filtration Rating Specification
3 µm ß 3 ≥ 200
6 µm ß 6 ≥ 200
10 µm ß 10 ≥ 200
25 µm ß 25 ≥ 200
Element Data:
Element Specifications
ISOMTD contamination
retention capacity in grams
at ∆p = 72 psi (5 bar) for BN/HC elements
Filter Type 3 µm 6 µm 10 µm 25 µm
160 27.5 29.3 33.1 36.7
250 46.0 49.0 55.2 61.3
400 76.2 81.3 91.4 101.5
Assembly Weight:
Filter Specifications
Weight lbs(kg)
Filter Type Port Element Size
with element
160 SAE 1 1/4” 0160 DN... 4.3 (9.5)
250 SAE 1 1/4” 0250 DN... 4.9 (10.8)
400 SAE 1 1/4” 0400 DN... 5.9 (13.0)
3
Engineering Data: FLN 160, 250, and 400
Design In-Line Low Pressure Filter
Mounting Method 2 Mounting Holes on top of Filter Housing
Connections Inlet: Outlet:
SAE-20 (1 7/8-12 UN-28) SAE-20 (1 7/8-12 UN-28)
Direction of Flow In-Line
Housing Pressure Ratings Operating: 360 psi (25 bar)
Proof: 540 psi (37.5 bar)
Fatigue: 360 psi (25 bar) @ 1 million cycles
Burst: Contact HYDAC office
Element Collapse Pressure Ratings Standard Elements: BN/HC: 435 psid (30 bar)
(ISO 2941) W/HC: 435 psid (30 bar)
Fluid Temperature Range -22°F to +210°F (-30°C to 100°C)
Fluid Compatibility Compatible with all petroleum oils and synthetic fluids rated for use
(ISO 2943) with Fluoro Rubber seals.
Contact HYDAC office for information on special for use with water
glycols,oil/water emulsions, and HWBF.
Flow Fatigue Resistance Filter medium is supported to achieve flow fatigue resistance.
Trip Pressure of Differential Indicator 29 psi (2 bar) ± 10% (standard)
Cracking Pressure of ∆P = 43 psid (3 bar) bar ± 10% (standard)
Bypass Valve No Bypass (optional - consult factory)
Hydraulic Symbols
with bypass (standard) without bypass (optional)
A A
VA
VA
B B
Above Subject to Technical Modifications
4
Pressure Drop Calculations:
Assembly
To calculate the pressure drop of a filter assembly use the equation:
∆P Assembly = ∆P Housing + ∆P Element
Housing Curves
The housing curve is based on test results using mineral oil with a specific gravity of 0.86. Differential pressure increases in
proportion to specific gravity of applicable fluid. To adjust the housing ∆P for the fluid being used, use the equation:
∆P Housing = ∆P Curve x Actual Specific Gravity

0.86
FLN 160, 250, & 400

0.80 12.0
0.70 10.5
0.60 9.0
0.50 p in psid 7.5
p in bar
0.40 6.0
0.30 4.5
0.20 3.0
0.10 1.5
0.00 0.0
0 13 26 40 52 66 79 92 106
Q in gpm
0 50 100 150 200 250 300 350 400

Q in L/min
Elements ∆P Calculations
All element curves are based on test results using mineral oil with a kinematic viscosity of 141 SUS and a specific
gravity of 0.86. The differential pressure across the element changes proportionally to the viscosity and specific gravity.
∆P Element = ∆P Curve x Actual Viscosity x Actual Specific Gravity

141 0.86
0160 DNXX BN/HC 3µm 0250 DNXX BN/HC 3µm

1.4 21 2.0 30
1.8 27
1.2 18
1.6 24
1.0 15 6µm
p in psid
1.4 21
p in bar
6µm
1.2 18
p in psid
p in bar
0.8 12
10µm 1.0 15
0.6 9 10µm
25µm 0.8 12
0.6 9 25µm
0.4 6
0.4 6
0.2 3
0.2 3
0.0 0 0.0 0
0 13 26 40 52 0 26 52 79 106
Q in gpm Q in gpm
0 50 100 150 200 0 100 200 300 400
Q in L/min Q in L/min
0400 DNXX BN/HC W/HC

2.0 30 0.08 1.20
size 160
1.8 27 0.07 1.05
1.6 24
0.06 0.90
p in psid
1.4 21
p in bar
3µm 0.05 0.75

1.2 18
p in psid
p in bar
size 250
1.0 15 0.04 0.60
0.8 12 6µm
0.03 0.45 size 400
0.6 9 10µm 0.02 0.30
0.4 6 25µm
0.2 3 0.01 0.15
0.0 0 0.00 0.00
0 26 52 79 106 0 13 26 40 52 66 79 92 106
Q in gpm Q in gpm
0 100 200 300 400

0 50 100 150 200 250 300 350 400
Q in L/min
Q in L/min
5
Dimensions: FLN 160, 250, and 400
1.7" SAE-2
43.5mm 1 1/4"
INLET OUTLET
3.0"
76mm
size 160
11.2"
285mm
size 250
14.3"
363mm
Drain Screw
size 400
20.2"
513mm
ø 3.9"
100mm
M10x8
2.4"
ø 5.1" ø
130mm 60mm
Indicator Plug/Port
5.9"
150mm
6
HYDAC FILTERTECHNIK
Inline Filter
FLN 160 / 250 / 400
SPARE PARTS LIST
MAINTENANCE INSTRUCTIONS
for customer Hägglunds
Only when using original HYDAC

parts and correct handling, we give
guarantee according to our conditions
of sales and delivery.
Table of contents
1.2 Installation
1.3 Commissioning
2. Maintenance
2.1 General
3. Element-changes
3.2 Element-mounting
4. Spare parts
4.1 Spare part-drawing FLN
4.2 Spare parts list FLN
HYDAC FILTERTECHNIK
This pressure vessel complies with the provisions of article 3 paragraph 3 of the
pressure vessels directive (97/23/EC) and so must not have a CE-mark.
This pressure vessel must be commissioned only in conjunction with a machine or

system.
Information
Information
The pressure vessel must be used only according to the operating instructions of
the machine or system.
Information
Information
The user must ensure appropriate actions to avoid air formation (e.g. venting)
Warning
W i
Repairs, maintenance and commissioning must be carried out only by specialists.

Do not touch the pressure vessel until cooled down.
Warning
W i
Pay attention to operating instructions of the machine or system.
Attention pressure vessel: please ensure for all works at the pressure vessel that the
referring side of the pressure vessel (filter housing) is released of pressure.
Danger
Modificatione of the pressure vessel are not allowed (welding, drilling, forced
opening..).
Danger
The operator/owner has to ensure adherence to the National Water Resources Act as
well as local water resources laws and other related regulations.
Information
Information
Follow the rules for prevention of accidents, safety regulations and data sheets for
fluids.
Smoking and open flames/fire are not allowed while working on or near hydraulic
systems.
Hydraulic media and water-polluting fluids are not be allowed to soak into the soil,
seep into bodies of water or the sewage system. Ensure an environmentally waste
management of hydraulic oils. Adherence is to be maintained to pertinent national
and local regulations pertaining to groundwater protection, disposal of waste/spent
oil and (hazardous) waste.
Work on filters may involve leaking hot oil which may cause injury and scalding as
result of its high pressure and/or temperature.
HYDAC FILTERTECHNIK
1.2 Installation
Before installation of the system it must be checked that the permissible operating pressure of
the system is not higher than the permissible operating pressure of the filter. Take a look at
the type code label!
1.3 Commissioning
Check whether the correct filter element (1) is fitted. Moisten thread and sealing surfaces on
the filter bowl and filter head, as well as the O-ring on bowl and element with clean system
fluid. Screw in the filter housing again fully and then unscrew by one quarter-turn (the sealing
effect will not be improved by over tightening). Switch on the hydraulic system and check the
filter for leakage. Vent filter.
2. MAINTENANCE
2.1 General
This section describes maintenance work, which should be carried out periodically. The
operational safety and the service-life of the filter, and whether it is ready for use, depend to a
large degree on regular and careful maintenance.
-Spare parts must fulfil the technical requirements specified by the manufacturer. This is
always guaranteed for HYDAC original spares.
-Keep tools, working area and equipment clean.
-After disassembling the filter, clean all parts, check for damage or wear and change if
necessary.
-When changing a filter element it must be paid attention to the best cleanliness.
The filter can be equipped with a clogging indicator (visual and/or electrical or electronic) to
observe the filter element. If the clogging indicator reacts, it is necessary to change or clean
the filter element without delay. If no clogging indicator is installed, we recommend to change
the elements in intervals (the filter element change depends on the filter design and the
conditions).
Higher dynamic loads across the element might necessitate shorter intervals between
changes. Shorter intervals can also be necessary during commissioning, repairs, oil changes
etc, on the hydraulic system.
The standard clogging indicators only respond when fluid is flowing through the filter. With
electrical indicators the signal can also be converted into a continuous display on the control
panel. In this case the continuous display has to be switched off after a cold start or element
change. If the clogging indicator reacts during a cold start only, it is possible that the element
does not need to be changed yet.
HYDAC FILTERTECHNIK
3. ELEMENT-CHANGES
1. Switch off the hydraulic system.
2. Remove oil drain plug (collect fluid in a suitable container and clean or dispose of in accordance
with environmental regulations).
3. Unscrew filter housing.
4. Remove filter element from element centering pivot (examine surface of element for dirt residue
and larger particles; these can indicate damage at the components).
5. Change or clean filter element (only W,W/HC, and V-elements can be cleaned)
Please request for cleaning instructions.
6. Clean filter bowl and filter head. Especially pay attention to the cleanliness of the threads.
7. Examine filter, especially sealing surfaces and thread, for mechanical damage.
8. Check O-rings and back-up rings - if necessary replace parts.
3.2 Element mounting
1. Moisten thread and sealing surfaces on the filter bowl and filter head, as well as the o-ring with
clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
3. Mount filter element carefully on the element centering pivot.
4. Screw in filter housing.
5. Screw in oil drain plug. Unscrew filter housing by one quarter-turn.
6. Switch on hydraulic system and vent filter on suitable part of the unit.
7. Check filter for leakage.
NOTE: Filter elements which cannot be cleaned must be disposed

in accordance to environmental regulations.
HYDAC FILTERTECHNIK
Spare Parts Drawing FLN 160 bis 400
2.4/3.3/5.6
2.1
2.2/3.1/5.4
2.3/3.2/5.5
1.2/5.1
1.1
4.3/5.3
4.2/5.2
4.1
4.4/5.7
HYDAC FILTERTECHNIK
Spare Parts List FLN 160 bis 400
cons. Article-no. Hägglunds-
Item pc. Designation
of Dimension No.
Filter Element:
1 1 0250 DN 006 BN3HC /-VPN-SO378-SPARE 01271038 478 3233 629
1.1 1 Filter Element DN... -
1.2 1 O-ring 40,87 x 3,53 -
Clogging Indicator:
2 01271999 478 3233 644
VD 2.2 LE.1 /-30C-SO378-03043225
2.1 1 Clogging Indicator VD 2.2 LE... -
2.3 1 O-ring 16 x 1 -
2.4 2 O-ring 12 x 1 -
Sealkit Clogging Indicator:
3 01272003 478 3233 651
SEALKIT-E VD /-SO378
3.2 1 O-ring 16 x 1 -
3.3 2 O-ring 12 x 1 -
Filter Bowl:
4 BOWL-ASS‘Y FLND250 W.0/-V -
01274801
4.1 1 Bowl FLN... FLN... -
4.2 1 Back-up-ring FLN... -
4.3 1 O-ring 102 x 3 -
Repair-kit:
5 01272216 -
REPAIR-KIT-E FLN..160/250/400 W.0
5.1 1 O-Ring (element) 40,87 x 3,53 -
5.2 1 Back-up-ring (Topf) FLN... -
5.3 1 O-ring (Bowl) 102 x 3 -
5.4 1 Profile sealing ring (clogging indicator) VD... -
PRESSURE GAUGE
PRECISION INSTRUMENT COMPANY
MODEL '201L', LIQUID FILLED GAUGES
Our ‘200’ Series Gauge Line Is A High Quality Line Of Liquid Filled Gauges. The Glycerine Filling Helps
Dampen The Effects Of Pulsation And Vibration, While Also Perpetually Lubricating The Movement (And
Keeping Contaminates Such As Dirt Away From All Moving Parts) Which Will Extend The Life Of The Gauge.
This Gauge Has Been Specifically Designed With The Original Equipment Manufacturers In Mind And
Are Typically Used On Hydraulic & Pneumatic Systems As Well As Any Commercial Or Industrial Application
Not Corrosive To Brass And Bronze Wetted Parts Where Glycerine Filling Is Suitable For Use.
SPECIFICATIONS:
• Available Dial Sizes: 1 ½”, 2”, 2 ½”, 4", 6"
• Available Connection Sizes:
1/8”MNPT on 1 ½” and 2”
1/4"MNPT on 2”, 2 ½” and 4"
1/2"MNPT on 4" and 6"
• Stainless Steel Case And Bezel
• Brass Internals & Connection
• Phosphour Bronze Bourdon Tube
• Liquid Filled (Dry Available)
• Accuracy : 1 ½” and 2” Dial = 2 %
2½ ”Dial Size = 1.5 %
4” and 6” Dial Size = 1 %
• Dual Scale: PSI & Bar (x100=kPa)
Single Scale available from stock
• Ambient temperature: FILLED: 30’F to 160’F
DRY: -30’F to 180’F
RANGE CODE Major In Minor In

Some ranges not available in all dial sizes, please call with your particular application
30/0"VAC A 5 0.5
30/0/15 CB 5 0.5
30/0/30 CC 10 1
30/0/60 CD 10 1
30/0/100 CE 20 2
30/0/150 CF 20 2
30/0/300 CH 50 10
0/15 B 2 0.2
0/30 C 5 0.5
0/60 D 10 1
0/100 E 20 2
0/160 F 20 2
0/200 G 40 4
A B C D E
0/300 H 50 5
0/400 I 50 5 1 ½” In 1.88 1.06 .89 2.77 1/8”
0/500 J 100 10 Dial MM 48 27 23 58 Npt
0/600 K 100 10
2” In 2.24 1.27 .71 2.80 1/8” or
0/800 L 100 10
0/1000 M 200 20 Dial MM 57 32 23 71 ¼”npt
0/1500 N 200 20 2 ½" In 2.80 1.28 1.07 3.55 1/4“
0/2000 O 400 50 MM 71 33 27 90 Npt
Dial
0/3000 P 500 50
0/4000 Q 500 50 4" In 4.32 1.63 1.25 5.57 1/4" or
0/5000 R 1000 100 Dial MM 110 42 32 141 ½
”npt
0/6000 S 2000 200
6" In 6.54 1.70 1.68 8.22 1/4“ or
0/10,000 U 2000 200
0/15,000 V 2000 200 Dial MM 166 43 43 210 ½”npt
OIL LEVEL INDICATOR
FLUID LEVEL
INDICATORS FSA/FSK
APPLICATION
The HYDAC FSA-Visual Fluid
Level indicators and FSK-
are used for monitoring fluid
levels and temperature in various
types of reservoirs. Typical
applications are hydraulic system
reservoirs and lubricating, cutting
and cooling fluid tanks. Visual and
are suitable for service in mineral
oils and phosphate-ester based
hydraulic fluids. For Water Glycols
and High Water based fluids, the
sight tube must be ordered in
glass construction. Fluid Level
Indicators can be supplied with
various types of thermometers:
Built-in Tube (FSA only), Dial
Gauge with Thermometer Probe
or Electrical Thermo-Switch.
SPECIAL FEATURES
• Attractive appearance
• Transparent Polyamide sight tube
• Thermometers furnished with
dual range for both Celsius and
Fahrenheit
• Simple and rugged construction
• Available in several sizes
• Choice of seals
• Easy mounting
• Available with Thermo-Switch
DESCRIPTION controls the oil temperature in the
hydraulic reservoir. The Thermo
The HYDAC FSA Visual Fluid Level Switch opens when the nominal
Indicator is available in five sizes. temperature is reached. The switch
The HYDAC FSK Electrical Fluid closes when the temperature is
Level Indicator is available in four approximately 36˚F (20˚ below
sizes and provides an electrical nominal temperature.)
signal at a low fluid level. This
reliable magnetically-operated
reed relay circuit is available in
two single pole single throw
(SPST) contact arrangements:
normally closed (type “O”) or
normally open (type “C”). The
HYDAC TS Thermo-Switch
TECHNICAL DATA THERMO SWITCH SELECTION CODE
Thermo Switch Switch Mounting
Code Temperature Thread
Mounting Thread TS50 50˚C/122˚F M 12
FSK or FSA................M 12 or M 10 TS60 60˚C/140˚F M 12
TS ...................................M 12 only TS70 70˚C/158˚F M 12
TS80 80˚C/176˚F M 12
Material
Housing............Anodized Alumnum
Sight Tube............Polyamide,Glass
Seals................Fluorocarbon, NBR MODEL CODE
Fluid Temperature FS A -127- 1 . 1 - - T - 12 -
-4˚F/-20˚C to176˚F/80˚C
Maximum Pressure Fluid Level Indicator
14.5 PSI (1 BAR)
Type
Thermometer A = Visual
Type T K = Electrical
(FSA only)
68˚F/20˚C to 176˚F/80˚C Size (Mounting Hole Centers)
Type FT 76 = 3 inches (FSA Only)
32˚F/0˚C to 212˚F/100˚C 127 = 5 inches
176 = 7 inches
Bolting Torque 254 = 10 inches
Max. 8 LB-FT+1 (10 Nm +2) 381 = 15 inches
see installation instructions on page 4
Electric Switch Seals
1 = NBR (FSA)
FSK...C FSK...O
2 = Fluorocarbon (FSA and FSK)
2 2
3 3 Modification Number
1 1 1 = FSA (Determined by Manufacturer)
3 = FSK (Determined by Manufacturer)
Electrical Switch
(omit) = For FSA
Contact Ratings.................Max. 8W “C”(SPST) = Normally open at Normal Level
Maximium Voltage.....50 VAC or DC “O”(SPST) = Normally closed at Normal Level
Maximum Current...............200 mA
Connection 3 not used Thermometer
TYPE C TYPE O T = Built-in Tube (FSA Only)
Normally Normally FT 200 = Probe Thermometer (200mm-7.87”LG)
Open Closed FT 300 = Probe Thermometer (300mm-11.87”LG)
TS = Thermo Switch (See Chart Above)
FSK - C FSK - O
Hex Head Bolt
12 = M12 Bolt (Standard)
10 = M10 Bolt (Optional)(Not Available with TS)
Contacts are Contacts are Sight Tube
closed at lower open at lower (omit) = Polyamide construction (not suitable for water glycols or high water
level of fluid level of fluid based fluids)
Thermo Switch Glass = Glass construction-Special Order for FSA Only. Not Available with
FSK.
TS
When ordering probe thermometer separately, please order one (1) drilled bolt, item
12, in spare parts list.
1 2
See installation procedures on page 4 to determine whether a washer is needed.
If a washer is needed, order part # 00001689
Switching Outputs 10.0 A/50 V-1 cycles

2.5 A/50 V-10,000 cycles
0.5 A/50 V-100,000 cycles
Minimum Current 50 mA
N/C Contact
2
FSA FSK
Fluid Level Indicator Fluid Level Indicator/Switch
max. .31
max. 8 max. .31 1.10
max. 8 28
.79 .20 1.34
20 5 34
M 12 or
M 10 M 12 or
M 10
CLEARANCE HOLE HYDAC

ø.51 (13mm) or CLEARANCE HOLE
ø.43 (11mm) ºC ºF ø.51 (13mm) or
80- -180
ø.43 (11mm)
70- -160
60- -140
50- -120 L2 L2
40- -100
L2 L L1 SWITCH
30- -80 LEVEL
20-
-60
10-
-40
0-
-10- -20
1.97
50
.79 20
20 5 1.34
34
1.77
45
1.77
SCREW-TYPE CONDUIT
45
FITTING PG 9
Size L L1 L2 Size L L2
inch 4.25 1.46 2.99 inch 8.07 5.00
76 127
mm 108 37 76 mm 205 127
inch 6.26 2.99 5.00 inch 10.00 6.93
127 176
mm 159 76 127 mm 254 176
inch 8.19 4.92 6.93 inch 13.07 10.00
176 254
mm 208 125 176 mm 332 254
inch 11.26 7.99 10.00 inch 18.27 15.00
254 381
mm 286 203 254 mm 464 381
inch 16.26 12.99 15.00
381
mm 413 330 381
Thermo Switch - TS FSA or FSK

Detail of Lower Connection WIth Optional Probe Thermometer (FT)
11
.67 SQ
SW 17
M 12
ø1.51
ø40
1.93
49
12
7.87" or 11.87"
200 or 300
.63 3.62
16 92
3
Recommended Installation Process
1. Drill mounting holes according to dimension L2 on page 3.
Mounting hole diameter is dependent on the bolt selected in the model code. see pages 2 & 3
2. Torque the Nut, item 9, to 8+ 1 LB-FT. If it is not possible to torque the nut, the bolt head must be torqued. To avoid
damaging the indicator a washer is recommended to be used under the bolt head.
This washer is available from HYDAC: Part Number 00001689.
Washer Dimensions: OD 18.8 mm, ID 13.10 mm, 0.5 mm thick
Spare Parts
FSA FSK
10 1
2
3
© Copyright 2001 HYDAC TECHNOLOGY CORPORATION - Brochure - Fluid Level Indicators FSA/FSK #02068184 / 9.02
9 13
4
5
6
7 14
or
15
Quanity Quanity
Item Description FSA FSK
1 Housing 1 1
2 Name Plate 1 -
3 Tube 1 1
4 O-Ring 13x2.5 2 2
5 Tube Connector 2 2
6 O-Ring 12.3x2.4 2 2
7 Sealing Washer 2 2
8 Hex Bolt 2 2
9 Hex Nut 2 2
10 Thermometer in Indicator Tube 1 -
11 Probe Thermometer (see page 3) 1 1
12 Hex Bolt for Probe Thermometer 1 1
13 Magnetic Float - 1
14 Base Assembly with Type “C” Switch - 1
15 Base Assembly with Type “O” Switch - 1
16 Washer (optional - see note 2 above) 1 1
HYDAC TECHNOLOGY CORPORATION

2260 City Line Road • Bethlehem, PA 18017
Phone (610) 266-0100 • Fax (610) 264-3540
www.hydacusa.com • powerup@hydacusa.com
4
AIR BREATHER
Breathers
Breather & Filler Breather Overview
Breather Max. Flow Element Connection Notes
BF...3/4 35/10 SCFM 3 or 10 µm Threaded Carbon Steel with External Epoxy Coating
250/80 GPM phenolic resin 1/4 to 3/4” BSPP and Zinc Plated Internals
impregnated paper (male) Pressurized (optional)
page 84
200 GPM phenolic resin 3/8 to 3/4” BSPP Pressurized (optional)
page 85
500 GPM phenolic resin 1” BSPP with optional differential gauge
Replaceable
page 86
BL... & BLT... 110 SCFM 3 or 10 µm Threaded, Flanged, Spin-on elements (BL...)
850 GPM phenolic resin or Welded Dehumidifying element (BLT...)
impregnated paper
page 88
BD... (Drymicron) 100 SCFM 2µm Threaded, Silica Gel Desiccant adsorbs water
750 GPM Disposable Flanged, or then changes color to indicate
Bayonet when breather should be changed
page 91
BF...5 220 SCFM 3 or 10 µm Threaded Carbon Steel
1600 GPM phenolic resin 2 1/2” BSPP
impregnated paper (female)
Replaceable
page 87
Filler/Breather Max. Flow Element Connection Notes

ELF...3/4 35/10 SCFM 3 or 10 µm 6 hole flange/ Carbon Steel with External Epoxy Coating
250/80 GPM phenolic resin Bayonet and Zinc Plated Internals
impregnated paper Lockable models available
Pressurized (optional)
page 79

200 GPM phenolic resin Threaded Pressurized (optional)
impregnated paper
page 81

500 GPM phenolic resin Threaded with optional differential gauge
impregnated paper
Replaceable
page 82
ELF...5 220 SCFM 3 or 10 µm Threaded Carbon Steel

1600 GPM phenolic resin 2 1/2” or 3” BSPP
impregnated paper (weld rings available)
Replaceable
page 83
Sizing: Maximum Flow is the greater of the maximum pump flow rate, or the maximum system return rate into
the reservoir. Flow rates given are based on a 0.6 psi initial pressure drop with a clean element in a normal
operating environment. Contact HYDAC for applications in extreme environmental conditions.
Breathers
Breathers & Filler Breather Technical Overview
Importance of Breathers
Breathers are a integral component in any Hydraulic system. Breathers provide protection from contamination found in harsh industrial
environments. It is well advised to address both contaminant exclusion and removal. An old rule of thumb states that it cost 10 times
as much to REMOVE a particle from your system as it does to EXCLUDE it. Since this is true, it is easy to see that the benefits of
using a high quality breather greatly out-weigh the costs.
Recommendations
1) HYDAC recommends selecting a breather with a filtration rating (micron rating)
that is equivalent to or finer than your finest system filter.
2) Breathers do get clogged over time. HYDAC recommends the following change-out schedules:
For breathers without pressure gauges
• Change you breather annually or with every service interval
For breathers with pressure gauges
• Change your breathers at a 3 psi pressure drop, at 7 psi pressure drop the pump can cavitate
HYDAC High Quality Breathers

All HYDAC Breathers use HIGH quality filtration.
(refer to Engineering Data on page 90 for details)
Elements are made of phenolic resin impregnated paper, which provides resistance to moisture, ensuring proper filtration over the
operational service life of your breather.
Pressurized Breathers
The use of pressurized breathers adds certain benefits:
• Provides additional protection from moisture which can condense in your tank, causing oil degradation and tank erosion
• Provides positive pressure to pump suction line
• Increased breather service life due to less breathing
• Performs anti-splash function
Tank Pressure Tank Pressure

Using a Standard Breather Using a Pressurized Breather
Positive Pressure Positive Pressure Above Cracking Pressure
Tank Pressure
Tank Pressure
(tank breathes out) (tank breathes out)

Breather
Cracking Pressure
Atmospheric
No Breathing Takes Place Atmospheric
Pressure Pressure
Vacuum Vacuum
(tank breathes in) (tank breathes in)
Time Time
When fluid level rises, the tank pressure rises When fluid level rises, the existing air volume is
and air is immediately expelled through the compressed, and no air is expelled until the cracking
breather whenever positive pressure exists. pressure is surpassed.
When fluid level lowers, the tank pressure drops When fluid level lowers, the tank pressure drops
and air is immediately drawn in through the breather until a vacuum is created at which point, air will be
whenever a vacuum exists. drawn in through the breather.
Air is constantly moving through the breather Air is only expelled when the tank pressure is
in order to maintain atmospheric pressure. above the cracking pressure, and air is only
drawn in below atmospheric pressure.
The majority of the operational cycle will take place
between these two conditions.

Breathers
ELF...3 & ELF...4 Series Filler Breathers
Specifications: Dimensions: 2.66"
• Maximum flow rate: 35 SCFM/250 GPM ø D2
67.5mm
Tab Thickness
2.26"
ø D1 57.5mm 0.08"
• Epoxy coated steel cap 2mm
H3 1.22"
• 3 or 10 micron 31mm
H1
• 500 micron plastic filler basket
Self-tapping Screw 0.83"
• Bayonet connection to access fill port M5 x 10 (DIN 963) Ø 8mm 21mm
H2
• Installs via 6 bolt circle (bolts included)
• Locking tabs (optional)
• Pressurized breather
ø D3
with relief valve (optional - ELF3 only)
Mounting Hole Patterns
Hydraulic Symbols: ELF 3
(Flange Interface to DIN 24557/T2) 0.18"
ELF 4
ø
4.5mm
(3 places)
Ø 2.36" Ø 1.18" Ø 1.63"

60mm Ø 2.87"
73mm 30mm 41.3mm
0.18"
with relief valve (ELF3 only) standard ø
4.5mm
(6 places)
Size D1 D2 D3 H1 H2 H3
2.99” 3.27” 2.05” 6.26” 3.80” 2.46”
ELF 3 Ø Ø Ø
76mm 83mm 52mm 159mm 96.5mm 62.5mm
1.73” 1.97” 1.10” 5.32” 3.21” 2.11”
ELF 4 Ø Ø Ø
44mm 50mm 28mm 135mm 81.5mm 53.5mm
Model Code: ELF...3/4

ELF P 3 F 3 W 1 . 0 / .
Filter Type
ELFL = Lockable Filler Breather (not available for size 4)
Size
3 = 35 SCFM (250 GPM) Max.
Type of Connection
F = Flanged
Gauge Options
Type
1 = ELF 3 and 4
RV = Relief Valve (for use on Pressurized Tanks; ELFP3 only)
SO169H3.5 = 3.5 inch plated steel filler basket
SO169H6 = 6 inch plated steel filler basket (ELFP3 only)
SO169H8 = 8 inch plated steel filler basket
Breathers
ELF 3 Series Filler Breather Parts
ELF 3 Breather Caps

Breather Cap ELF P 3 CAP 10 W 1.0 W/CHAIN 02080124
Breather Cap
Breather Cap ELF P 3 CAP 10 W 6.0/RV W/CHAIN 02080125
with 6 psi relief valve
6 bolt Bayonet Flange
Self Tapping
Bayonet Flange Kit
Screws
M5x10 (DIN 963)

Bayonet Flange Bayonet Flange Kit ELF3 BAYONET FLANGE KIT ASSY 00002680
Note: Parts not sold separately
Gaskets
1 for under basket
1 for on top of basket

3.5” Steel Filler Basket ELF3 STRAINER BASKET 3.5” PLATED STEEL 02701474
6-bolt Filler Basket
4” Plastic Filler Basket ELF3 STRAINER BASKET 4” PLASTIC 01202916
Weld Neck Bayonet Flange

Installation
Cross Section
Weld Neck
Bayonet Flange

Weld Neck ELF3 WELD NECK W/CHAIN 02080126
Reservoir Wall
Drop-in Filler Basket

Drop-in Strainer ELF3 WELD NECK STRAINER 02078939

Breathers
• Maximum flow rate - 25 SCFM/200 GPM ø 83mm
ø 81mm
• 3 or 10 micron
• 500 micron plastic filler basket 62mm
• Threaded connection to access fill port
83mm
• Installs via 6-bolt circle (bolts included)
• Optional dipstick (contact factory)
• Pressurized breather 185mm Self
with relief valve (optional) approx. Tapping
Screw
M5 x 10 (DIN 963)
Hydraulic Symbol:
Mounting Hole Pattern
ELF 30
with relief valve

Ø 2.36"
60mm Ø 2.874"
73mm
0.18"
ø
4.5mm
standard
(6 places)
Model Code: ELF...30

ELF P 30 F 10 W 1 . X / .
Filter Type
Size
30
Type of Connection
F = Flanged
Gauge Options
Type
1 = Flanged Connection to DIN 24557/T2
(omit) = standard
Breathers
• Durable synthetic material (PA6) ELF 7
• 3 or 10 micron
Optional
• 500 micron plastic filler basket Gauge
• Threaded connection to access fill port ø 4.72"
• Installs via 6-bolt circle (bolts included) 120mm
2.36" Clearance Required

Replacement Elements 60mm For Element Removal
Micron Model Code Part No.
ø 4.57"
3 0007L003P 00310948 116mm
10 0007L010P 00310485 1.73"
44mm
Hydraulic Symbols:
Mounting Hole Pattern 3.31"

(Flange Interface to DIN 24557/T2) 84mm
7.13"
with gauge ø 2.36" ø 2.87" 181mm
60mm 73mm Counter Sunk
3.82" Slotted Screw
97mm
ø 0.18" M5 x 10 (DIN 963)
4.5mm
(6 places)
ø 1.93"
49mm
without gauge
Model Code: ELF...7

ELF P 7 F 10 K 1 . 0.
Filter Type
Size
7
Type of Connection
F = Flanged
Gauge Options
Type
1 = (standard)

Breathers
ELF 5
• Maximum flow rate - 220 SCFM/1600 GPM 3.54" Clearance Required
90mm For Element Removal
• Steel element housing
• 240 mm Zinc-plated metal filler basket ø 6.97"
177mm
• 3 or 10 micron
• Replaceable element 4.13"
• Removable Lid to access fill port 105mm
• Installs via threaded connection

(weld ring optional)
HEX
0.98" 3.54"
25mm 90mm
13.78"
9.45" 350mm
240mm
2.68"
Replacement Elements 68mm
G3
Micron Model Code Part No. (ELF5...3.0)
3 0005L003P 00309450 G2 1/2

(ELF5...2.0)
10 0005L010P 00306097
2.56"
(ELF5...2.0)
65mm
Weld Rings Weld Ring
2.80"
(ELF5...3.0)
Size Model Code Part No. 71mm
G 2 1/2 RING WELD ELF 5 G 21/2 02065053 3.46"
Reservoir opening Ø (ELF5...2.0)
88mm
G3 RING WELD ELF 5 G 3 02065054 for weld ring
3.98"
Ø (ELF5...3.0)
101mm
Model Code: ELF...5

ELF P 5 F 3 W 1 . 0 / .
Filter Type
Size
5
Type of Connection
G = Threaded (matching threaded weld ring available see supplementary details below)
Gauge Options
Connection Type
2 = ELF 5 with G 2 1/2 threaded connection
3 = ELF 5 with G 3 threaded connection
NO WELD RING = without weld ring
W/ WELD RING = with weld ring
Breathers
BF...3 & BF...4 Series Breathers
• Epoxy coated steel cap
ø D1
• 3 or 10 micron
• Threaded connection
• Pressurized breather H1
with relief valve (optional - BF3 only)
H3
Hydraulic Symbols: HEX
D2
Size D1 D2 (male) H1 H3 HEX

BF 3...1.0 2.99” G 3/4 3.11” 0.63” 1 7/16”
with relief valve (BF3 only) Ø 76mm
BF 3...RV (ISO 228) 79mm 16mm 36mm
2.99” G 3/8 2.83” 0.47” 7/8”
BF 3...2.0 Ø 76mm (ISO 228) 72mm 12mm 22mm
2.99” G 1/2 2.99” 0.55” 1 1/16”
BF 3...3.0 Ø 76mm (ISO 228) 76mm 14mm 27mm
1.73” G 1/4 2.44” 0.53” 11/16”
standard BF 4...1.0 Ø 44mm (ISO 228) 62mm 13.5mm 17mm
Model Code: BF...3 & BF...4

BF P 3 G 10 W 1 . 0 / __
Filter Type
BF = Breather
Size
3 = 35 SCFM (250 GPM) Max.
Type of Connection
G = Threaded
Gauge Options
1 = BF3
3/4 = G
1 = BF4
1/4 = G
2 = BF3
3/8 = G
3 = BF3
1/2 = G
4 = BF3 = G
5 = BF3 = G
6 = BF3 = G
(omit) = (standard)
RV = Relief Valve (For Use on Pressurized Tanks)(BF3P only)

Breathers
ø 81mm
• 3 or 10 micron
• Threaded breather connection
• Optional dipstick (contact factory) 56mm
• Pressurized breather 14mm SW32 (Types 1 & 2)
with relief valve (optional) SW46 (Type 3)
16mm
O-Ring
Hydraulic Symbol: G 3/4 male

(ISO 228)
with relief valve
standard
Model Code: BF...30

BF P 30 G 10 W 1 . X / .
Filter Type
BF = Breather
Size
30
Type of Connection
G = Threaded
Gauge Options
Type
1 = G 3/4
(omit) = standard
Breathers
• Durable synthetic material Optional
• 3 or 10 micron Gauge
• Threaded breather cap connection ø 4.72"
120mm
Micron Model Code Part No. 2.36" Clearance Required for
3 0007L003P 00310948
60mm Element Removal
10 0007L010P 00310485
ø 4.57"
116mm
1.73"
Hydraulic Symbols: 44mm
4.33"
110mm
with gauge
1 5/8"
HEX
41mm
0.71"
18mm
G 1"
ISO 228
without gauge
male
Model Code: BF...7

BF P 7 G 10 K 1 . 0
Filter Type
BF = Breather
Size
7
Type of Connection
G = Threaded
Gauge Options
1 = G1

Breathers
• Steel housing 3.54"
90mm
• 3 or 10 micron Clearance
• Replaceable element Required
• G2 1/2 female threaded connection ø 6.97" For
177mm Element
Removal
Micron Model Code Part No. 4.21"
3 0005L003P 00309450 107mm
10 0005L010P 00306097
G 2 1/2"
Hydraulic Symbol: (ISO 228)
female
Model Code
BF P 5 G 10 W 1 . 0
Filter Type
BF = Breather
Size
5
Type of Connection
G = Threaded
Gauge Options
1 = G 2 1/2 (standard)
Breathers
BL Series Spin-on Breathers
• Maximum flow rate H3
Clearance needed
110 SCFM/850 GPM for removal Ø D1
• 3 or 10 micron Mounting Hole Pattern for Flange Connection (F)
• Steel Canister
• 10 micron Betamicron® 2.87"
ø 73mm ø
2.36"
60mm
• Replaceable element H2
H1 ø 0.18"
4.5mm
(6 places)
Hydraulic Symbol:
D3
D2
F Connection G Connection S Connection
Size D1 D2 D3 H1 (F or S) H1 (G) H2 H3
3.67” 7” 5.4” 0.75”
BL...80 3/4” NPT 1”-12UNF-2B -
Ø 93mm 178mm 137mm 19mm
5.00” 9.25” 8.75” 7” 1.00”
BL...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 235mm 222mm 178mm 25.4mm
5.00” 13.25” 12.75” 11” 1.00”
BL...180 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 337mm 324mm 279mm 25.4mm
5.33” 9.25” 8.75” 7” 1.00”
BLT...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 136mm 235mm 222mm 178mm 25.4mm
Model Code: BL... BL P 160 G 10 W 2 . 0

Filter Type
BL = Spin-on Breather
BLT = Spin-on Breather with Dehumidifying Element (size 160 only)(in 3 micron only)
BN = Betamicron®
M = Desiccant (type BLT only)
Size
080 = 35 SCFM (250 GPM) Max.
160 = 110 SCFM (850 GPM) Max.
180 = 110 SCFM (850 GPM) Max.
Type of Connection
G = Threaded
F = Flanged Available in sizes BL 160 and BL 180 Only
S = Weld Fitting
3 = 3µm Air Filtration (paper only)
Gauge Options
Type Number
Size Tank Connection
1 = BLT 160 1 1/4” NPT Thread, Flange, or Weld Fitting
2 = 160/180 1 1/4” NPT Thread, Flange, or Weld Fitting
3 = 080 3/4” NPT Thread
Model Codes containing red selections are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability

Breathers
BL... Series Breather Components
Size 10 micron 3 micron 10 micron 3 micron
Paper Paper Betamicron BLT
0080MA010P 0080MA003P 0080MA010BN
80 N/A
02058058 02058079 02059424
0160MA010P 0160MA003P 0160MA010BN 0160MU003P
160
02058116 02058114 02059436 01265765
0180MA010P 0180MA003P 0180MA010BN
180 N/A
02058121 02057912 02059440
Adapters
Fiber Gasket Sold Separately

Order Part Number 00247102
Size G F S
Threaded Adapter Flanged Adapter Welded Adapter
ADAPTER BL 080G 3/4” NPT NBR
80 N/A N/A
02064393
160
ADAPTER BL 160/180 G 1 1/4” NPT NBR ADAPTER BL 160/180 F (PHOS) ADAPTER BL 160/180 S (PHOS)
02064394 00407646 00416311
180
Breathers
Engineering Data
Mounting Position: ELF & BF Vertical (max. 30° off vertical axis)
BL, BLT, BLG, & BLS Vertical or Horizontal
Air Filter Material: Phenolic Resin Impregnated Paper
Note: None of the air filter elements can be cleaned.
Fluid Temperature Range: -15° to 250°F (-26° to 121°C)
Please contact HYDAC for information on extreme low
temperature applications (below -15°F.)
Fluid Compatibility: Compatible with all petroleum oils.
Weights
Model lbs. kg.
ELF 3 0.55 0.25
ELF E RV 0.66 0.30
ELF 4 0.44 0.20
ELF 5 (TYPE NO. 2) 5.95 2.70
ELF 5 (TYPE NO. 3) 6.83 3.10
ELF 7 0.84 0.38
BF 3 0.62 0.28
BF 3 RV 0.73 0.33
BF 4 0.18 0.08
BF 5 4.41 2.00
BF 7 0.88 0.40
BL 160 4.63 2.10
BL 80G 1.40 0.60
BL 160G 2.60 1.20
BL 180G 3.48 1.58
BL 160S 3.86 1.75
BL 180S 4.22 1.91
BLT 160 5.31 2.41
Retention Value
dx
x refers to the percentage of particles of a particular size that the breather will filter.
i.e. d80 for a 10µm filter will capture 80% of 10 µm particles

Breathers
BD Series Drymicron Operational Features
Bi-directional Air Flow
• Air entering is cleaned and dried. Expelled air partially
regenerates the silica gel and “backflushes” the
particulate filter to prolong the life of the breather.
Durable Construction
• DRYMICRON is manufactured from rugged ABS
plastic and impact-modified Plexiglas.
Water Vapor Adsorbent
• Silica gel is chemically inert, non-toxic, and non-
corrosive. The internal structure is composed of
interconnected microscopic pores that adsorb up to
40% of its weight.
Color Indicator
• When maximum adsorption is reached, the silica gel
turns from gold to green to indicate that replacement
Description of the breather is required.
DRYMICRON breathers use a three-stage filtration
REPLACE
design to ensure optimum protection by removing GOLD
ACTIVE
water vapor and solid contaminant before they enter
the fluid system. GREEN
DRYMICRON Breathers replace the standard breather
cap or vent tube on a tank or reservoir. They are easy Safety Sealed
to install using one of several adapters designed for • Seals keep moisture from entering the units until they
different applications. are placed in service. They are easily removed without
When the fluid in the system is lowered, or pressure tools or sharp instruments.
changes occur, air is drawn in through openings under
the breather cap. First, air passes through a fine, 2
Solid Contaminant
micron solid particle filter. The air then passes through Filter (2 µm)
a diffuser to ensure maximum effectiveness within the
Air Diffuser
silica gel chamber.
Next, water vapor is removed as the air travels through
360˚ Air Flow
a bed of silica gel — the highest capacity adsorbent
available. After being dried, the air passes through a
second 2 micron solid particle filter and enters the
reservoir clean and dry!
High Capacity
Advantages Water Vapor
Adsorbent
DRYMICRON Breathers protect expensive equipment, Solid Contaminant
increase Filter (2 µm)
operation efficiency, and reduce maintenance costs by:
• eliminating corrosion
• extending life of hydraulic, lubrication, and process
fluids CLEAN DRY AIR
• minimizing component wear,

downtime, and repairs ø 5"
(128 mm)
• eliminating oil oxidation, additive
depletion, and freezing
• extending oil filter life
A
Applications
• Hydraulic Reservoirs
• Gear Boxes BD 100, 200, 400
standard 1" friction fit
• Storage Tanks (see adapter selection guide)
1.25" BD 800
(32 mm) 2"NPT only
(no adapter needed)
Breathers
Product Specifications
Performance Specification
Nominal Air Flow Rate BD 100-400 35 SCFM (990 l/min)
Nominal Air Flow Rate BD 800 100 SCFM (2850 l/min)
Solid Contamination Filtration Level 2 micron, 100% efficiency @ 35 SCFM air flow
Solid Contamination Filtration Surface area 20.6 in2 / 133 cm2
Operating Temperature Range -26˚ to 200˚F / -32˚ to 93˚C
Silica Gel: Adsorption Up to 40% of its weight of water
Chemical Resistance Resistant to alkalis, hydrocarbons, non-oxidizing
acids, salt water, and mineral or synthetic oils
Flow Rate vs Pressure Drop Unit Selection Guide (adapters sold separately)
GPM Max. H2 0
Height (A) Weight
Model Code Part No. Capacity
37 75 112 150 187 225 262 300 inches (mm) lbs (kg)
1.0 lbs (ltr)
BD 100 X 2 W 0.0 02074253 3.5 (90) 1.3 (0.6) 0.2 (0.1)
0.8
BD 200 X 2 W 0.0 02074254 5 (128) 1.9 (0.9) 0.4 (0.2)
∆P (PSI)
0.6 BD 400 X 2 W 0.0 02074465 8 (205) 3.3 (1.5) 0.9 (0.5)

0.4 BD 800 X 2 W 0.0 02075158 10 (254) 4.9 (2.2) 1.3 (0.6)
0.2
0
0 5 10 15 20 25 30 35 40
SCFM
Adapters Selection Guide (adapters sold separately - Note: no adapter needed for BD 800)
Bayonet Adapter Threaded Adapter Threaded Standpipe Adapter Flange Adapter
Part No. 02074251 Part No. 02074248 (3/4" NPT) Part No. 02077124 Part No. 02074250 (not drilled)
Part No. 02074249 (1" NPT) Part No. 02075193 (pre-drilled)
gasket not provided
1 1/2-16 UN-2B Mounting Hole Pattern

Existing Standpipe for Pre-drilled Adapter
or HYDAC: 00416311 (Flange Interface to DIN 24557/T2)
ADAPTER BL 160/180 S (PHOS) 2.874"
ø 73mm
Bayonet Flange Kit with 3.5" Steel Basket Bypass Adapter Part No. 01270816 ø 0.18"
4.5mm
Part No. 02079076 (6 places)
Press-Fit to
2.36"
Drymicron ø
60mm
1 Bayonet Fitting
2 gaskets Vent to
atmosphere
1 Filler Basket
Press-Fit to any
6 Screws Drymicron Adapter
for Installation

Breathers
HBRP Series
• Durable synthetic material
• 40 micron
ø
X
Description:
This compact plastic design has a sponge element and threaded
connection with anti-splash baffle. Dipsticks are available to the D
customer’s requirements - see ordering information below. C
Construction: NPT Male Thread A

X
Cap
40 Micron Element
Wire Mesh Overall

Dipstick Length
To Full Mark
Labyrinth Baffle
Body To Add Mark

SECTION X-X
40 micron Breathers (Contact HYDAC for 10 micron)

Model Code Part No. Displace (GPM) Airflow (SCFM) A (NPT) ØB C D
1.36 1.31” 0.73”
HBRP-3/8NPT-40-1-1-A 02076916 55 7 3/8”
34.54mm 33.27mm 18.54mm
1.57” 1.56” 0.76”
HBRP-1/2NPT-40-1-1-A 02076917 75 10 1/2”
39.88mm 39.62mm 19.30mm
1.77” 1.60” 0.78”
HBRP-3/4NPT-40-1-1-A 02076109 115 15 3/4”
44.96mm 40.64mm 19.81mm
1.97” 1.93” 0.95”
HBRP-1NPT-40-1-1-A 02076918 150 20 1”
50.04mm 49.02mm 24.13mm
Ordering:
• Overall Length
• To Full Mark
Breathers
HBRM Series
• Chrome-plated carbon steel
• 10 or 40 micron
Description: Overall
These chrome plated breathers have a paper element and NPT Dipstick Length
threads. Dipsticks are available to the customer’s requirement. To Full Mark
See ordering information below.
To Add Mark
ØA
C B
HEX
SIZE
D
(NPT Male)
Model Micron Displacement Airflow Hex Dimensions

Code Part Number Rating (GPM) (SCFM) Size ØA B C D (NPT)
HBRM-1/4NPT-10-1-2 02080116 10 24 3 0.75” 1.85” 2.00” 0.20” 1/4”
HBRM-1/4NPT-40-1-2 02080117 40 40 5 0.75” 1.85” 2.00” 0.20” 1/4”
HBRM-3/8NPT-10-1-2 02080118 10 24 3 0.75” 1.85” 2.00” 0.20” 3/8”
HBRM-3/8NPT-40-1-2 02080119 40 40 5 0.75” 1.85” 2.00” 0.20” 3/8”
HBRM-1/2NPT-10-1-2 02080120 10 24 3 1.00” 1.75” 2.50” 0.32” 1/2”
HBRM-1/2NPT-40-1-2 02080121 40 40 5 1.00” 1.75” 2.50” 0.32” 1/2”
HBRM-3/4NPT-10-1-2 02077313 10 105 14 1.18” 3.15” 2.80” 0.5” 3/4”
HBRM-3/4NPT-40-1-2 02076096 40 190 25 1.18” 3.15” 2.80” 0.5” 3/4”
HBRM-1NPT-10-1-2 02080122 10 105 14 1.18” 3.15” 2.80” 0.5” 1”
HBRM-1NPT-40-1-2 02080123 40 190 25 1.18” 3.15” 2.80” 0.5” 1”
Ordering:
• Overall Length
• To Full Mark

TEMPERATURE/LEVEL ASSEMBLY
Electronics
Electronic Pressure Switch
ENS 3000
Operating Manual
2 ENS 3000 Manual
CONTENTS
1. ENS 3000 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Assembly and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. ENS 3000 Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Output Characteristics
5.1 Switching Ouputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.1 Switch Point Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1.2 Window Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Switch Point and Hysteresis Setpoint Adjustment and/or Window Function Setpoint Adjustment . . . . . . . . . . 8
5.4 Switch Point Setting Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Hysteresis Setting Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Menu Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Changing menu settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Menu settings overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. Resetting Peak Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. Setting Lock-outs
8.1 Changing the setpoint lockout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.2 Changing the main program lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11. Connection Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
12. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 ENS 3000 without Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
12.2 ENS 3000 with Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13. Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
14. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.1 Electrical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14.2 Mechanical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15. Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
16. Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENS 3000 Manual 3

1. ENS 3000 Functions
Depending on the unit ordered, the ENS 3000 offers the following functions:
• Display of the measured level in cm or inch (depending on version).
• Display of measured temperature in °C or °F.
• Display of the maximum value of the level or temperature or a switching setpoint.
• Change the switchpoint to level or temperature and adjust the setpoints independently.
• Analog output (either level or temperature).
• Menu for basic adjustment (Adapt the ENS 3000 to a particular application).
• Program lockouts.
2. Mounting
The electronic level sensor ENS 3000 is to be fastened as completely as possible to the metal tube of the connecting
piece with an assembly fitting. An assembly fitting can take and hold a metal tube with 22 mm in diameter. We recom-
mend a bulkhead union with an inserted sleeve fitting (see Accessories section). The active range is to rise up as freely as
possible into the container. For optimal function a part of the active range should be over the upper edge of the con-
tainer or over the overflow of the container.
mode
mode
mode
Device for
Metal Part Attachment
of ENS 3000 Device for
for Connection Attachment Structure
Active
Range
For safe and simple assembly use assembly accessories from HYDAC ELECTRONICS
Attention: The electronic level sensor ENS 3000 is not suitable for tanks with positive pressure. A brief pressure of up
to 3 bar is tolerated and is not harmful up to a time span of 1 minute
1 ENS 3000 Manual

For the safe operation of the ENS 3000 the following conditions should be fulfilled:
• For small plastic container installation the unit should be mounted in the center of the container
• If fastening the unit in dirty media, place it where there is strong motion (e.g. at the expiration of inlet)
• With the installation in metallic tubing (bypass) the sensor must be installed in the center of the pipe. The tubing inside
diameter must amount to at least 4.72 inches.
• Metallic articles within the container (e.g. metallic pipes, installations) must keep a minimum distance from 2.36 inches to
the active range of the sensor. Otherwise the assembly elements are recognized by the unit and the measured value
is falsified.
• With installation into metallic containers the distance between sensor and container wall must amount to at least
0.78 inches.
mode
min
0.78”
min
2.36”
Active
Range
Metallic
Tube
Additional assembling instructions, which reduce the influence of electromagnetic disturbances:

• Keep connections as short as possible
• Use wiring screen cable (e.g. LIYCY 4 x 0.5 mm2 / LIYCY = overall length)
• The cable screen is to be used depending on site conditions and for the purpose of interference suppression.
• Direct proximity to power lines or disturbing electrical or electronic devices is to be avoided if possible.
At the mechanical connecting piece is a grounding screw, which takes over the function of an electrical ground. The
earth ground must be attached, if no grounding connection is given (e.g.: with the plastic tank). It is recommended to use
as leads a cable with diameter of 1 mm2 and as short a conduit length as possible.
ENS 3000 Manual 2

3. ENS 3000 Control Elements
Display selection for

temperature sensor
4-digit
display
Display for
level sensor SP1 in SP2
mode LED display for active

switching point
Keys for adjusting switch points,

reset points, and auxillary functions
4. Digital Display
After switching on the supply voltage on the equipment the display shows ENS&niU briefly. Afterwards the value (level or
temperature) in the display appears indicated and begins with the display of the current value (basic adjustment).
2s 2s
A level below the measurable range of the electronic level sensor is recognizable by the following operational sequence
on the announcement:
2s 2s
In the basic adjustments the announcement can be changed as follows:

• Display of the maximum value of the level “n.TOP”
The highest level since the power-on of the equipment and/or the last resetting procedure, measured in the system, is
• Display of the minimum value of the level “n.MIN”
The lowest level since the power-on of the equipment and/or the last resetting procedure, measured in the system, is
• The temperature value “TEMP”
• Display of the maximum value of the temperature. “T.TOP”
The highest temperature since the power on of the equipment and/or the last resetting procedure, measured in the
• Display of the minimum value of the temperature. “T.TOP”
The lowest temperature since the power on of the equipment and/or the last resetting procedure, measured in the
• Display of the switch point(s) “S.P. 1”, “S.P. 2”
Depending upon variant the switching point 1 and/or switching point 2 can be displayed.
• Display dark “oFF”
The display is switched off
3 ENS 3000 Manual

Depending on the display chosen “n.TOP”, “n.MIN”, “TEMP”, “T.TOP”, “T.MIN”, “S.P. 1”, “S.P. 2” or “oFF” is dis-
played. By using the keypad buttons or you can scroll through the display options. When the keys are not
touched for 5 seconds the display returns to the primary one chosen.
Hint:
• If the current level exceeds the nominal level range of the equipment, then it cannot not be indicated any more and
the announcement begins to flash.
• If the level of liquid falls below the lower measuring range, the display shows the value of the off set and the display
in such a way begins to flash
• During the display of the actual level; the possibility exists through pressing the key first the maximum value of
the level will be indicated. With each press of the key, the minimum value of the level, the current value, the
maximum value of the temperature, and the minimum value of the temperature are cycled through the display.
ENS 3000 Manual 4

5. Output Behavior
5.1 Switching Outputs
The ENS 3000 has 1 or 2 switching outputs. In the basic adjustments the following switching settings can be made:
5.1.1Switchpoint Function (SP)

To each switching output a switching point and a hysteresis can be set. The respective output switches if the adjusted
switching point was reached and switches back if the reset point is reached. The reset point is determined by adjusted
hysteresis (reset point = switching point minus hysteresis).
Abbreviations: “S.P.1”, “S.P.2” = Switchpoint 1 or 2

“HyS.1“, “HyS.2” = Hysteresis 1 or 2
5.1.2 Window Function (WIN)

The window function makes it possible to supervise a measured range. To each switching output, an upper and a lower
switching value can be entered, which determine the range.
The respective output switches, if the level or the temperature comes within this range. When leaving the range the
output shifts back. The lower value is just under the lower switching value (lower switching value minus 3x increment, see chap-
ter 5.4). The upper value lies just over the upper switching value (upper switching value plus 3x increment, see chapter 5.4). The
range between switching and reset value forms a security zone, which prevents unwanted oscillation of the shifting
process from taking place.
Example of switchpoint 1 (window function):
OUT
Hi. 1 plus 3xincrement Switch-back value
Hi. 1 Safety Zone Switching value
IN
IN
Lo. 1 Switching value
Safety Zone Switch-back value
Lo. 1 minus 3xincrement
OUT
t
IN
OUT
Abreviations: “HI 1”, “HI 2” = High level 1 or 2 = upper switching value 1 or 2

“Lo 1“, “Lo 2” = Low level 1 or 2 = lower switching value 1 or 2
Hint: The window function works (switching on and off) only if all switching values (including security zone) are over 0 cm or
0°C, and under the nominal measuring range.
5 ENS 3000 Manual

5.2 Analog output
Analog output signal: 4..20mA or 0..10V
Selection of the Analog Output: Level or Temperature

5.3 Adjusting switch points and hysteresis and/or switching values

for the window function
• Press the mode button.
• On the display, “S.P.1” or “Hi.1” appears
• Select the desired parameter by further pressing of the “mode” key (with switching point function, “S.P.1”, “hYS.1”, “S.P.2”,
“hYS.2” appears; with adjusted window function (WIN) “Hi.1”, “Lo.1”, “Hi.2” oder “Lo.2” appears).
• After 2 seconds the current selection flashes.
• Change the selection with and buttons.
• Press the mode key and choose the next setting to change and use and to modify the setting.
• After 3 seconds without key actuation the display resets and the changes are stored.
SP1 in SP2 2s SP1 in SP2 3s SP1 in SP2
mode mode mode

Display Actual
Switch Point 1
Keep pressing "mode" key Switching Point Change
until required parameter
is displayed = Decrease
= Increase
References:
• If “LOC” appears when attempting changes, the programming is locked. Programming should be changed to “free”
(see chapter 7 “programming releases”)
• When changing, if the key or is held, the value will continue to increase or decrease automatically.
• After changing the settings “PROG” appears in the display. The settings will then be stored in the unit.
ENS 3000 Manual 6

5.4 Ranges of adjustment for the switching outputs
Switching Point
Hystersis and/or
Lower Switching
in cm Switching Value in cm
Point in cm*
in cm*
26 0.4 to 26.0 0.1 to 25.7 0.1
36 0.5 to 36.0 0.2 to 35.6 0.1
Switching Point
Hystersis and/or
Lower Switching
in inches Switching Value in inches
Point in inches*
in inches*
10.25 0.15 to 10.25 0.05 to 10.15 0.05
14.15 0.20 to 14.15 0.05 to 14.00 0.05
5.5 Ranges of adjustment for the offset

in cm for Offset in cm* in cm
25 0 to 104 0.1
36 0 to 144 0.1

in inches for Offset in inches* in inches
16.2 0 to 64.8 0.05
20.5 0 to 82.0 0.05
7 ENS 3000 Manual

6. Basic Adjustments
For adjustment to the respective application, the behavior of the ENS 3000 can be changed over several basic adjust-
ments. These are combined into a menu.
6.1 Changing the Basic Adjustments

Important note: When changing menu functions, no switching functions are occurring!
Activate the Basic Menu Adjustment:
SP1 SP2 3s SP1 SP2 SP1 SP2
mode mode mode

Display
(release mode key)
Hold "mode" key down

while switching on Press mode key until Change menu option with
supply voltage until the required menu point
appears.Then release key. or
the message "menu"
(for summary, see 6.2)
appears on the display
Terminate the Basic Menu Adjustment:

From the menu option “END”, select “YES” which will return the ENS 3000 to the normal display mode.
Hint: If no keys have been pressed for 25 seconds the menu is terminated automatically, without possible changes
becoming effective.
ENS 3000 Manual 8

6.2 Outline of the Adjustment Menu Points
Setting Default
Choices Setting
Association of Swith Output 1 (S.S.1)
with the level measurement.
niv / TEMP niv

with the temperature measurment.
Switch Mode Function for Switch Output 1 (S.m.1)

in switch point\hysteresis mode
SP/ Win SP

in window mode.
Switching direction Switching output 1 (S 1)

Normally open function.
ON/ OFF ON
Normally closed function.
Switch-on delay switching output 1 (Ton 1)

once the switch point has been reached
Switch-off delay switching output 1 (Toff 1)

once the switch back point has been reached
The adjustment procedure for switch point 2 is the same as described above.
9 ENS 3000 Manual

Setting Default
Choices Setting
Primary display (primary)
Display function shown:
Actual pressure
niv/ niv
Level-Peak value n.Top/
n.Min/
Temp/
T.Top/
Level-Min value T.Min/
S.P.1/
S.P.2/
OFF
Actual Tempurature
Tempurature-Peak value
Tempurature-Min value
or Switchpoint 1 or 2
Display off
Dark display (see section 4 for detail)
Display
Display reacts slowly to pressure changes. SLOW/ FAST
FAST
Display reacts quickly to pressure changes.
Level Range Scale

Level indicated in inches.
inch/ cm
cm
Level indicated in centimeters.
Level Offset
A positive offset is able to be programmed 0
to account for baseline level adjustment.
ENS 3000 Manual 10

Setting Default
Choices Setting
Tempurature Range Scale
Tempurature indicated in °F
Fahr/ celc
celc
Tempurature indicated in °C
Analog signal output association (Select Output)

The signal output is assigned to the level.
niv/ niv
TEMP
The signal output is assigned to the tempurature.
Analog Signal Output

The analog output is set
to a 4-20 mA current sourcing. MAMP / VOLT
VOLT
The analog signal output is set

to a 0-10 Vdc output.
Software Version
Indicates the software version installed at time of manufacture.
Exit the adjustment menu

Select yes to exit the menu.
YES / NO NO
Select no to stay in the menu.
If menu adjustments were changed, then upon exiting “ProG” will be displayed. This notifies the user changes have
been made and stored.
11 ENS 3000 Manual

7. Reset the Peak Values
The equipment has the possibility of resetting the peak values of the level and the temperature (depending upon variant).
For resetting, proceed as follows.
SP1 inch SP2 6s 3s SP1 inch SP2 3s
mode mode
Display
(arrow keys
released)
ENS 3000 Manual 12

8. Programming Lockouts
The equipment had 2 programming releases the two given to be must around attitudes change. The operating pro-
gramming release can be set and/or waived during the enterprise. It offers protection from unintentional changes.
Closing programming over the main programming release causes that during the enterprise no change of the attitudes
can be made. This serves e.g. as safety function or as protection from bad changes.
8.1 Change for the operating programming release
SP1 inch SP2 6s 3s 2s SP1 inch SP2 3s
mode mode
Display
(arrow keys
released)
8.2 Change for the main programming release

Switch supply voltage off or separate equipment from supply voltage.
SP1 SP2 6s 2s SP1 inch SP2 3s
mode mode
Display
(arrow keys
released)
Hint: If a setting was changed, the display briefly changes to “ProG” after changing the setting. The new setting was
then stored in the equipment.
13 ENS 3000 Manual

9. Error Messages
If an error is recognized, an appropriate error message, will appear which must be acknowledged with depressing any
key. Possible error messages are:
E.01 The setpoint and hysteresis were adjusted in such a way that the resulting reset point is not within the per-
mitted range of adjustment.
Example: Setpoint of 10 in. and hysteresis of 15 in.
Action: Change setpoint or hysteresis.
E.10 A data error was recognized within the stored settings. Possible causes are strong electromagnetic distur-
bance or a defective component.
Action: Examine all settings (programming releases, switching points, reset points and basic adjustments) and cor-
rect these if necessary. If the error should arise more frequently, contact our service department.
E.20 A communication error was recognized within the equipment. Possible causes are strong electromagnetic
disturbance or a defective component.
Action: Acknowledge error by depressing any key. If the error should remain, please contact our service department.
ENS 3000 Manual 14

10. Start-up
Alignment of the level sensor on medium:
If the ENS 3000 is operated with any liquid for the first time, then the ENS 3000 automatically adjusts itself with the first
measurement automatically to the media. This characteristic offers the possibility for any medium to adjust themselves
and to compensate for changes within the medium.
Do not use with the following media:

• Strongly leading and adhering media (adhesive, shampoo, up-foaming media)
• Dry granulates with small density
• Media which are unhomogenously mixed and thus interfaces form (e.g.: water sump at the reason of a container filled with oil)
Example for the determination of the offset-value:

For the determination of the value for the tank offset we suggest the following procedure:
• First the ENS 3000 is built into the tank and/or bolted.
• Afterwards the display of the ENS 3000 flashes or indicates a value less than zero.
• The display flashes while gradually filling in a liquid to increase the level until the display indicates a zero value.
• Afterwards the ENS 3000 is taken again out of the tank and the level of the tank is measured with another measuring
device (such as a measuring stick).
• This value is entered in the menu option where units n.oFS is entered.
15 ENS 3000 Manual

11. Connection Diagrams
Wiring with 2 switching outputs

ENS 3X16-2
Imax 1.2 A
+ 1 4
SP 1
9 to 35 V
Imax 1.2 A
– 3 2
SP 2
Wiring with 1 switching output and 1 analog output

ENS 3X16-3
Imax 1.2 A
+ 1 4
SP 1
18 to 35 V
I = 4 to 40 mA
– 3 2
Analog
RL
Wiring with 2 switching outputs and 1 analog output

ENS 3X18-5 Imax 1.2 A
+ 1 4 SP 1
Imax 1.2 A
18 to 35 V 5
SP 2
– 3 I = 4 to 20 mA
2
Analog
RL
ENS 3000 Manual 16

12. Technical Data
12.1 ENS 3000 without Temperature Sensor
General
Output Data
Switching Outputs 2
Ambient Conditions
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
IEC 68-2-6 at 10 to 500Hz
Other Data
circuit protection
17 ENS 3000 Manual

12.2 ENS 3000 with Temperature Sensor
General
Temperature Principle of Sensor semiconductor senor
Measuring Range 32° to 176°F (0° to 80˚C)
Output Data
Temperature Accuracy ± 2.7°F (± 1.5°C)
Switching Outputs 2
Ambient Conditions
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
IEC 68-2-6 at 10 to 500Hz
Other Data
circuit protection
ENS 3000 Manual 18

13. Model Code
ENS 3 X X X - X - XXXX - 400
Series
ENS 3 = 3000 series Level Sensor
Temperature Sensor
1 = with temperature sensor
2 = without temperature sensor
1 = metric tube ø22mm for ZBM 19 & ZBM 20
Output
2 = 2 switch outputs
Rod Length (physical)
0162 = 16.14”
0205 = 20.47”
other lengths on request
Modification
400 = US standard
19 ENS 3000 Manual

14. Accessories
14.1. Electrical Connectors
14.1.1 For output types “ 2 “ und “ 3 “
ZBE 06 (4-pol.) 1.38"
(35mm)
Part #: 06006788 ø 0.79"
(20mm)
1.10"
(28mm)
1.04"
ZBE 06-02 with 2m length (26.5mm)
Part #: 06006790
Colour code:
ZBE 06-05 with 5m length Pin 1: brown
Part #: 06006789 1.24"
(31.50mm)
Pin 2: white
Pin 3: blue
Pin 4: black
14.1.2 For all output variants

ZBE 08 (5-pol.) 1.38"
(35mm)
Part #: 06006786 ø 0.79"
(20mm)
1.10"
(28mm)

1.04"
Part #: 06006792 (26.5mm)

Part #: 06006791 Colour code:
1.26"
(32mm)
Pin 1: brown
ZBE 08S-02 (5-pol.) with 2m shielded length Pin 2: white
Part #: 06019455
Pin 3: blue
Pin 4: black
Pin 5: grey
Part #: 06019456

Part #: 06023102
ENS 3000 Manual 20

14.2. Mechanical Adapter
14.2.1 ZBM 19 – Straight Bulkhead Union nach ISO 8434
Fits min. 1 1/8” tank hole
1.40"
(36mm)
0.87"
(22mm)
1.50"
(38mm)
1.42"
(36mm)
3.15"
(80mm)
1.61"
(41mm)
0.74"
(19mm)
14.2.2 ZBM 20 – Straight screwing in connector piece with Lock nut

G3/4 BSPP tank hole
1.40"
(36mm)
0.87"
(22mm)
1.50"
(38mm)
1.25" 2.13"
(32mm) (54mm)
G 3/4 BSPP
21 ENS 3000 Manual

15. Dimensions
ø 1.65"
(42mm)
ø 2.15" M12x1
(54.5mm)
mode
3.68"
(93.5mm)
0162
19.82"
(503.5mm)
or
0205
24.15"
(613.5mm)
0.63" 1.13"
(16mm) (28.6mm)
Inactive Range
3.69"
(93.65mm)
0.87"
(22mm)
Active Range
10.24"
(260mm)
or
14.17”
0162 (360mm)
16.14"
(410mm)
or
0205
20.47"
(520mm) 15.02"
(381mm)
Inactive Range
1.09
(27.75mm)
ENS 3000 Manual 22

16. Application Examples
tank. An alarm is to be sounded, if the fill height falls below 10 cm, and reset when exceeding the 15 cm level.
follows:


23 ENS 3000 Manual

Tank. Likewise a minimum temperature is not to be fallen below. Becomes the temperature of e.g.: 20°C is spent
reached in such a way a stop signal. Furthermore the temperature is as the 4 to 20 mA signal of a SPS map to be
made available.
follows:


ENS 3000 Manual 24

25 ENS 3000 Manual
QUICK COUPLING
Hydraulic
Quick
Couplings

Special Order Information

60 Series couplings are available in zinc plated steel, brass,
303 stainless steel, and 316 stainless steel. Brass couplings
have double O-Ring seals and stainless locking balls.
Standard seal materials are Buna-N (Nitrile); optional seal
materials are available.
For 316 stainless steel products, standard seal material is
Viton™, and other seal materials are available upon request.
See Fluid Compatibility Chart at end of this catalog.
All sizes of 60 Series can be furnished with locking sleeves.
Place suffix letters “-SL” (Sleeve-Lok) after regular catalog
numbers. Example H3-62-SL. Parker 60 Series heavy duty
nipples are recommended where high cycle rates and
pressure surges are encountered. Machined from high tensile
steel and induction hardened, they are zinc plated with a
Applications yellow chromate finish. To specify a heavy duty nipple, add
Parker general purpose couplings, are used across the the prefix “HD” to the steel part number; thus: HDH2-63.
spectrum of hydraulic applications. These Double Shut-Off
couplings can be found anywhere that fluid transfer lines
need to be connected and disconnected for operation or
maintenance of equipment, and a loss of fluid is undesirable. Note
Primarily used with hydraulic fluid, general purpose Double
Shut-Off couplings are also used with chemicals, water, Protective dust plugs and caps play a crucial role in the life of
steam, and some gases. a quick coupling and no purchase of a hydraulic quick
coupling is complete without the selection of an appropriate
dust plug and cap. See pages noted in Table of Contents for
dust plugs and caps for the Parker full line of hydraulic
couplings.
Specifications
ANSI/ISO Pressure Rating: Dynamic applications with normal to moderate hydraulic Low Cycle, Non-pulsating Pressure Rating: Applications with lower cycle
shocks such as general industrial equipment, hydraulic presses, agricultural equip- life and no severe cyclic pressure fluctuations, essentially steady pressure during
ment, etc. Impulse tested at a multiple (125% to 133%) of rated pressure. an operating cycle. Typical applications include hydraulic jacks, mine roof
support systems, and high pressure fluid transfer (pumping water or slurry in
oil wells). Minor pump ripple is considered non-pulsating. Impulse tested at rated
pressure.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Pressure (PSI) Rated Pressure (PSI)
Brass 1000 1000 1000 1000 1000 1000 800 800 3000 3700 2700 3500 2200 1500 1500 1200
Stainless steel 2000 2000 1500 1500 1500 1000 1000 1000 5000 5000 5000 5000 3000 3000 1500 1500
Steel 5000 5000 4000 4000 2500 2000 1000 1000 5000 5000 4000 4000 2500 2000 1500 1500
Steel w / HD N/A 5000 4000 4000 3000 3000 N/A N/A 5000 5000 4000 4000 3000 3000 N/A N/A
nipple
Temperature Range: Standard seals (Buna-N) -40° to +250° F Optional Viton seals -10° to +400° F
Vacuum Data: 27.4 inches Hg. both connected and disconnected (1-1/2" and 2-1/2" body size 60 Series couplings are not reccommended for service in diconnected mode)
Note: Read the Safety Guide for Selecting and Using Quick Action Couplings and Related Accessories before making a coupling selection. It may be found in
Parker Hannifin Quick Coupling Divison catalogs and is available as Parker Publication No. 3800-B1.0.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Flow (GPM) .8 3 6 12 28 50 100 200

4. Hardened nipples and sleeves (steel) and solid barstock

4 construction make for a quality coupling with maximum re-
6 sistance to damage from hydraulic and mechanical shock.
5. The seal is designed to withstand high pressures and pro-
vide reliable sealing. A wide selection of optional seal ma-
terials are available, see Fluid Compatibility Chart at end
2 of this catalog for selection assistance. Steel versions fea-
9
1 ture Teflon™ back-up rings that support mating seals for
high pressure applications. Brass couplers have a double
O-ring seal for redundancy in low pressure, vacuum and
steam applications.
3 5 1 6. Durable ball-locking mechanism assures reliable connec-
tion, every time. A large number of locking balls distributes
7 2 the work load evenly while providing alignment and swivel-
ing action to reduce hose torque and prolong hose life.
7. Manufactured from brass, steel and stainless steel as
Features
standard materials. A wide range of seals allow these
1. Large flow areas machined into the body of the coupler couplings to be used with a broad range of media.
and nipple facilitate flow around the valve, for a high flow 8. Industry-wide interchangeability. Parker 60 Series couplers
capacity. and nipples are the “Industrial Interchange” design and
2. Positive valve stop. The perch maintains valve alignment meet the dimensional requirements of Series B in ISO
and provides metal to metal valve stop to ensure that the 7241-1.
valves open fully, every time. 9. Also available with a Straight Thread (ORB) end configura-
3. Captive valve seal assures “bubble tight” poppet sealing. tion available as standard, for reduced leakage.
The valve seal is positively captured by the metal poppet to
minimize seal washout or damage from high velocity fluid.
Performance
60 Series (1/8;1/4") 60 Series (3/8;1") 60 Series (11/2;21/2")
Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS
30 30 200 200
40 40
30 30
2-1/2"
20 20 100 100
80 80
20 20
1/8" 60 60
1/4" 50 50
1/2" 1" 40 40
10 10

3/8" 3/4"
9 9 30 30
8 8 10 10
9 9 1-1/2"
7 7 8 8 20 20
6 6 7 7
5 5 6 6
5 5 10 10
4 4 8 8
4 4
3 6 6
3
5 5
3 3
4 4
2 2 3 3
2 2
2 2
1 1 1 1 1
1
.2 .3 .4 .5 .6 .7 .8 .9 1 2 3 4 1 2 3 4 5 6 7 8 910 20 40 60 80 10 20 30 40 50 60 80 100 200 300
Flow in USGPM Flow in USGPM Flow in USGPM

Couplers A
Female Thread
A B C
1/8 BH1-60 0.16 H1-62 0.16 SH1-62 0.16 SSH1-62Y** 0.15 1/8-27 – 1.90 0.68 0.96
1/8 – – H1-62-T4 0.18 SH1-62-T*4 0.10 SSH1-62Y-T4 0.17 – 7/16-20 2.06 0.68 0.96
1/4 BH2-60 0.32 H2-62 0.30 SH2-62 0.30 SSH2-62Y 0.30 1/4-18 – 2.26 0.81 1.14
1/4 – – H2-62-T6 0.31 SH2-62-T6 0.31 SSH2-62Y-T6 0.31 – 9/16-18 2.41 0.81 1.14
3/8 BH3-60 0.43 H3-62 0.40 SH3-62 0.40 SSH3-62Y 0.40 3/8-18 – 2.49 0.88 1.40
3/8 – – H3-62-T8 0.51 SH3-62-T8 0.51 SSH3-62Y-T8 0.51 – 3/4-16 2.75 1.00 1.40
1/2 BH4-60 0.80 H4-62 0.73 SH4-62 0.75 SSH4-62Y 0.76 1/2-14 – 2.87 1.12 1.77
1/2 – – H4-62-T10 0.78 SH4-62-T10 0.75 SSH4-62Y-T10 0.78 – 7/8-14 3.05 1.12 1.77
3/4 BH6-60 – H6-62 1.30 SH6-62 1.31 SSH6-62Y 1.33 3/4-14 – 3.56 1.31 2.14
3/4 – – H6-62-T12 1.39 SH6-62-T12 1.34 SSH6-62Y-T12 1.40 – 1-1/16-12 3.56 1.31 2.14
1 BH8-60 – H8-62 1.95 SH8-62 1.95 SSH8-62Y 1.95 1-11 1/2 – 4.18 1.62 2.52
1 – – H8-62-T16 1.95 SH8-62-T16 1.95 SSH8-62Y-T16 1.95 – 1-5/16-12 4.18 1.62 2.52
Nipples D
Female Thread
D E F G
1/8 BH1-61 0.04 H1-63 0.03 SH1-63 0.03 SSH1-63Y** 0.04 1/8-27 – 1.61 0.41 0.56 0.65
1/8 – 0.06 H1-63-T4 0.05 SH1-63-T*4 – SSH1-63Y-T4 0.06 – 7/16-20 1.32 0.57 0.69 0.79
1/4 BH2-61 0.09 H2-63 0.08 SH2-63 0.08 SSH2-63Y 0.08 1/4-18 – 1.39 0.65 0.75 0.87
1/4 – 0.11 H2-63-T6 0.10 SH2-63-T6 0.10 SSH2-63Y-T6 0.10 – 9/16-18 1.54 0.70 0.88 1.01
3/8 BH3-61 0.10 H3-63 0.12 SH3-63 0.12 SSH3-63Y 0.12 3/8-18 – 1.50 0.54 0.88 1.01
3/8 – 0.12 H3-63-T8 0.16 SH3-63-T8 0.16 SSH3-63Y-T8 0.14 – 3/4-16 1.76 0.80 1.00 1.15
1/2 BH4-61 0.25 H4-63 0.24 SH4-63 0.24 SSH4-63Y 0.24 1/2-14 – 1.75 0.69 1.12 1.30
1/2 – 0.28 H4-63-T10 0.27 SH4-63-T10 0.27 SSH4-63Y-T10 0.27 – 7/8-14 1.94 0.87 1.19 1.37
3/4 BH6-61 0.50 H6-63 0.46 SH6-63 0.45 SSH6-63Y 0.46 3/4-14 – 2.16 0.79 1.38 1.59
3/4 – 0.55 H6-63-T12 0.46 SH6-63-T12 0.50 SSH6-63Y-T12 0.50 – 1-1/16-12 2.27 0.90 1.34 1.59
1 BH8-61 0.76 H8-63 0.76 SH8-63 0.76 SSH8-63Y 0.76 1-11 1/2 – 2.91 0.99 1.62 1.88
1 – 0.80 H8-63-T16 0.80 SH8-63-T16 0.80 SSH8-63Y-T16 0.80 – 1-5/16-12 2.91 0.99 1.62 1.88*
Optional Seals Optional Seals Suffix*
60 Series W Ethylene Propylene (EPR)

Y Standard Viton™ Seals
Z Neoprene
-264 Perfluoroelastomer (Kalrez)™
* See Ordering Information at end of Section B.

A
Couplers
Female Thread
C
A B C
1 1/2 BH12-60L 4.58 H12-62L 4.70 SH12-62L 4.68 SSH12-62LY** 4.68 1 1/4-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 BH12-60N 4.58 H12-62N 4.70 SH12-62N 4.68 SSH12-62NY 4.68 1 1/2-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T20 4.72 SH12-62-T20 4.71 SSH12-62Y-T20 4.71 – 1 5/8-12 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T24 4.72 SH12-62-T24 4.71 SSH12-62Y-T24 4.71 – 1 7/8-12 4.86 2.38‡ 3.00
2 1/2 BH2016-60 11.06 H2016-62 10.58 SH2016-62 – SSH2016-62Y – 2-11 1/2 – 5.57 3.75 4.10
2 1/2 BH2020-60 11.42 H2020-62 10.91 SH2020-62 – SSH2020-62Y – 2 1/2-8 – 6.04 3.75 4.10
2 1/2 BH2024-60 – H2024-62 – SH2024-62 – SSH2024-62Y – 3-8 – 6.96 4.00 4.35
‡Wrench Flat on 303 Stainless is 2.50 in.
D
Nipples E
Female Thread
G
D E F G
1 1/2 BH12-61L 2.96 H12-63L 3.10 SH12-63L 3.06 SSH12-63LY** – 1 1/4-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 BH12-61N 2.96 H12-63N 3.10 SH12-63N 3.06 SSH12-63NY – 1 1/2-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T20 3.15 SH12-63-T20 3.14 SSH12-63Y-T20 – – 1 5/8-12 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T24 3.15 SH12-63-T24 3.14 SSH12-63Y-T24 – – 1 7/8-12 4.76 2.69 2.38‡ 2.75†
2 1/2 BH2016-61 7.78 H2016-63 7.90 SH2016-63 7.92 SSH2016-63Y – 2-11 1/2 – 5.48 2.90 3.75 4.10
2 1/2 BH2020-61 8.12 H2020-63 8.16 SH2020-63 8.16 SSH2020-63Y – 2 1/2-8 – 5.95 3.37 3.75 4.10
2 1/2 BH2024-61 – H2024-63 – SH2024-63 – SSH2024-63Y – 3-8 – 6.87 4.29 4.00 4.35
† Largest diameter on Brass is 2.96" across Hex Corners
‡Hex on 303 Stainless is 2.50 in.
Replacement Parts Repair Kits

60 Series Couplers Couplers Nipples
Body Repair Kit Used For Repair Kit Used For
Body Size (in.) O-Rings - Buna N Back-Up Rings Size (in.) Part No. Part No. Part No. Part No.
3/8 H67E-62K H3-62 H67E-63K H3-63
1/8 2-013N0674-70 H67A-28 BH67E-60K BH3-60 BH67E-61K BH3-61
1/4 2-015N0674-70 H67C-28 SH67E-62 SH3-62 SH67E-63K SH3-63
3/8 2-116N0674-70 4118007 SSH67-62K SSH3-62Y SSH67E-63K SSH3-63Y
1/2 2-213N0674-70 4128002 1/2 H67F-62K H4-62 H67F-63K H4-63
3/4 2-218N0674-70 4148001 BH67F-60K BH4-60 BH67F-61K BH4-61
1 2-222N0674-70 4158001 SH67F-62 SH4-62 SH67F-63K SH4-63
1-1/2 2-124N0674-70 2-138N0552-90 SSH67F-62K SSH4-62Y SSH67F-63K SSH4-63Y
(Valve) (Fitting) 3/4 H67G-62K H6-62 H67G-63K H6-63
2-224N0674-70 BH67G-60K BH6-60 BH67G-61K BH6-61
(Body 2 req.)
SH67G-62 SH6-62 SH67G-63K SH6-63
2-1/2 2-133N0674-70 2-234N0674-70 SSH67G-62K SSH6-62Y SSH67G-63K SSH6-63Y
(Valve) (Fitting)
1 H67J-62K H8-62 H67J-63K H8-63
2-333N0674-70
(Body)
BH67J-60K BH8-60 BH67J-61K BH8-61
SH67J-62 SH8-62 SH67J-63K SH8-63
SSH67J-62K SSH8-62Y SSH67J-63K SSH8-63Y

Hydraulic Quick Couplings 60 Series Steam Couplings
Specifications
Body Size (in.) 1/4 to 1
Rated Pressure (PSI)
with saturated steam at 338°F 100
Temperature Range (std seals) Ethylene Propylene
Continuous +250°F
Intermittent +400°F
Coupler
Female Pipe Thread
Size No. Size Overall Wrench Largest Wt. (LB.)
(in.) Brass NPTF Length Flats Diameter P/Piece
A B C G
1/4 BH2-60-STM 1/4-18 2.26 0.81 1.14 0.30
3/8 H3-68 3/8-18 2.50 0.88 1.77 0.50
1/2 BH4-60-STM 1/2-14 2.87 1.12 1.77 0.75
A
3/4 BH6-60-STM 3/4-14 3.56 1.31 2.14 1.31
1 BH8-60-STM 1-11 1/2 4.18 1.62 2.52 1.95
C
Nipple
Female Pipe Thread

Size No. Size Overall Exposed Hex Largest Wt. (LB.)
(in.) Brass NPTF Length Length Size Diameter P/Piece
D E F G
1/4 BH2-61-STM 1/4-18 1.39 0.65 0.75 0.87 0.08
3/8 H3-69 3/8-18 1.50 0.52 0.88 1.01 0.13
D
E 1/2 BH4-61-STM 1/2-14 1.75 0.69 1.12 1.30 0.24

3/4 BH6-61-STM 3/4-14 2.16 0.79 1.38 1.59 0.46
1 BH8-61-STM 1-11 1/2 2.91 0.99 1.62 1.88 0.76
G
Repair Kits
Body Repair Kit Used For
Steam Coupling Size Part No. Part No.
3/8 H68E-67K H3-68
3/8 H69E-67K H3-69

Dust Plugs and Dust Caps
Hydraulic Quick Couplings
Applications
Parker offers a complete line of dust plugs and caps for their Protective dust plugs and caps play a crucial role in the use of
hydraulic quick couplings. Each series shown in this catalog quick couplings and no purchase of a hydraulic quick coupling
has a dust plug and cap specifically designed to be used with is complete without the selection of an appropriate dust plug
that style of coupling. and cap. When ordering the dust cap/plug body size must
correspond to that of the coupler or nipple.
Dust plugs and caps serve a twofold function. They keep the
mating surface clean and free of contamination and protect Parker’s full line of dust plugs and caps can be found below
the critical mating elements of the coupling halves when they and on the following pages.
are disconnected. In this way the nipple is protected from
damage that would make the total coupling unusable. Dust Plug: Used on Coupler (female half)
Dust Cap: Used on Nipple (male half)
Dust Plugs
Body Dust Plug Dust Plug Dust Cap Dust Cap
60 Series Size Part No. Part No. Part No. Part No.
(in.) Aluminum Geolast Aluminum Geolast
1/8 H1-65 H1-65M H1-66 H1-66M
1/4 H2-65 H2-65M H2-66 H2-66M
3/8 H3-65 H3-65M H3-66 H3-66M
1/2 H4-65 H4-65M H4-66 H4-66M
3/4 H6-65 H6-65M H6-66 H6-66M
1 H8-65 H8-65M H8-66 H8-66M
1 1/2 H12-65 NA H12-66 NA
2 1/2 H20P-65 NA H20P-66 NA
NA = Not Available
6600 Series Body Dust Plug Dust Cap

Size Part No. Part No.
(in.) Rubber Rubber
1/4 H1-65M H166M
3/8 TR-37 TR-37
1/2 5205-4M 5209-4M
3/4 6659-12M 6657-12M
1 6659-16M 6657-16M
SM Series Body Size Dust Plug Dust Cap

(in.) Part No. Part No. Material
1/4 PL-25 N/A Plastic
1/4 PR-25 CR-25 Rubber
1/2 DP-50 DC-50 Rubber

HEAT EXCHANGER [AIR-OIL]
PRESSURE SWITCH
Pressure Switches
EDS 3000
About EDS 3000 Pressure Switches:
The EDS 3000 electronic pressure switch is the result of joint development and
innovation in the field of adjustable pressure switches with display. It is a compact
unit which combines a pressure switch, digital display, and transducer for controlling
pressure in hydraulic and pneumatic applications. The most noticeable innovation
350˚ is the alignment of the serial four-digit display. After mounting, the switch may be
turned as a whole. Additionally, the front panel with push buttons may be turned.
270˚ This eliminates the need for mechanical adapters. Display units can be shown in
bar, psi, or mpa. It is also possible to scale the pressure range to any desired
engineering unit, such as force or tonage. Pressure ranges from vacuum to 9000
psi are available. Switching outputs in one or two switch versions with or without
analog output are available when choosing model code.
Technical Details:
Input Data
Applications:
Measuring ranges (type 1) 0 to 15, 50 psi
(type 3) 0 to 15, 30, 50, 150, 250, 500 psi
-14 to 75 psi
(type 4) 0 to 1000, 3000, 6000, 9000 psi
Overload pressure 200%FS max. 900 bar (13000 psi)
Burst pressure 300%FS max. 2000 bar (29000 psi)
G 1/4 A male, 1/4”-18 NPT male
Mechanical Connection SAE 6 9/16-18 UNF2A male
Tightening torque approx. 15 lb-ft (20 Nm)
Parts in contact (types 1 & 3) Stainless steel, ceramic, FPM seal
with media (type 4) Stainless steel, FPM seal
Output Data
Accuracy (B.F.S.L) ≤ ±0.5 %FS
including linearity & hysteresis
Temp. comp. zero point ≤ ±0.017%FS/°F max.
Temp. comp. over range ≤ ±0.017%FS/°F max.
4 to 20 mA, ohmic resistance ≤ 500Ω
Analog output signal, adjustable 0 to 10 V, ohmic resistance ≥ 1k Ω
Switching Outputs
Type PNP transistor output
Repeatability ≤ ±0.5%FS max.
Switching current max. 1.2 A
Switching cycles ≥ 100 million
Reaction time < 10 ms
Ambient Conditions
Nominal temperature range -13° to 185°F (-25° to 85°C)
Ambient Temperature range -13° to 176°F (-25° to 80°C)
Fluid temperature range -13° to 176°F (-25° to 80°C)
EN 61000-6-1, EN 61000-6-2
mark EN 61000-6-3, EN 61000-6-4
Vibration resistance ≤ 10g / 0 to 500Hz (IEC 60068-2-6)
Shock resistance ≤ 50g / 11ms (IEC 60068-2-29)
Safety type to DIN 40050 IP 67 (molded M12x1 connector is used)
Approvals:
Other data
Supply voltage 9 to 35 VDC for signal 1,2
18 to 35 VDC for signal 3, 5
Electrical connection M12x1 (4 pin or 5 pin)
Current consumption approx. 100 mA (without switching output)
Reverse polarity protection of the
supply voltage, excess voltage, standard
override and short circuit protection
Display 4 digit, 7 segment LED red
Weight approx. 300 g
25 Electronics Catalog
Model Code:
EDS 3 X X X - X - XXXX - 400 X 1
Series
EDS 3 = 3000 Series Electronic Sensor
Sensor Type
1 = Ceramic absolute
3 = Ceramic relative
4 = Thin-film relative
4 = G 1/4 BSPP male thread*
8 = 1/4” - 18 NPT male thread
7 = SAE-6 male thread (9/16-18 UNF2A)
6 = M12x1 plug, 4 pole for output codes 1, 2, and 3 (connector not included)
8 = M12x1 plug, 5 pole for output code 5 (connector not included)
Output
1 = 1 Switch output (only with electrical connection 6)
2 = 2 Switch outputs (only with electrical connection 6)
Pressure Ranges
Type 1 (ceramic - absolute) Type 3 (ceramic - relative) Type 4 (thin-film, relative)
0050 = 0 to 50 psi 0089 = -14 to 75 psi 6000 = 0 to 6000 psi
0150 = 0 to 150 psi 9000 = 0 to 9000 psi
Modification Number
400 = standard in psi
Sealing Material (in contact with media)
F = FPM seal (to be used for example with hydraulic fluid)
E = EPDM seal (to be used for example with refrigerant coolant or fluids containing ammonia)
Material for Mechanical Connection / Housing (in contact with media)
1 = Stainless Steel
* G 1/4 port sizes are available upon request
Plug Connection:
EDS 3XX6 EDS 3XX8 use with ZBE 06 (4-pole) & ZBE 08 (5-pole)
(4-pole) (5-pole) (see page 60)
4 3 4 3
1 2 1 5 2
Circuit Connection:
Model with 1 switch output Model with 1 switch output
Plug 4-pol. M12x1 and signal output Dimensions: ø 1.65"
M12x1
(42mm)
Plug 4-pol. M12x1
ø 2.15" (54.5mm)
EDS 3X46-1 EDS 3X46-3
Imax 1.2 A
+ 1 + 1 4
Imax 1.2 A SP 1
9 to 35 V 4 18 to 35 V
SP 1 I = 4 to 20 mA
– 3 – 3 2
Analog
RL
3.68"
(93.5mm)
mode
2.95"
(75mm)
Model with 2 switch outputs Model with 2 switch outputs
Plug 4-pol. M12x1 and signal output
Plug 5-pol. M12x1
EDS 3X46-2 EDS 3X48-5 Imax 1.2 A
Imax 1.2 A
+ 1 4 + 1 4
SP 1 SP 1
9 to 35 V Imax 1.2 A
Imax 1.2 A 18 to 35 V 5 0.47"
2 SP 2 (12mm)
– 3 – I = 4 to 20 mA
3 2
SP 2
Analog ø 1.16"
RL SAE 6 (29.5mm)
0.63"
6kt-SW27 (16mm)
1-877-GO HYDAC Electronics Catalog 24

OIL IMMERSION HEATER
Chromalox
®
SERVICE REFERENCE
DIVISION 4 SECTION ARTM
SALES
REFERENCE (Supersedes PD419-8) PD419-9
161-058027-001
DATE SEPTEMBER, 2002
Screwplug Immersion Heaters

(ARTM, ARTMO, ARTMS and ARTMI)
11/8” 7/ ” Dia. Hole For 1/ ” BX Connector
8 2 11/4” Pipe Outlet
(One Outlet Plugged)
1” Std. Well for 11/8” Ref.
Pipe Threads Thermostat
Bulb
35/16” 61/4”
Dia.
B ± 1/4”
53/16”± 1/16”
1” Approx. Cold End
1” Approx. Cold End 11/8”
51/16” 11/2”
Removable 3” B ± 1/4”
Cover 11/2” Type E2 Terminal Enclosure
Type E1 Terminal Enclosure Moisture Resistant/Explosion Proof
General Purpose (Rotatable) (E4 Moisture Resistant is available)
GENERAL
Chromalox types ARTM (copper sheath), ARTMO (steel sheath), (ARTMO) and stainless steel (ARTMS) and (ARTMI).
ARTMS (stainless steel sheath) and ARTMI (INCOLOY® sheath) C. Medium to high watt densities.
screwplug immersion heaters are designed for a wide variety of heat- D. Built-in thermostat standard with ranges of 0-127˚F, 60-180˚F
ing applications. and 60-240˚F.
E. Broad selection of sheath materials to operate successfully in
many corrosive solutions. Note: Proper selection of the sheath
material is the sole responsibility of the customer.
IMPORTANT: It is the responsibility of the purchaser F. E1 (General Purpose), E2 (Moisture Resistant/Explosion
of the heater to make the ultimate choice of sheath Proof) and E4 (Moisture Resistant, not shown) terminal hous-
material based upon his knowledge of the chemical ings are standard.
composition of the corrosive solution, character of the
materials entering the solution, and controls which he
maintains on the process.
Heater Construction Characteristics: The system designer is responsible for the safety of
A. High quality resistance wire held in place by compacted this equipment and should install adequate back-up
Magnesium Oxide refractory enclosed in a wide variety of controls and safety devices with their electric heating
sheath materials. equipment. Where the consequences of failure could
B. 1” NPT Screwplug is standard in brass (ARTM), steel result in personal injury or property damage, back-up
controls are essential.
INSTALLATION
This Portion of the Heater Above Liquid Level and
Expected Low Liquid Exposed to Air Will Lead to Premature Burnout of Element
ELECTRIC SHOCK HAZARD. Disconnect all power Level
before installing or servicing heater. Failure to do so
could result in personal injury or property damage.
Heater must be installed by a qualified person in accor- WRONG
dance with the National Electrical Code, NFPA 70.
RIGHT
1. Before installing, check your type ARTM immersion heater
for any damage that may have occurred during shipment. Expected Maximum
Sediment Level
2. Check to insure that the line voltage is the same as that stamped
on the nameplate. Note: Locate Heater as low as possible for maximum heated liquid storage
3. Do not bend the heating elements. If bending is necessary, capacity. Heat does not move downward.
check factory. Figure 1 - Open Tank Installation
4. IMPORTANT: Mount heater in the tank so the liquid level will
always be above the effective heated portion of the heater (see
Figure 1).
© 2002 Chromalox®, Inc
INSTALLATION
If the heater is not properly submerged, the heating elements will Drip loop recommended
overheat and create heater damage or a possible fire hazard due to to minimize passage of moisture
along wiring into terminal
Outlet
excessive sheath temperatures. wiring and connections
5. Where work will pass over or near equipment, additional protec-

tion, such as a metal guard, may be needed. Suitable
Wiring
1-1/2” 1” Approx. Cold End
Inlet
Maximum Sediment Level.

Install Heater Above
Locate Drain Pipe at Bottom of Heater. This Level But As
Sediment Deposits may be Near to it as Possible for Maximum
Removed Through Drain Pipe Heated Water Storage Capacity
Figure 4 - Closed Tank in Vertical Position
Provisions should be made to prevent damage from

Heavy Tank Walls may be drilled and tapped - if thickness is sufficient to engage any eventual leaking of tank or components.
3/4 of threads. Failure to comply could result in personal injury or
Lighter Tank Walls must be equipped with suitable pipe coupling attached with property damage.
proper solder or weld material.
9. Adjustment Instructions for Rotating Housing (E1) Only —
WARNING: Care must be taken to insure the heated portion does not extend into
the coupling area (see Dimensions). SCREWPLUG #10-32 COVER SCREWS #8-32 BASE MOUNTING
(FOR REFERENCE) 3 REQ’D (180˚ APART) (ITEM “B”) SCREWS (3 REQ’D) (ITEM “C”)
Figure 2 - Exploded View Screwplug Mounting
ROTATING BASE WITH
CONDUIT OPENING
6. Heater must not be operated in sludge.
7. Install the heater using a high quality pipe sealing compound on the
threads. Screw the heater into the opening (Figure 2). Tighten suf-
ficiently with wrench applied on the hex portion of the screwplug.
8. Closed Tank Installation ADAPTER PLATE
(ITEM “B”) NEMA 1 COVER

Figure 5 (ITEM “A”)
WARNING: When heating in closed vessels, controls A. After tightening the heater into the tank opening. The terminal
and back-up controls must be used to regulate housing can be rotated to a more convenient position to install
buildup of temperature and/or pressure. the power feed.
A. Horizontal Position (Figure 3) B. Remove the terminal box cover (Item A) by loosening the three
A1.Place heater at an elevation so that natural circulation can cover screws (Item B) (do not completely remove the screws
take place. since the cover holes are open slotted).
Note: In A Forced Circulation System,
C. To rotate the terminal housing base, loosen the three mounting
Figure 3 - Closed Tank in Horizontal Position
Use Pump On Inlet Side. screws (Item C) until the base rotates freely (do not complete-
ly remove).
D. Turn the base until the conduit opening is on the desired position.
Outlet Inlet E. Tighten the base mounting screws securely (Item C).
CAUTION: Do not over tighten.
Heater
F. Follow the rest of the screwplug installation instructions to
complete installation.
A2.Position outlet and inlet in a vertical plane, facing upward to

prevent air pockets. Be sure all trapped air is removed from the FREEZE HAZARD. This unit may be equipped with
closed tank. Bleed the air out of the liquid piping system and a thermowell for process control or over-tempera-
heater housing prior to operation. ture control. Do not allow moisture to accumulate
A3.IMPORTANT: Heater should never be located at the highest in thermowell. Freezing temperatures can cause
point of the liquid system. Provide expansion tank, if necessary. damage that may result in the heated medium
leaking into terminal enclosure.
10. To prevent moisture accumulation in cryogenic applications or
when heater is exposed to freezing temperatures:
FIRE HAZARD. If heater is not properly submerged, A. Slope conduit away from housing (drip loop).
the heating elements will overheat and could result in B. Seal all conduit openings to moisture/explosion resistant ter-
a fire or damaged equipment. minal enclosure.
B.Vertical Position (See Figure 4) C. Insulate terminal enclosure.
D. Fill thermowell(s) with silicone fluid when heater is mounted
with terminal enclosure up.
FIRE HAZARD. Since heaters are capable of devel-

oping high temperatures, extreme care should be
taken to: FIRE OR SHOCK HAZARD. Moisture accumulation in
A. Use explosion-proof terminal housing in hazardous locations. the element refractory material, element or overtem-
See Chromalox catalog for selection of explosion-proof termi- perature, or sheath, generating arcing and molten
nal housing for hazardous locations. metal. Install Ground Fault Circuit-Interrupter (GFCI)
B. Avoid contact between heaters and combustible material. to prevent personal injury or Equipment Ground Fault
C. Keep combustible materials far enough away to be free of the Protection to prevent property damage.
effects of high temperatures.
WIRING
4. If flexible cord is employed, a watertight connector should be used
for entry of the cord into the terminal housing. Outdoor applica-
ELECTRIC SHOCK HAZARD. Any installation involv- tions require liquid-tight conduit and connectors.
ing electric heaters must be performed by a quali- 5. Bring the power line wires through the opening in the terminal-
fied person and must be effectively grounded in housing. Connect line wires as shown in the wiring diagram
accordance with the National Electrical Code to (Figure 6).
eliminate shock hazard.
1. Electric wiring to heater must be installed in accordance with the Thermostat
National Electrical Code and with local codes by a qualified per-
son. Use copper conductors only.
2. When element wattages are not equal, heaters must not be con- L1
nected in series.
3. Electrical wiring to heater equipped with a moisture resistant hous-
ing should be contained in rigid conduit or in sealed flexible hose L2
to keep corrosive vapors and liquids out of the terminal housing. If
high humidity is encountered, the conduit should slope down away Figure 6
from the heater.
OPERATION
1. Do not operate heaters at voltages in excess of that stamped on the insulation resistance of less than twenty megohms. Normally, this
heater since excess voltage will shorten heater life. megohm value corrects itself after heatup and does not affect
2. Always maintain a minimum of 2” of liquid above the heated por- heater efficiency or life.
tion of the element to prevent exposure of the effective heated
length. If the heater is not properly submerged, it may overheat and A low megohm condition can be easily corrected by removing the
damage heating elements, tank or contents. DO NOT OPERATE terminal housing and baking the heater in an oven at 350˚F for sev-
HEATER IF DRY. eral hours, preferably overnight. Note: Before baking, the lid must
3. Be sure all trapped air is removed from a closed tank. Bleed the air be removed from an E2 housing. The housing and screwplug gas-
out of the liquid piping system and heater housing prior to ener- ket must be removed from E4 models.
gizing.
Note: The tank or heating chamber in closed tank systems An alternate procedure is to disconnect the thermostat and energize
must be kept filled with liquid at all times. the heater(s) at low voltage until the megohm reading returns to
4. Keep heating elements above sediment deposits. normal. When energizing heater(s) in air, the sheath temperatures
5. Low Megohm Condition — The refractory materials used in elec- should not exceed 400˚F for copper and 750˚F for steel and alloy
tric heaters may absorb moisture during transit or when subject to elements.
a humid environment. This moisture absorption results in a cold
MAINTENANCE
3. Remove any accumulated sludge deposits from heater and
from tank.
ELECTRIC SHOCK HAZARD. Disconnect all power 4. Check for loose terminal connections and tighten if necessary.
before installing or servicing heater. Failure to do 5. If corrosion is indicated in the E2 or E4 terminal housing,
so could result in personal injury or property dam- check terminal box gasket and replace if necessary. Check screw-
age. Heater must be installed by a qualified person plug gasket on E4 models and replace if necessary. Check conduit
in accordance with the National Electrical Code, layout to correct conditions that allow corrosion to enter the termi-
NFPA 70. nal housing.
1. Heaters should be checked periodically for coatings and corro- 6. Clean terminal ends of all contamination.
sion and cleaned if necessary. 7. Check thermostat for proper identification.
2. The tank should be checked regularly for sediment around
the heater as sediment can act as an insulator and shorten heater life.
RENEWAL PARTS IDENTIFICATION
Thermostats General-Purpose Terminal Enclosure

0 - 127˚F . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-019560-007 Terminal Cover . . . . . . . . . . . . . . . . . . . . . . . . .306-018167-001
60 - 180˚F . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-019560-002 Conduit Bracket . . . . . . . . . . . . . . . . . . . . . . . .027-018183-001
60 - 240˚F . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-019560-003 Cup Sub-Assembly . . . . . . . . . . . . . . . . . . . . . .194-018181-003
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and the work (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii) refund an equitable por-
performed by Chromalox when performed, will meet all applicable specification and other specific product and tion of the purchase price.
work requirements (including those of performance), if any, and will be free from defects in material and work- THE FOREGOING IS CHROMALOX'S ONLY OBLIGATION AND BUYER'S EXCLUSIVE REMEDY FOR BREACH OF
manship under normal conditions of use. All claims for defective or nonconforming (both hereinafter called defec- WARRANTY, AND IS BUYER'S EXCLUSIVE REMEDY AGAINST CHROMALOX FOR ALL CLAIMS ARISING HERE-
tive) Products, parts or work under this warranty must be made in writing immediately upon discovery, and in any UNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT
event, within one (1) year from delivery, provided, however all claims for defective Products and parts must be (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, BUYER'S FAILURE TO SUBMIT A
made in writing no later than eighteen (18) months after shipment by Chromalox. Defective and nonconforming CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF,
items must be held for Chromalox's inspections and returned to the original f.o.b. point upon request. THE FORE- INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS. IN NO EVENT SHALL BUYER BE ENTI-
GOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATU- TLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND BUYER SHALL HOLD CHROMALOX HARMLESS
TORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS THEREFROM. ANY ACTION BY BUYER ARISING HEREUNDER OR RELATING HERETO, WHETHER BASED ON
FOR A PARTICULAR PURPOSE. BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, MUST
Notwithstanding the provisions of this WARRANTY AND LIMITATION Clause, it is specifically understood that BE COMMENCED WITHIN ONE (1) YEAR AFTER THE DATE OF SHIPMENT OR IT SHALL BE BARRED.
Products and parts not manufactured and work not performed by Chromalox are warranted only to the extent and W2008M
in the manner that the same are warranted to Chromalox by Chromalox's vendors, and then only to the extent that
Chromalox is reasonably able to enforce such warranty, it being understood Chromalox shall have no obligation
to initiate litigation unless Buyer undertakes to pay all cost and expenses therefor, including but not limited to attor-
ney's fees, and indemnifies Chromalox against any liability to Chromalox's vendors arising out of such litigation.
Upon Buyer's submission of a claim as provided above and its substantiation, Chromalox shall at its option either
2150 N. RULON WHITE BLVD., OGDEN, UT 84404

Phone: 1-800-368-2493 www.chromalox.com TA - W2 - EF
Litho in U.S.A.
SUCTION BUTTERFLY VALVE
BUTTERFLY VALVES
1. General 2. Technical Data:
HyrdoWer is a globally recognized manufacturer of power unit Operating Pressures:
accessories. They have become specialists in the design of Maximum pressure: 232 p.s.i.
Butterfly Valves and Hydraulic Compensators. Negative pressure: 10 p.s.i.
Pressure difference: 58 p.s.i.
The shut off valve is installed into the pump suction line. The (per side when valve is closed)
valve has a SAE (4 - bolt flange) connection, SAE standard
J518. Material:
Body + Shift Handle : Aluminum
The valve can be actuated with or without the shift handle Seals: NBR
(option H) and the locking bolt will automatically snap the valve Other Parts: Steel Galvanized
into the open or closed position.
The optional tank flange (T-option) can be welded to the

reservior, giving a bolting surface for the butterfly valve. A limit
switch (E-option) can be mounted to the top of the valve. 3. Ordering Code:
Explosion-proof limit switches are available.
AB 16 S [NG] - T H B E Additional description
Basic equipment item #4
Limit-switch (see option #8)
Tapped bushings (see option #7)

4. Butterfly Valve: AB 16 [NG]
Shifter (see option #6)
Tank welded (see option #5)
Pump side Tank side Pump side
Mounting, screws and O-Ring

is supplied with valve.
Type [NG] Size A B D C E F G H J K L M N O SW O-Ring

SAE (in) (in) (in) (in) (mm) (mm) (in) (in) (in) (in) (in) (mm) (in) (mm) (mm) (mm)
AB 16 S 32 1 1/4" 1.19 2.31 1.38 1.42 M12 14 2.24 3.31 1.14 1.38 0.28 M6 2.28 13 9 41x3.5
AB 16 S 40 1 1/2" 1.41 2.75 1.75 1.81 M12 14 2.72 3.74 1.14 1.38 0.28 M6 2.28 13 9 52X3.5
AB 16 S 50 2" 1.69 3.06 2.13 2.20 M12 14 3.15 4.09 1.14 1.38 0.28 M6 2.28 13 9 62X3.5
AB 16 S 63 2 1/2" 2.00 3.50 2.62 2.68 M12 14 3.86 4.53 1.22 1.65 0.31 M6 2.52 13 12 75X4
AB 16 S 80 3" 2.44 4.19 3.25 3.35 M16 16 4.57 5.31 1.22 1.65 0.35 M8 2.52 17 12 92X4
AB 16 S 100 4" 3.06 5.13 4.17 4.17 M16 16 5.39 6.26 1.22 1.65 0.35 M8 2.52 17 12 114X4
AB 16 S 125 5" 3.63 6.00 5.16 5.16 M16 16 6.42 7.13 1.22 1.65 0.35 M8 2.52 17 12 140X4

www.icfluid.com
-2-
BUTTERFLY VALVES
5. Flange - Option “T”: The flange can be welded to the
Tank side Pump side reservoir, giving a bolting surface for the butterfly valve.
Type [NG] Size ØD1 ØN1 ØO1 ØP Q Q1 R

SAE (in) (in) (in) (in) (in) (in) (in)
AB 16 S 32 1 1/4" 1.38 3.54 3.15 1.69 0.12 0.16 0.55

AB 16 S 40 1 1/2" 1.65 3.94 3.54 1.93 0.12 0.16 0.55
AB 16 S 50 2" 2.17 4.33 3.94 2.40 0.12 0.16 0.55
AB 16 S 63 2 1/2" 2.68 4.92 4.53 3.07 0.12 0.16 0.67
AB 16 S 80 3" 3.31 5.71 5.31 3.58 0.12 0.16 0.67
AB 16 S 100 4" 4.13 6.89 6.50 4.57 0.12 0.16 0.67
AB 16 S 125 5" 5.12 7.87 7.48 5.59 0.12 0.16 0.67
Tank side Pump side

6. Shift Handle Option “H”:
Type W X
(in) (in)
AB 16 S 32 to 50 4.13 1.57
AB 16 S 63 to 125 4.33 1.57
90° to shut
7. Threaded Adapter Bushing Inserts - Option “B”

Threaded busing that adapts to standard SAE tapped
holes. With these bushings, it will accept the screws
provided with Butterfly valve.
Type E L1 SW1
UNC-2B in mm
AB 16 S 32 to 63 7/16 - 14 0.47 12
Threaded bushing AB 16 S 40 to 63 1/2 - 13 0.51 12
AB 16 S 80 to 125 5/8 - 11 0.51 17
8. Limit switch - option “E”

Type E L1 SW1
UNC-2B (in) (mm)
AB 16 S 32 to 63 7/16 - 14 0.47 12
Wiring diagram when AB 16 S 80 to 125 5/8 - 11 0.51 17
Butterfly valve is closed
to
to

www.icfluid.com
-3-
COMPENSATORS 1" - 4"
1. General:
The HydroWer Rubber Compensators is a product that
qualifies as one of the best kept secrets of power unit
accessories. The Hydrower Rubber Compensators are
flexible connectors with SAE-flanges. The oscillation
compensators are used for damping of oscillators and
vibrations, noises and movements in axial and
transversal direction.
The HydroWer Compensator is constructed of an inner

liner of a reinforced high strength rubber (Nitril-
caoutchouc. Perbunan). The outer and inside layers
are smooth and have an aerodynamic design that 1
Pump
eliminates cavitation. The outside rubber (neoprene 2 3 4
caoutchouc) is weather resistant. Both ends of the
Compensators have vulcanized sealing lips. With the
vulcanized sealing lips on each end, additional seals
are not necessary.
Typical Installation: Tank

1 - Tank wall
2 - Flange
3 - Butterfly Valve Pump
4 - Compensator
2. Technical Data: 4
Working Pressure: 87 p.s.i.
2
Max. Pressure: 174 p.s.i.
Tank 2 3
Burst Pressure: 290 p.s.i.
Vacuum: 20" Hg
Temperature -4°F to 176°F
Acceptable Movement
For Acceptable Movements See Tables 1, 2, 3, 4

www.icfluid.com
-4-
COMPENSATORS
Compensator with SAE to SAE Flange connecting sizes after SAE-Standard J 518c
sealing surface
with sealing lips
Size
Table 1
Type [NG] Size A B D E F G H L Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) Push/Pull Offset Angle(°) Weight (lbs.)
K 16 S 25 1" 1.03 2.06 1.69 0.43 0.43 2.17 2.76 2.56 ±0.20 in ±0.20 in 7.5° 0.8
K 16 S 32 1 1/4" 1.19 2.31 1.97 0.43 0.51 2.76 3.15 2.56 ±0.20 in ±0.20 in 7.5° 1.10
K 16 S 40 1 1/2" 1.41 2.75 2.44 0.51 0.51 3.15 3.54 3.94 ±0.39 in ±0.39 in 10° 1.76
K 16 S 50 2" 1.69 3.06 2.83 0.51 0.51 3.54 3.94 3.94 ±0.39 in ±0.39 in 10° 2.21
K 16 S 63 2 1/2" 2.00 3.50 3.43 0.55 0.51 4.13 4.53 3.94 ±0.39 in ±0.39 in 10° 2.65
K 16 S 80 3" 2.44 4.19 4.09 0.55 0.71 4.72 5.20 3.94 ±0.39 in ±0.39 in 10° 3.97
K 16 S 90 3 1/2" 2.75 4.75 4.09 0.55 0.71 5.12 5.75 3.94 ±0.39 in ±0.39 in 10° 4.19
K 16 S 100 4" 3.06 5.13 5.12 0.63 0.71 5.51 6.14 3.94 ±0.39 in ±0.39 in 10° 5.51
Compensator with SAE to DIN-Flange

SAE-Flange DIN-Flange
sealing surface
with sealing lips
connecting sizes
after SAE-Norm
(J 518ci) and
after DIN 2633 - ND 16
Table 2
Type [NG] Size A B C D E F G H K L M N Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (mm) (in) Push/Pull Offset Angle (°) Weight (lbs.)
K16SD- 25 1" 1.031 2.062 4.53 1.69 0.43 0.43 2.17 2.76 3.35 2.56 4x14 0.63 ±0.20 in ±0.20 in 7.5° 3.31
K16SD- 32 1 1/4" 1.188 2.312 5.51 1.97 0.43 0.51 2.76 3.15 3.94 2.56 4x18 0.63 ±0.20 in ±0.20 in 7.5° 3.97
K16SD- 40 1 1/2" 1.406 2.750 5.91 2.44 0.51 0.51 3.15 3.54 4.33 3.94 4x18 0.63 ±0.39 in ±0.39 in 10° 4.85
K16SD- 50 2" 1.688 3.062 6.50 2.83 0.51 0.51 3.54 3.94 4.92 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 6.17
K16SD- 63 2 1/2" 2.00 3.500 7.28 3.43 0.55 0.51 4.13 4.53 5.71 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 7.06
K16SD- 80 3" 2.438 4.188 7.87 4.09 0.55 0.71 4.72 5.20 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 8.82
K16SD- 90 3 1/2" 2.750 4.750 7.87 4.09 0.55 0.71 5.12 5.75 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 9.04
K16SD- 100 4" 3.062 5.125 8.66 5.12 0.63 0.71 5.51 6.14 7.09 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 10.58

www.icfluid.com
-5-
COMPENSATORS
Compensator with NPT Thread to NPT Thread
Table 3
Type [NG] NG L R SW1 SW2 Acceptable Movement

(in) (in) (NPT) (mm) (mm) Push/Pull Offset Angle(°) Weight (lbs.)
K 16 R 25 0.98 6.42 1" 35 54 ±0.20 in ±0.20 in 7.5° 1.54
K 16 R 32 1.26 6.97 1 1/4" 45 66 ±0.20 in ±0.20 in 7.5° 2.43
K 16 R 40 1.57 9.06 1 1/2" 53 73 ±0.39 in ±0.39 in 10° 2.87
K 16 R 50 1.97 9.45 2" 66 90 ±0.39 in ±0.39 in 10° 3.31
Check when installing
When installing the compensator, it must be in line and maintain the dimension "L" length. For compensators with NPT pipe thread
the nut SW2 must only be hand tight.
The movement absorption in static and dynamic loads and the different types of movements must be added together and the totals
are not allowed to exceed the data given.
Attention: Pressure spikes are push loads which add to the axial movement. Do not exceed given data!
Compensator with SAE-Flange to NPT Thread

sealing surface
with sealing lips
Flange connecting after

SAE-Norm J 518 -
NPT Pipe Thread
Table 4
Type [NG] Size A B D E F G H L R SW1 SW2 Acceptable Movement

SAE (in) (in) (in) (in) (in) (in) (in) (in) (in) (mm) (mm) Push/Pull Offset Angle (°) Weight (lbs.)
K16SR- 25 1" 1.03 2.06 1.61 0.43 0.43 2.17 2.76 4.49 1" 35 54 ±0.20 in ±0.20 in 7.5° 0.80
K16SR- 32 1 1/4" 1.19 2.31 1.89 0.43 0.51 2.76 3.15 4.76 1 1/4" 45 66 ±0.20 in ±0.20 in 7.5° 1.80
K16SR- 40 1 1/2" 1.41 2.75 2.32 0.51 0.51 3.15 3.54 6.18 1 1/2" 53 73 ±0.39 in ±0.39 in 10° 2.40
K16SR- 50 2" 1.69 3.06 2.76 0.51 0.51 3.54 3.94 6.42 2" 66 90 ±0.39 in ±0.39 in 10° 2.90

www.icfluid.com
-6-
SCREW-IN TYPE
CHECK VALVES
• Ball Type Poppet Design - patent pending • Pressures to 10,000 psi (700 bar) - Flows to 23 gpm (90 l/min)
• Nominal Size: 1/16 - 1/8 - 1/4 - 3/8 - 1/2 - 3/4 • Threads: BSP, Metric, and Inch sizes on request
Type: RVA Type: RVB
Type Max G L I b zxød 0-Ring Curve # Type Max G L I SW 0-Ring Curve #

GPM (90 sh) GPM (90 sh)
RVA 2-M 0.79 M6 6 3.5 3.5 4x1.2 2.5x1 1 RVB 2-M 0.53 M6 6.5 3.5 3 2.5x1 8
RVA 3-M 1.59 M8x1 6 3.5 5 6x1.6 4x1 2 RVB 3-M 1.06 M8x1 6.5 3.5 3 4x1 9
RVA 4 2.64 G 1/8 RVB 4 2.11 G 1/8 7 4 4 6x1 10
6.5 3.5 6 6x1.8 6x1 3
RVA 4-M 2.64 M 10x1 RVB 4-M 2.11 M 10x1
RVA 6 6.61 G 1/4 RVB 6 4.76 G 1/4 8 4.5 5 9x1 11
8 4.6 9 8x2.2 9x1 4
RVA 6-M 6.61 M 14x1.5 RVB 6-M 4.76 M 14x1.5
RVA 8 11.89 G 3/8 RVB 8 7.93 G 3/8
10 5.5 11 8x3 11x1.5 5 9.5 5.5 6 11x1.5 12
RVA 8-M 11.89 M18x1.5 RVB 8-M 7.93 M18x1.5
RVA 10 18.49 G 1/2 RVB 10 15.85 G 1/2
11.5 6.5 14.5 8x3.8 14x1.5 6 11.5 6.5 8 14x1.5 13
RVA 10-M 18.49 M22x1.5 RVB 10-M 15.85 M22x1.5
RVA 16 26.42 G 3/4 RVB 16 23.78 G 3/4
14 7.5 18.5 8x4.6 18.77x1.78 7 14 8 10 18.77x1.78 14
RVA 16-M 26.42 M27x2 RVB 16-M 23.78 M27x2
Techincal Data:
Operating Pressure: 10,150 psi (lock pressure)
Proof Pressure: 40,600 psi
Temperature Range: -40°F to 176°F
Viscosity Range: 5 to 500 c St
Installation Position: Any direction
Flow Rate: See section 4
Stainless Steel on Request
Type G K d T U X
RVA +RVB 2 M6 2 7 5 4.5 2.5

RVA +RVB 3 M8x1 7 3.5 7 4.5 2.5
RVA +RVB 4 G 1/8 8.7 5 8.5 6 2.5
RVA +RVB 4 M 10x1 9
RVA +RVB 6 G 1/4 11.7 8 9 6 3
RVA +RVB 6 M 14x1.5 12.5
RVA +RVB 8 G 3/8 15.2
10 11 6 8
RVA +RVB 8 M18x1.5 16.5
RVA +RVB 10 G 1/2 19
12 13 9.5 3.5
RVA +RVB 10 M22x1.5 20.5
RVA +RVB 16 G 3/4 24.5
It is absolutely necessary 16 17 12.5 4.5
RVA +RVB 16 M27x2 25
to maintain the "x" dimension
of the cavity (item #5) X - Thread run-out. It can be smaller, but not larger.
T - Minimum depth without plug, thread joint, transverse drill and so on.
In case of stronger impacts and vibration, it is recommended to
secure the valves with loctite or similar.
*All dimensions in mm.
Oil viscosity measured at 50 cSt.
Warning: In case of sudden loading of the check-valve in flow direction, for example behind tank or hoses, the specified flow quantity
must not be exceeded.
www.icfluid.com
-7-
E01P X10-2258

Job 2005 032, Unit 1

Art. No: 276 0023-801
Card revision: R2C

Notes:
E01PX10-2258.txt
Printout time: 2005-09-27 11:55:37
Main settings
Function
Configuration
Language
Protection
Pump outputs
Pump 1
Pump 2
Pump 3
Pump 4
Friction
Page 1
E01PX10-2258.txt
Digital inputs
Digital in 1 - 22
Digital in 23 - 43
Digital outputs
Digital out 1
Digital out 2
Digital out 3
Page 2
E01PX10-2258.txt
Digital out 4
Digital out 5
Digital out 6
Digital out 7
Digital out 8
Digital out 9
Digital out 10
Digital out 11
Digital out 12
Digital out 13
Pulse inputs
Drive 1
Drive 2
Page 3
E01PX10-2258.txt
Analog inputs
Setpoint 1
Setpoint 2
Analog in 1
Analog in 2
Analog in 3
Page 4
E01PX10-2258.txt
Analog in 4
Analog in 5
Analog in 6
Analog in 7
Analog in 8
Page 5
E01PX10-2258.txt
Analog in 9
Tank temp
Power limit
Analog outputs
Analog out 1
Analog out 2
Analog out 3
Analog out 4
Bus
Type && Function
Page 6
E01PX10-2258.txt
Digital in
Analog in 1
Analog in 2
Analog in 3
Analog in 4
Analog out
Pump monitor
Pump 1
Page 7
E01PX10-2258.txt
Pump 2
Pump 3
Pump 4
Tank monitor
Digital
Page 8
E01PX10-2258.txt
Analog
Aux monitor
Aux 1
Aux 2
Aux 3
Aux 4
Aux 5
Aux 6
Aux 7
Aux 8
Page 9
E01PX10-2258.txt
Aux 9
Aux 10
Aux 11
Aux 12
Aux 13
Aux 14
Aux 15
Aux 16
Aux 17
Aux 18
Page 10
E01PX10-2258.txt
Aux 19
Aux 20
Drive monitor
Start interlock
Drive 1
Drive 2
Emotor interlock
Drive 1 basic
Setpoint
Ramp
Regulator
Page 11
E01PX10-2258.txt
Feedback
Power limitation
Drive 2 basic
Setpoint
Ramp
Regulator
Feedback
Power limitation
Shredder 1
Function
Page 12
E01PX10-2258.txt
Setpoint
Counter
Shredder 2
Function
Setpoint
Counter
Synchro
Function
Drive 1 reset
Drive 2 setpoint
Drive 2 indication
Drive 2 reset
Master setpoint
Drive 1 setpoint
Pressure 1
Function
Page 13
E01PX10-2258.txt
Pr. setpoint
Regulator
Pressure 2
Function
Pr. setpoint
Regulator
Reading 1
Scroll menu
Page 14
E01PX10-2258.txt
Left upper
Right upper
Left lower
Right lower
Reading 2
Scroll menu
Left upper
Right upper
Left lower
Right lower
Page 15
E01P X10-2511

Job 2005 032, Unit 2

Art. No: 276 0023-801
Card revision: R2D

Notes:
E01PX10-2511.txt
Printout time: 2005-09-27 11:56:01
Main settings
Function
Configuration
Language
Protection
Pump outputs
Pump 1
Pump 2
Pump 3
Pump 4
Friction
Page 1
E01PX10-2511.txt
Digital inputs
Digital in 1 - 22
Digital in 23 - 43
Digital outputs
Digital out 1
Digital out 2
Digital out 3
Page 2
E01PX10-2511.txt
Digital out 4
Digital out 5
Digital out 6
Digital out 7
Digital out 8
Digital out 9
Digital out 10
Digital out 11
Digital out 12
Digital out 13
Pulse inputs
Drive 1
Drive 2
Page 3
E01PX10-2511.txt
Analog inputs
Setpoint 1
Setpoint 2
Analog in 1
Analog in 2
Analog in 3
Page 4
E01PX10-2511.txt
Analog in 4
Analog in 5
Analog in 6
Analog in 7
Analog in 8
Page 5
E01PX10-2511.txt
Analog in 9
Tank temp
Power limit
Analog outputs
Analog out 1
Analog out 2
Analog out 3
Analog out 4
Bus
Type && Function
Page 6
E01PX10-2511.txt
Digital in
Analog in 1
Analog in 2
Analog in 3
Analog in 4
Analog out
Pump monitor
Pump 1
Page 7
E01PX10-2511.txt
Pump 2
Pump 3
Pump 4
Tank monitor
Digital
Page 8
E01PX10-2511.txt
Analog
Aux monitor
Aux 1
Aux 2
Aux 3
Aux 4
Aux 5
Aux 6
Aux 7
Aux 8
Page 9
E01PX10-2511.txt
Aux 9
Aux 10
Aux 11
Aux 12
Aux 13
Aux 14
Aux 15
Aux 16
Aux 17
Aux 18
Page 10
E01PX10-2511.txt
Aux 19
Aux 20
Drive monitor
Start interlock
Drive 1
Drive 2
Emotor interlock
Drive 1 basic
Setpoint
Ramp
Regulator
Page 11
E01PX10-2511.txt
Feedback
Power limitation
Drive 2 basic
Setpoint
Ramp
Regulator
Feedback
Power limitation
Shredder 1
Function
Page 12
E01PX10-2511.txt
Setpoint
Counter
Shredder 2
Function
Setpoint
Counter
Synchro
Function
Drive 1 reset
Drive 2 setpoint
Drive 2 indication
Drive 2 reset
Master setpoint
Drive 1 setpoint
Pressure 1
Function
Page 13
E01PX10-2511.txt
Pr. setpoint
Regulator
Pressure 2
Function
Pr. setpoint
Regulator
Reading 1
Scroll menu
Page 14
E01PX10-2511.txt
Left upper
Right upper
Left lower
Right lower
Reading 2
Scroll menu
Left upper
Right upper
Left lower
Right lower
Page 15
E01P X10-2526

Job 2005 032, Unit 3

Art. No: 276 0023-801
Card revision: R2D

Notes:
E01PX10-2526.txt
Printout time: 2005-09-27 11:56:20
Main settings
Function
Configuration
Language
Protection
Pump outputs
Pump 1
Pump 2
Pump 3
Pump 4
Friction
Page 1
E01PX10-2526.txt
Digital inputs
Digital in 1 - 22
Digital in 23 - 43
Digital outputs
Digital out 1
Digital out 2
Digital out 3
Page 2
E01PX10-2526.txt
Digital out 4
Digital out 5
Digital out 6
Digital out 7
Digital out 8
Digital out 9
Digital out 10
Digital out 11
Digital out 12
Digital out 13
Pulse inputs
Drive 1
Drive 2
Page 3
E01PX10-2526.txt
Analog inputs
Setpoint 1
Setpoint 2
Analog in 1
Analog in 2
Analog in 3
Page 4
E01PX10-2526.txt
Analog in 4
Analog in 5
Analog in 6
Analog in 7
Analog in 8
Page 5
E01PX10-2526.txt
Analog in 9
Tank temp
Power limit
Analog outputs
Analog out 1
Analog out 2
Analog out 3
Analog out 4
Bus
Type && Function
Page 6
E01PX10-2526.txt
Digital in
Analog in 1
Analog in 2
Analog in 3
Analog in 4
Analog out
Pump monitor
Pump 1
Page 7
E01PX10-2526.txt
Pump 2
Pump 3
Pump 4
Tank monitor
Digital
Page 8
E01PX10-2526.txt
Analog
Aux monitor
Aux 1
Aux 2
Aux 3
Aux 4
Aux 5
Aux 6
Aux 7
Aux 8
Page 9
E01PX10-2526.txt
Aux 9
Aux 10
Aux 11
Aux 12
Aux 13
Aux 14
Aux 15
Aux 16
Aux 17
Aux 18
Page 10
E01PX10-2526.txt
Aux 19
Aux 20
Drive monitor
Start interlock
Drive 1
Drive 2
Emotor interlock
Drive 1 basic
Setpoint
Ramp
Regulator
Page 11
E01PX10-2526.txt
Feedback
Power limitation
Drive 2 basic
Setpoint
Ramp
Regulator
Feedback
Power limitation
Shredder 1
Function
Page 12
E01PX10-2526.txt
Setpoint
Counter
Shredder 2
Function
Setpoint
Counter
Synchro
Function
Drive 1 reset
Drive 2 setpoint
Drive 2 indication
Drive 2 reset
Master setpoint
Drive 1 setpoint
Pressure 1
Function
Page 13
E01PX10-2526.txt
Pr. setpoint
Regulator
Pressure 2
Function
Pr. setpoint
Regulator
Reading 1
Scroll menu
Page 14
E01PX10-2526.txt
Left upper
Right upper
Left lower
Right lower
Reading 2
Scroll menu
Left upper
Right upper
Left lower
Right lower
Page 15
SPIDER USERS MANUAL
Users Manual
SPIDER 2
Program Release v 2
Software Version 4.1.2
SPIDER AS
Engineering manual
Preface
04-04-02, New
Preface
Hägglunds is one of the worlds leading manufacturers of large hydraulic Drive Systems. A leading position,
made possible by unbeatable service spirit and of continuing development of both products and markets
all over the world. Our drives are to be found in most industrial and marine segments, where there are
extremely high demands for efficiency and reliability. Our main office and production plant is in Mellansel,
Sweden and we have our own sales- and representation offices in some 40 different countries.
This Engineering manual provides necessary information for Spider control system. In order to find particular
information, just search for the wanted section as listed in the table of contents. However, changes in the
equipment may occur. We therefore reserve the right to introduce amendments in the manual as we deem
necessary without notice or obligations.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will cause
personal injury or substantial property damage. Depending on the probability of the hazard, and how
serious the injury or property damage could be, there are three levels of classification.



AS-1
Spider Introduction
1.1 Description
The Spider unit is a microcontroller based system, configurable to suit different application
needs. It is designed to match the two or three door power unit also with one door unit added.
The control system can control pumps with double coil (Denison 9A, Brueninghaus EP, Sauer
Sundstrand KA or similar pumps) or single coil in one direction (Denison 5A).
The unit can be mounted inside the power unit, in the power unit door, on the outside of the
power unit or delivered separate with wall brackets or panel flange to be wired in by the
customer. Cable sets can be supplied as an option.
The configuration of the pre-programmed system functions is done using the front panel with
help from the text displays or via a serial connection from a laptop. The configuration mode can
be protected with a password.
The Spider unit can control the system with different settings of electric motor/pump
configuration.
• One to four pumps for one drive:
EM EM EM EM
DRIVE P DRIVE P P P
EM EM EM EM EM
DRIVE P P
DRIVE P P
P P
• Two to four pumps for two drives with separate function:
EM EM
P P
DRIVE P P
DRIVE
EM EM
DRIVE P P
DRIVE
EM EM EM
DRIVE P P P
DRIVE
-------
• Two to four pumps for two drives with common function. If one stops by a fault the other will
also stop:
EM EM EM
DRIVE P
DRIVE P
DRIVE P
DRIVE P
EM EM EM EM
DRIVE P P
DRIVE P P
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P
DRIVE P P
EM EM EM
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P P
DRIVE P
The Monitor function can health monitor the power unit switches and give information on the text
display about warnings or alarms. An alarm will stop the electric motor or motors if the digital
interlock output is connected via a relay to the starter interlock circuit. Up to 4 pumps can be
controlled in parallel for the same drive
M M M
M M
The Basic function has added functions for power limitation and closed loop speed feedback via
a PID-regulator. Inputs are available for analog or digital speed encoders.
The unit can also monitor analog signals on the display such as speed, E-motor current,
pressure etc.
The Shredder function has the same functions as Basic and added functions for reversing by an
overload-stopped drive. It is possible to maximise the number of reversals within a time limit and
stop the drive when exceeded. The drive can be set to change direction after an adjustable time
interval.
The Friction function has the same functions as Basic and added functions for control of two
hydraulic drives driven together with a ratio between the motors.
The Friction slave function has the same functions as Basic and added functions for control of
two hydraulic drives driven together with a ratio in relation to the master setpoint.
The Synchro function has the same functions as Basic and added functions for position control
between two hydraulic drives. It is possible by an external signal to set the angle between the
rolls. Ratio drive is also possible. This mode requires digital speed encoders.
The pressure control function output is added to the ramped flow command. The function
compares actual pressure to a setpressure and gives a positive or negative output depending on
sign of the difference and action direction of regulation.
The Spider unit front has push-buttons for start and stop of the drive, local/remote, speed
setpoint by increase and decrease in local mode, inch reverse, regulated/non-regulated drive
and auto/manual drive in shredder mode. These push-button functions can be bypassed in the
configuration of the system functions.
All inputs and outputs are configurable and can be connected to pre-programmed functions in
the setup of the system. All signals are as standard wired to contact terminals or via fieldbus port
(optional).
The digital inputs can be configured to functions for eg. start/stop, reverse, reset, monitoring of
the power unit, auxiliary monitor where it is possible to set the function and display monitor text.
The digital outputs can be configured to functions for eg. common alarm/warning, ready to use,
drive started, shredder blocked, cooler and heater control. The outputs are of dry relay contact
type.
The analog inputs can be configured to functions for eg. tank temp, speed, pressure, power for
monitoring and control. The inputs can be configured for current loop or voltage.
The analog outputs can be configured to monitor eg. speed, pressure, temp. The outputs can be
configured for current loop or voltage.
The system includes a drive monitoring function with drive time counters, alarm/warning list and
8 scalable log channels with data download via serial interface. A remote drive monitoring
system with access via GSM can be added as an option.
1.5 Ordering code
AS-2
Spider Technical data
2.1 Mechanical
2.1.1 Mechanical data
Cubicle dimension W=400mm H=300mm D=145mm

Encapsulation class IP 65
Ambient temperature -20..+70°C *
Material enclosure Stainless steel
Material front Polyester film
Mounting Wall brackets or flange
Weight 8kg
(10kg with brackets or flange)
Cable size Max 2.5mm²
2.1.2 Wall bracket mounting
2.1.3 Flange mounting
2.1.4 Polyester front

Chemical resistance to:
- Alcohols
- Dilute acids
- Dilute alkalis
- Esters
- Hydrocarbons
- Ketones
- Household cleaning agents
2.2 Supply and output voltage

2.2.1 Supply voltage
Main supply voltage Autoranging 90-132, 180-264 VAC

47-63Hz (No configuration needed)
Power consumption 175VA (150W supply unit 376 0071-802)
300VA (250W supply unit 376 0071-801)
(+50VA with heater)*
Inrush current Max 30A
Main fuse 6A
Card supply 24VDC±10% , Max 8A
Card consumption (without 320mA
Load)
2.2.2 Output voltage
Analog reference voltage +10VDC 35mA

(isolated) -10VDC 35mA
Analog input supply +24VDC 0.3A
Emergency stop supply +24VDC 0.3A
Digital output supply +24VDC 0.8A
E-motor interlock supply +24VDC 0.3A
2.3 Inputs
2.3.1 Analog inputs
No Description Type Impedance

±0-20mA 250Ω
±0-20mA 250Ω
(isolated) +0-10VDC 100kΩ
+4-20mA 250Ω
+0-20mA 250Ω
(diffrential) +0-10VDC 100kΩ
+4-20mA 250Ω
+0-20mA 250Ω
1 Tank temp input, -29...+107ºC PT100
04-04-02
No Description Type Impedance Max input

direction signal
logical 1=6,6-32VDC
direction signal
logical 1=6,6-32VDC
43 Configurable inputs logical 0=0-3,9VDC 3kΩ
logical 1=6,6-32VDC
1 Emergency stop input logical 0=0-4,7VDC 3kΩ
logical 1=8,0-32VDC
2.4 Outputs
2.4.1 Pump control
No Description Type Impedance Max output

4 Stroker output, dual coil PWM (Pulse width 5-100Ω** 2A*
modulated)
*Total current for all outputs 5A
**Max output reduced above 10Ω to 20/Impedance (A)

13 Configurable outputs Relay contact 3A, 30VDC, 250VAC

4 Configurable analog outputs +0-10VDC 1kΩ
(isolated, needs external +2-10VDC 1kΩ
supply, min.21,0VDC) +0-20mA 500Ω
+4-20mA 500Ω
04-04-02
2.5 Communication
2.5.1 PC connection
No Description Type Connection to PC

1 RS-232 connection for setup 9-pole male D-sub Null modem cable
and drive log download
2.5.2 Fieldbus connection
No Description Type Connection

1 Connection for fieldbus module Profibus
(optional module) Modbus
AS-3
Spider Connection
Engineering manual
04-04-02
3.1 Wiring
Shielded cables are preferred for the installation.
The wire must be min 0,5mm2 for input signals and min 1mm2 for supply and output cables.
Max distance between control system and power unit is 50m.
3.2 Supply
SUPPLY VOLTAGE & HEATER

HEATER WITH THERMOSTAT
SUPPLIED AS OPTION
3.3 Input signals

3.3.1. Remote speed setpoint.
The input for remote speed setpoint are isolated and can be bidirectional (forward and reverse
speed setpoint) or unidirectional (forward speed setpoint and fixed reverse speed if needed).
The setpoint can be a voltage or a current signal. The selection is made with a jumper on the
board (see also AS4.3) and in the set up menu (see AS5.2.6).
SETPOINT DRIVE 1
I I
SETPOINT DRIVE 2
I I
3.3.2.1 Configurable isolated analog inputs.

a current signal. The selection is made with a jumper on the board (see also AS4.3) and in
the set up menu (see AS5.2.6).
I I
I I
3.3.2.2 Configurable analog inputs.

a current signal. The selection is made with a jumper on the board (see AS4.5.2) and in the
set up menu (see AS5.2.6).
I I
I I
I I
I I
I I
I I
I I
CONNECTION OF ANALOG 2-WIRE SENSOR
3.3.2.3 Tank temperature analog input.

The tank temperature can be measured with a PT100 sensor.
PT-100 TANK TEMPERATURE INPUT
3.3.3. Digital speed encoder.

If a differential encoder is used and the input 2 pulse comes before the input 1 pulse, the Rpm
signal will be positive.
If a single pulse encoder is used, a low level on the direction signal will give positive sign of
the Rpm signal. If the signal has wrong sign the polarity can be changed with parameter P1I06
for drive 1 and parameter P2I06 for drive 2.
3.3.4. Electric motor started inputs.

The inputs must be high (switch closed) when the motor is stopped and open at motor start.
The inputs are used for bypass of charge pressure alarm and delay of drive start.
INPUT SIGNALS FROM STARTER UNIT
3.3.5. Emergency stop input.

Emergency stop input must be connected for the system to operate. If the input is opened, the
output to fte pumps will be set to zero without ramp to destroke the pumps as quickly as
possible.The electric motor interlock contacts will open after a time delay set with parameter
DMD 0x and with a rotary switch on top left of main board (see AS4.5.4).
EMERGENCY STOP INPUT
3.3.6. Configurable digital inputs.

The input functions are configured in the set up menu (see AS5.2.3). All inputs are
configurable but the first 24 inputs are as first choice selected for monitoring of the power unit
switches.
3.4 Output signals

3.4.1. Pump strokers.
Pumps with separate coils for A and B side can be used. If pumps with a common coil for both
directions is used, the drive can only be controlled in one direction.
3.4.2. Starter interlock outputs.

The normally open contact of the auxiliary relay must be connected in the stop circuit for the
electric motors. The output will open at alarm.
Note! The polarity for the freewheeling diode over the relay coil. The function of the diode is to
protect against induced voltage at switch off and should be mounted close to the relay coil.
STARTER INTERLOCK
3.4.3. Configurable digital outputs.

The output functions are configured in the set up menu (see AS5.2.4).
DIGITAL OUTPUT SIGNALS
Note! All outputs must be protected against induced voltage at switch off by e.g. free wheeling
diode (see 3.4.2), varistor, RC circuit or other overvoltage protection device mounted close to
the load.
3.4.4. Configurable analog outputs.

The outputs are isolated and needs external supply. If no isolation is needed the card can be
supplied from Spider terminals. The output functions are configured in the set up menu (see
AS5.2.7).
3.5 Interconnection terminal

For internal connection use.
INTERCONNECTION TERMINAL
04-04-02
3.6 Serial ports

3.6.1. SpiderCom port.
Connector for RS232 serial communication. Port is used for log data dump and for setup of system
via a PC and SpiderCom software.
SERIAL CONNECTOR PINOUT
1 2 3 4 5
6 7 8 9
Pin1 CD, Carrier detect

Pin2 RXD, Receive data
Pin3 TXD, Transmit data
Pin4 DTR, Data terminal ready
Pin5 GND, System ground
Pin6 DSR, Data set ready
Pin8 CTS, Clear to send
Pin9 RI, Ring indicator
3.6.2. Optional fieldbus connection.

Profibus connection for external serial control
PROFIBUS CONNECTOR PINOUT
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not connected
Pin3 B-line, Pos TXD/RXD
Pin5 GND BUS
Pin6 +5V BUS
Pin7 Not connected
Pin8 A-line, Neg TXD/RXD
Pin9 Not connected
04-04-02
Modbus connection for external serial control
MODBUS CONNECTOR PINOUT
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not used
Pin3 Not used
Pin4 Not connected
Pin5 GND
Pin6 +5V
Pin7 RS485 B-line
Pin8 RS485 A-line
Pin9 Not connected
3.7 Terminal functions

Table of terminal functions.

1 Power Input DC1 4 24V_IN (+)
3 24V_IN (+)
2 GND (-)
1 GND(-)
2 Common pump 4
2 Common pump 3
2 Common pump 2
2 Common pump 1

2 24V_DO
1 GND

11 Common Digital output 11-13
2 24V_DO
1 GND
4 E-motor interlocks EO1 8 Interlock Electric motor 3

2 24V_DO
1 GND
5 E-motor started EI 8 E-motor 3 started

inputs 7 E-motor 2 started
6 E-motor 1 started
5 24V_EI
4 24V_EI
3 GND
Em stop EM 2 Em.stop
1 24V_EM

6 Pulse 2 Drive 1+
5 Pulse 1 Drive 1 -
4 Pulse 1 Drive 1+
3 12V+
2 24V_DE
1 GND

6 Pulse 2 Drive 2+
5 Pulse 1 Drive 2 -
4 Pulse 1 Drive 2+
3 12V+
2 24V_DE
1 GND

8 Configurable DI1 8 Config input 6 (Drain filter)
digital inputs 7 Config input 5 (Low oil level in tank)
Predefined 6 Config input 4 (Min oil level in tank)
monitoring inputs 5 Config input 3 (Min oil temperature in tank)
4 Config input 2 (High oil temperature in tank)
3 Config input 1 (Max oil temperature in tank)
2 24V_DI_1
1 GND

3 24V_DI_1
2 24V_DI_1
1 GND

3 24V_DI_1
2 24V_DI_1
1 GND

10 Config input 31
9 Config input 30
8 Config input 29
7 Config input 28
6 Config input 27
5 Config input 26
4 Config input 25
3 24V_DI_2
2 24V_DI_2
1 GND

10 Config input 41
9 Config input 40
8 Config input 39
7 Config input 38
6 Config input 37
5 Config input 36
4 Config input 35
3 Config input 34
2 24V_DI_2
1 GND

Isolated 11 Config input 2+
10 Config input 1 -
9 Config input 1+
4 Isolated 10VREF -
3 Isolated 10VREF+
2 Isolated GND
1 Isolated GND

Not isolated 11 Config input 6+
10 Config input 5 -
9 Config input 5+
8 Config input 4 -
7 Config input 4+
6 Config input 3 -
5 Config input 3+
4 24V_AI
3 24V_AI
2 GND
1 GND

15 Analog inputs AI3 14 Tank temp, force high
Not isolated 13 Tank temp, sense high
12 Tank temp, sense low
11 Tank temp, force low
10 Config input 9 -
9 Config input 9+
8 Config input 8 -
7 Config input 8+
6 Config input 7 -
5 Config input 7+
4 24V_AI
3 24V_AI
2 GND
1 GND
16 Analog outputs AO2 6 Current output 4

5 Voltage output 4
4 Current output 3
3 Voltage output 3
1 GND (external)
AO1 6 Current output 2
5 Voltage output 2
4 Current output 1
3 Voltage output 1
1 GND (external)
17 CAN1 CA 8 DATA2-
7 NC
6 DATA2+
5 0VCAN2
CAN2 4 DATA1-
3 NC
2 DATA1+
1 0VCAN1
Spare terminals IC 6 For interconnection purpose
AS-4
Spider Indication and setting
4.1 Display information

POWER UP E-MOTOR STOPPED
boot v1.1 OFF EXT

E-MOTOR STOPPED
0% 0%
0rpm 0Amp
Indication that e-motor is off
boot version
START UP TIME E-MOTOR STARTING
HÄGGLUNDS DRIVES OFF REM

SPIDER II STARTING UP
0% 0%
ver. 4.0.0 0rpm 0Amp
Indication of e-motor start
Software version
E-MOTOR STARTED
TESTING HARDWARE
SYSTEM READY TO USE
TESTING HARDWARE OFF REM

READY TO USE
0% 0%
0rpm 0Amp
DRIVE MODE
OFF REM
-> TANKTEMP 34°C <-
0% 0%
0rpm 0Amp
4.2 Information on normal drive and alarms
DRIVE INDICATION
WARN = Common Warning
ALARM = Common Alarm
INT = Interlock
ON = Drive Started
OFF = Drive Stopped
REM = Remote speed command
LOC = Local speed command
BUS = Fieldbus remote speed command
"Blank" = Open loop drive
REG = Closed loop speed feedback drive
WARN ON REM REG AUT MAN = Manual mode (Only in Shredder function)
AUT = Auto mode (only in Shredder function)
> TANKTEMP 35°C <
85 % 92 %
Scroll list shown
20.5 rpm 120 kW
Four settable registers to be displayed
ALARM INDICATION WARNING INDICATION
ALARM DRIVE 1 WARNING DRIVE 1

MIN OIL LEVEL LOW OIL LEVEL
INTERLOCK INDICATION
INTERLOCK DRIVE 1
NO EXT FEED
4.3 Reset of alarms and warnings
RESET OF ALARMS/WARNINGS
ALARM OFF REM OFF REM
E-MOTOR STOPPED E-MOTOR STOPPED
0% 0% 0% 0%
0.0 rpm 0 mA 0.0 rpm 0 mA
DRIVE 1 3 sec.
DRIVE 1
OR
OR
DRIVE 2 3 sec.
DRIVE 2
ALARM DRIVE 1
LOW CHARGE PRESS P1
NO MORE ALARMS OR
WARNINGS
MORE THAN ONE

ALARM OR WARNING
ALARM DRIVE 1
MIN OIL LEVEL
4.4 Front panel buttons

4.4.1 Set up buttons
Go down one level in display menu.
Accept a change in parameter.
Reset alarm, warning or interlock
Go up one level in display menu.

Escape without change of parameter.

V
Scroll up in display menu.

Go to next alarm / warning.
Increase parameter.
Scroll down in display menu.

V Go to previous alarm / warning.
Decrease parameter.
Press 3 sec. to enter setup list
Inrease contrast on display
V Decrease contrast on display
4.4.2 Drive buttons
Switching between manual and auto drive mode.

MAN/AUTO (Only avaliable in Shredder function)
Switching between front panel setpoint

and external setpoint if this function
is selected.
INCREASE
Increase speed setpoint when driving
Decrease speed setpoint when driving

DECREASE
FORWARD
Manual forward in Shredder function.
Same
button Switching between open and closed loop
REG/UNREG
speed control when speed feedback used.
(Not avaliable in Shredder function)
Inch reverse with fixed speed.
REVERSE Manual reverse in Shredder function.
START Start of drive.
STOP Stop of drive.
P24
To displays
P23
P27
1 Jtag programming port for Microcontroller IC4
2 1 2
P25
Microcontroller TP2 1 2
TP5 TP4
1
Contact for Spidercom connection
TP23
SW1 5
TP21
TP22 P22
IC15 1
Jtag programming port for CPLD
4.5.1 Revision A
P28
TMS To memory card
CPLD TDI
TP3 TMO
TCK
GND To front keypad
+3V3
C137 C138
Watchdog
indicator TP19 TP16
TP18 TP15
D1 SW3
J1 2 TP17
TP20
W-DOG
1
ON
OFF
TP1 Display type selection

Optional Fieldbus card
TP14 Restart of program
RESET
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN

SW2
1
TP9 P47
4.5 Main card jumpers and indications
12
Logger connection
TP10
TP6
REL15
REL16
REL14
TP7
+
+ TP13
TP12
DC1
- TP11 Supply voltage
indicators
1
Jumpers for analog
P3
- Supply voltage indicators current loop inputs
Jumpers for analog TP8
REL17
current loop inputs
D170 D171 D172 D173 D174 D175 D176 D181
U
AS4, Indication and setting, Engineering manual
I Logger connections
AI6 I AI7 I AI8 I AI9 I AI3 I AI4 I AI5
DO EM EI DE DI1 DI2 AI DE D116 D117
12V 1 1 1 1 1 1 1
PO4
PO4
I I I I P43 P44 P45 P46 P40 P41 P42
SP SP AI_1 AI_2
D1 D2 + - 10V
P2
CA2
CA1
REL18
REL6
REL5
REL9
REL8
REL4
REL7
REL11
REL10
REL3
REL12
REL13
REL1
REL2
PO3
PO3
AO2
1
CA1
CA1
1
P21
P19
1
AO2
PO2
PO2
P1
IC1
IC1
P20
DO1 DO2 EO1 EI/ DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
EM
P14
PO1
PO1
P18
P9
P10
P16
P11
P15
P17
1
1
1
1
1
1
1
1
1
P7
P8
P12
P13
P6
P5
P4
1
1
1
1
1
1
DO1 DO2 EO1 EI/EM DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
05-01-21, replaces 04-04-02
6(14)
04-04-02
4.5.2 Jumpers
Function Jumper Settings

name
Signal type for configurable AI 6 Upper position = voltage signal
4.5.3 Indicators
Function Indicator Note

name
Shutdown D1, red Normally off. Will be active by
(W-DOG) microprocessor watchdog error.
Digital output supply D170, green Normally on. Indicates supply to digital
(DO) outpus. Will be off by external short circuit
or by emergency stop.
Emergency stop supply D171, green Normally on. Will be off by external short
(EM) circuit
E-motor input supply D172, green Normally on. Will be off by external short
(EI) circuit
(DE) circuit
(DI1) circuit
(DI2) circuit
Analog input supply D176, green Normally on. Will be off by external short
(AI) circuit
(DE 12V) circuit
+10V ref. voltage for D116, green Normally on. Will be off by external short
potentiometer (+10V) circuit
-10V ref. voltage for D117, green Normally on. Will be off by external short
potentiometer (-10V) circuit
04-04-02
4.5.4 Switches
Function Pot. Note

name
Emergency stop shutdown SW1 Timer for backup emergency stop
shutdown
Display type SW3-1 On = LCD display type (standard)

Off = VFD display type
SW3-2 No function
4.5.5 Contacts
Function Contact Note

name
Display P24
Front keypad P22
Memory card P23
Spidercom connection P26 RS232
Memory programming port P27 JTAG connection
CPLD programming port P28 JTAG connection
Fieldbus card connection J1 Optional card
DC supply DC1
Electric motor output EO1 8 pole contact
Electric motor input EI/EM 8 pole contact
Emergency stop input
Internal connection IC 6 pole contact
-4.6 Power supply
24V OK
DC connection
Fuse
Main switch
Main connection
04-04-02
4.7 Fieldbus card

4.7.1 Profibus
Profibus connector
Termination switch
D5
S1
ON
S3 S2
1 2
LED indicators
901 901
23
23
78
78
456 456
4 3
Address switches
4.7.1.1 Indicators
name
D1 Not used Not used Normal function
D2 On line Green Module is On-Line and ready, data

exchange is possible.
Off Module is not On-Line.
D3 Off line Red Module is Off-Line.

D4 Diagnostics Red flashing 1 Hz Configuration error. Data length.
Red flashing 2 Hz Configuration error. User

parameters.
Red flashing 4 Hz Initialisation error of the Profibus

communication ASIC.
Off No error.

in bootloader mode.
04-04-02
4.7.1.2 Switches
Indicator Function Information
name
S1 Terminating switch On= Enabled (if first or last in a network)
Off= Disabled
4.7.2 Modbus

D12
Modbus connector
Termination switch
S1
ON
S2 S3
1 2
LED indicators
3 4
1 2 3 4 5 6 7 8 1 2 3 4
Parity switches
Baudrate switches
Node Address switches
4.7.2.1 Indicators
name
D1 Processing Green flashing Receiving Query and building
response.
Off No Query
D2 Bus error Red Bus error
Off Normal operation.

D3 Bus ready Red Module is Off-Line.

D4 HW setting status Green Bus ready. Normal operation.
Red Bus timeout error.
Off Bus not initialized correctly.


in bootloader mode.

04-04-02
4.7.2.2 Switches
Indicator Function Setting Information
name
S1 Terminating switch On Enabled (if first or last in a
network)
Off Disabled
S2: 1-7 Node Address Binary value:
Switch: 1234567
0000000 Not valid
0000001 1
0000010 2
0000011 3
… …
… …
1111111 127
S2: 8 Baud rate Binary value:
S3: 1-2 Switch: 812
000 Not valid
001 1200
010 2400
011 4800
100 9600
101 19200 (Default)
110 38400
111 57600
S3: 1-2 Parity Binary value:
Switch: 34
00 Not valid
01 None(Default)
10 Even
11 Odd
4.9 Error codes

4.9.1 Program start
WARNING EEPROM READING FAILED
This error message indicates that the Spider software can't read saved parameter values from the memory
card. This error can occur if : No memory card connected, memory card defect or wrongly mounted or the
information on the memorycard is corrupt. Spider software will start with default values on parameters.
WARNING WRONG EEPROM VERSION
This error message indicates that the Spider software can't use the parameter values that's stored on
the memorycard because the parameter format stored on the memorycard not is compatible with the Spider
software used. Spider software will start with default values on parameters.
WARNING WRONG CPLD VERSION
This error message indicates that the Spider software version used not is compatible with the software
version in the CPLD (Complex Programmable Logic Device). The CPLD is used for digital in and outputs,
counters, display and Anybus. The Spider will work in an unpredictable way.
WARNING LOG INIT ERROR
This error message indicates that the Spider software can't read the real time clock, saved alarms, warnings,
drive times or setpoints from the memory card. Theese functions will not function.
This error can occur if : No memory card connected, memory card defect or wrongly mounted or the
information on the memorycard is corrupt.
WARNING 3D-LOG INIT ERROR
This error message indicates that the Spider software can't read the 3D-log on the memorycard.
The 3D -log function will not function. This error can occur if : No memorycard connected, memory card
defect or wrongly mounted or the information on the memorycard is corrupt.
4.9.2 Hardware monitoring

HW ERROR, FC 1
This test is to verify that the delay for electric motor interlock set in hardware with SW1 matches the
delay set in the Spider parameters (for electric motor interlock). If emergency stop is actuated the relays in
the hardware will open after set time 2-32 sec. (in 2 sec. steps). If this test not performes within the
below shown limits, the error message ”HW ERROR, FC 1” will be displayed.
The test is performed upon system start up.
HW delay < SW delay Software stops
HW delay > Only Warning, press a button for OK.

SW delay + 4s
HW delay > Software stops
SW delay + 5s
When the software stops both Hardware(M) time and Software(S) time is displayed in 1/10 sec so that
the times can be verified/corrected.
HW ERROR, FC 2
This test is to verify that the relay that feeds the PWM-outputs opens. If emergency stop is actuated
the Spider hardware for emergency stop open this relay. This test is performed when all e-motors are
stopped. If the relay doesn't open on this test, error message ”HW ERROR, FC 2” is displayed and
the software stops.
HW ERROR, FC 3
This test is to verify that the electric motor interlock relays opens. When electric motor interlock is
OK the relay is closed and open when interlock not is OK. If the relay not opens, error message ”HW
ERROR, FC 3” is displayed and the software stops. This test is performed at power on and once when all
electric motors are stopped.
HW ERROR, FC 4
Watchdog indication should not be acived during normal program execution. If it happens during normal
program execution, error message ”HW ERROR, FC 4” is displayed and the software stops. This test is
performed continiously.
HW ERROR, FC 5
If measured current is 50% greater than max configured current a shortcircuit is assumed,
error message ”HW ERROR, FC 5” is displayed and the software stops. This test is performed continiously.
4.9.3 Software monitoring

WATCHDOG TIMEOUT
If the software halts or executes incorrect in that way that the control loop or the user interface loop
can't execute within set time limits, error message ”WATCDOG TIMEOUT” is displayed and the software
stops. Program address where the execution stopped is also displayed.
4.9.4 Bus
BUS FAIL
Anybus function is selected but the communication does not function. This error is likely to occur if the bus
cable not is connected.
BUS HW FAIL
Anybus function is selected but the hardware is not functioning. This error is likely to occur if the bus module
is missing or defect.
AS-5
Spider Parameters V4.1.x
5.1 Parameter tree

Overview of configurable parameters.
Drive log Drive 1

Drive 2
AMA
AMB
Aux Monitor (26) Aux 1 AMC
Aux 2 AMD
Aux 3 AME
Aux 4 AMF
Setup Password MAin settings (2) Function MAA Aux 5
Configuration MAB AMG
Aux 6 AMH
Language MAC Aux 7 AMI
Protection MAD Aux 8 AMJ
Reset MAE Aux 9 AMK
Aux 10 AML
Pump Outputs (3) Pump 1 POA
Aux 11 AMM
Pump 2 POB
Contrast Aux 12 AMN
Pump 3 POC
Aux 13 AMO
Pump 4 POD
Aux 14 AMP
Friction POE
Aux 15 AMR
Digital Inputs (5) DIN Aux 16 AMS
Aux 17 AMT
Digital Outputs (9) Digital out 1 DOA Aux 18 AMU
Digital out 2 DOB Aux 19
HW Calibration Digital out 3 DOC Aux 20
Digital out 4 DOD
Digital out 5 DOE Drive Monitor (29) Start interlock DMA
Digital out 6 DOF Drive 1 DMB
Digital out 7 DOG Drive 2 DMC
Digital out 8 DOH Emotor interlock DMD
Digital out 9 DOI
Digital out 10 DOJ
Ramp D1B
Digital out 11 DOK
Regulator D1C
Digital out 12 DOL
Feedback D1D
Digital out 13 DOM
Power limitation D1E
Pulse Inputs (13) Drive 1 P1I
Drive 2 P2I
Ramp D2B
Regulator D2C
Analog Inputs (14) Setpoint 1 AIA Feedback D2D
Setpoint 2 AIB Power limitation D2E
Analog in 1 AIF
Analog in 2 AIG SHredder 1 (34) Function SHA
Analog in 3 AIH Setpoint SHB
Analog in 4 AII Counter SHC
Analog in 5 AIJ
Analog in 6 AIK SHredder 2 (35) Function SHG
Analog in 7 AIL Setpoint SHH
Analog in 8 AIM Counter SHI
Analog in 9 AIN
SYnchro (36) Function SYA
Tank temp AIP
Drive 1 reset SYB
Power limit AIR
Drive 2 setpoint SYC
Analog Outputs (19) Analog out 1 AOA Drive 2 indication SYD
Analog out 2 AOB Drive 2 reset SYE
Analog out 3 AOC Master setpoint SYF
Analog out 4 AOD Drive 1 setpoint SYG
Bus (20) Type&Function BTF PRessure 1 (37) Function PRA

Digital in BDI Pr.setpoint PRB
Analog in 1 BAA Regulator PRC
Analog in 2 BAB
Analog in 3 BAC PRessure 2 (38) Function PRG
Analog in 4 BAD Pr.setpoint PRH
Analog out BAO Regulator PRI
Pump Monitor (23) Pump 1 PMA Reading 1 (39) Scroll menu R1A
Pump 2 PMB Left upper R1B
Pump 3 PMC Right upper R1C
Pump 4 PMD Left lower R1D
Right lower R1E
Tank Monitor (25) Digital TMA
Analog TMB Reading 2 (40) Scroll menu R2A
Left upper R2B
Right upper R2C
Left lower R2D
Right lower R2E
Drive log (42) Password Time/Date

Log 1
Log 2
Log 3
Log 4
Log 5
Log 6
Log 7
Log 8
Reset time
5.2 Configurable Parameters

5.2.1 Main settings

BASIC = Monitor and Basic function BASIC BASIC
SHREDDER = Shredder function SHREDDER
SYNCHRO = Synchro and Friction SYNCHRO
function

E-motor 2
E-motor 3
OFF
E-motor 2
E-motor 3 OFF
OFF
E-motor 2
E-motor 3 OFF
OFF
E-motor 2
E-motor 3 OFF
OFF
Drive 2
OFF
Drive 2
OFF OFF
Drive 2
OFF OFF
Drive 2
OFF OFF
MAB09 Separate= One drive or two separate Separate Separate
drives
Common= Two drives with common Common
function

German
French
Spanish
Portuguese
Italian
Japanese
Dutch
Finnish
Swedish
Short
Chinese

*Characters changed with ∧ and ∨ buttons and selected with >button.
Main settings-Reset
5.2.2 Pump outputs
Pump outputs-Pump1

Pump outputs-Pump2

Pump outputs-Pump3

Pump outputs-Pump4


Digital Inputs

* Possible digital input function settings:






06 DRF 75 Monitor of drain filter clogged to 3/4
06 DRF 100 Monitor of drain filter fully clogged
06 F TEMP Interlock of filter warning inputs
07 LO LEVEL Low oil level monitor for tank

07 MN LEVEL Min oil level monitor for tank
08 MAX TEMP Max oil temp monitor for tank

08 HI TEMP High oil temp monitor for tank
08 MIN TEMP Low oil temp monitor for tank
09 ALARM R Remote reset of alarms and warnings

09 BUS R Reset of alarms and warnings via bus
09 BUS M Switching to Bus command signal, External master

10 SHR 1+2A Shredder forward stop, Drive 1 and 2
10 SHR 1+2B Shredder forward stop, Drive 1 and 2
10 SH RES12 External reset of Shredder blocked function, Drive 1 and 2

12 RES EN 1 External enable of counter reset in Synchro mode, Drive 1

12 RES EN2 External enable of counter reset in Synchro mode, Drive 2
12 FRICTION Friction drive in Synchro counter mode
12 INV M Inverting of master speed command in Synchro mode, Drive 1
13 AUX 1 Connected to Monitor Auxiliary 1


14 START 12 Drive start in Remote mode, Drive 1 and Drive 2
NOTE1
NOTE1
NOTE1
NOTE1

15 FORW 1+2 Forward drive with fixed speed, Drive 1 and Drive 2
15 REV 1+2 Reverse drive with fixed speed, Drive 1 and Drive 2

16 REM 1+2 Activated input = remote mode Drive 1 and 2, Open input = local mode
17 AUTO 1+2 Activated input = auto mode Drive 1 and 2, Open input = manual mode
18 REG 1+2 Activated input = Closed loop speed feedback active Drive 1+2, Open input = Open loop
18 ERR1+2 R External reset of Error too large function, Drive 1 and 2


21 OFF Not used

NOTE1
The input will be active for drive start/stop in:
− local mode
− in remote mode if a digital input not is used for start


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO


ON=On delay 1
OFF=Off delay 2
time
NO=No delay NO
* Possible function settings:

01 A1+A2 Alarm, Drive 1 or Drive2
01 W1+W2 Warning, Drive 1 or Drive 2
01 INT 1+2 Interlock, Drive 1 or Drive 2

02 START1+2 Drive 1 or Drive 2 started
02 START1*2 Drive 1 and Drive 2 started
03 READY1+2 Drive 1 or Drive 2 ready
03 READY1*2 Drive 1 and Drive 2 ready



06 PLIM 1+2 Power limit active, Drive 1 or Drive 2
06 PLIM Power limit active

08 C ZERO Indication for found zero position in Synchro counter function (synchro activated)
08 SYNCHRO Synchro within limits set in parameter L22

10 EMOTD1+2 Electric motor(s) for drive 1 or 2 started
10 EMOTD1*2 Electric motor(s) for drive 1 and 2 started
11 LOW TEMP Low temp active indicator

11 HI TEMP High temp active indicator
11 MAX TEMP Max temp active indicator
11 COOL CONI Cooler control interlocked by electric motor start when using analog temp sensor
11 COOL COND Cooler control without interlock when using analog temp sensor
11 HEAT CON Heater control when using analog temp sensor
11 FLUSHCON Flushing control when using analog temp sensor




OFF Not used
5.2.5 Pulse inputs
P1I01 Pulses/rev 1 1000 1 10000

1=Normal 1 1
2=Inverted 2
P1I07 Encoder type
1=Quad 1 1
P2I01 Pulses/rev 1 1000 1 10000

1=Normal 1 1
2=Inverted 2
P2I07 Encoder type
1=Quad 1 1
* Possible units of measure settings: rpm, m/m, m/s, f/m, f/s
5.2.6 Analog inputs


AIA02 Zero point adjustment Set point Drive1 1bit 0bit -102bit 102bit
AIA03 Max point adjustment Set point Drive1 1bit 0bit -102bit 102bit
%=% value Actual
(AIA01)


AIB02 Zero point adjustment Set point Drive2 1bit 0bit -102bit 102bit
AIB03 Max point adjustment Set point Drive2 1bit 0bit -102bit 102bit
%=% value Actual
(AIB01)


AIF04 Min input, REG401 1 0 -1000 2000
AIF12 Function for min indication at 4-20mA ****** OFF
input type


AIG04 Min input, REG402 1 0 -1000 2000
AIG12 Function for min indication at 4-20mA ****** OFF
input type


AIH04 Min input, REG403 1 0 -1000 2000
AIH12 Function for min indication at 4-20mA ****** OFF
input type


AII04 Min input, REG404 1 0 -1000 2000
AII12 Function for min indication at 4-20mA ****** OFF
input type


AIJ04 Min input, REG405 1 0 -1000 2000
AIJ12 Function for min indication at 4-20mA ****** OFF
input type


AIK04 Min input, REG406 1 0 -1000 2000
AIK12 Function for min indication at 4-20mA ****** OFF
input type


AIL04 Min input, REG407 1 0 -1000 2000
AIL12 Function for min indication at 4-20mA ****** OFF
input type


AIM04 Min input, REG408 1 0 -1000 2000
5
5
AIM12 Function for min indication at 4-20mA ****** OFF
input type


AIN04 Min input, REG409 1 0 -1000 2000
AIN12 Function for min indication at 4-20mA ****** OFF
input type



* Possible input type settings:

4-20mA
0-20mA
0-5V
0-10V
** Possible function settings:

13 AUX1-AUX20 Auxiliary monitor function




OFF Not used
*** Possible units of measure settings: rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm, A, kW, hp, °, %
**** Possible units of measure settings: °C, °F
***** Possible function settings:

AS1+2 = Analogue speed, Drive 1 and Drive 2 (rpm)
SM = Synchro master speed setpoint, Drive 2 (%)
SO = Synchro offset, Drive 2(°)
SP1+2 = Shredder pressure, Drive 1 and Drive 2 (bar)
PR1+2 = Actual pressure for pressure control, Drive 1 and Drive 2 (bar)
TANK A = Tank analog monitor function (°C)
P FRICT = Friction control of pump (%)
OFF = Not used
****** Possible function settings:

AUX1-AUX20 Auxiliary monitor function








* Possible register readings for output:

REG103 = Input command
REG104 = Feed forward command Analog in
Drive 2 REG410 = Tank temp
REG201 = Remote input command
REG202 = Speed setpoint Bus command in
REG203 = Input command REG501 = Bus in 1
REG204 = Feed forward command REG502 = Bus in 2
REG205 = Error signal REG503 = Bus in 3
REG209 = Digital speed
REG504 = Bus in 4
OFF =Output off
** Possible output settings
REG213 = Pressure compensation
OFF = 0-20mA or 0-10V output
REG214 = Offset (Synchro)
ON = 4-20mA or 2-10V output
5.2.8 Bus

Profibus
Modbus
Interlock Interlock


* Possible digital input function settings: Same as Digital in (DIN)
Bus – Analog in 1

Bus – Analog in 2

Bus – Analog in 3

Bus – Analog in 4

** Possible units of measure settings: %, rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm,
*** Possible function settings:
BSO = Synchro offset (Synchro function)
BMS = Master speed setpoint (Synchro function)
PF = Pump friction
OFF = Not used
Bus – Analog out


**** Possible register readings for output:

Drive 1 REG109 = Digital speed
REG101 = Remote input command REG110 = Speed feedback
REG102 = Speed setpoint REG111 = Pressure command
REG103 = Input command REG112 = Regulated pressure command
REG104 = Feed forward command REG113 = Pressure compensation
REG105 = Error signal REG114 = Master command

REG203 = Input command Analog in
REG214 = Offset (Synchro) REG409 = Analog in 9
REG410 = Tank temp
OFF =Output off
5.2.9 Pump monitor
Pump monitor-Pump 1

20, 25sec
Pump monitor-Pump 2

20, 25sec
Pump monitor-Pump 3

20, 25sec
Pump monitor-Pump 4

20, 25sec

*** Possible delay time settings: 0 / 1.0 / 5.0 / 7.0 / 10.0 / 20.0 / 30.0 / 60.0 seconds
**** Possible delay time settings: 2, 4, ..., 22, 24h, Off
5.2.10 Tank monitor

Tank monitor-Analog

TMB02 Not used

*** Possible delay time settings: 2, 4, ..., 22, 24h, Off
5.2.11 Aux monitor
Aux monitor-Aux1

Aux monitor-Aux2

Aux monitor-Aux3

Aux monitor-Aux4

Aux monitor-Aux5

Aux monitor-Aux6

Aux monitor-Aux7

Aux monitor-Aux8

Aux monitor-Aux9

Aux monitor-Aux10

Aux monitor-Aux11

Aux monitor-Aux12

Aux monitor-Aux13

Aux monitor-Aux14

Aux monitor-Aux15

Aux monitor-Aux16

Aux monitor-Aux17

Aux monitor-Aux18

Aux monitor-Aux19

Aux monitor-Aux20

* Possible function settings: A D1( connected to Alarm Drive 1 )
A D2( connected to Alarm Drive 2 )
A D1 D2( connected to Alarm Drive 1 and Alarm Drive 2)
W D1 D2( connected to Warning Drive 1 and Warning Drive 2)
INT D1 D2 ( connected to Interlock Drive 1 and Interlock Drive 2 )
OFF (Not connected to output)
***Characters changed with ∧ and ∨ buttons and selected with >button.
5.2.12 Drive monitor


OR
20, 25sec
OR
20, 25sec




* AND = All selected E-motors for the drive must be started to allow drive start.
* OR = Drive start allowed if any E-motor for the drive is started
** Possible delay time settings: 0 / 0.1 / 0.5 /1.0 seconds
*** Possible delay time settings: : 0 / 1.0 / 5.0 / 7.0 / 10.0 / 20.0 / 30.0 / 60.0 seconds

1=Local 1 1
2=Remote 2
3=Local/remote 3
mode
FORW 1)
REV 1)
Drive 1 basic-Ramp


regulated drive
non-regulated drive
3=No feedback 3



1=Local 1 1
2=Remote 2
3=Local/remote 3
mode
FORW 2)
REV 2)
Drive 2 basic-Ramp


regulated drive
non-regulated drive
3=No feedback 3


5.2.15 Shredder 1
Shredder 1-Function

2=Speed 2
1=Reverse stop 1
change
change
Shredder 1-Setpoint

remote 2
(D1A05)
SHB01 = 1
Shredder 1-Counter

5.2.16 Shredder 2
Shredder 2-Function

2=Speed 2
1=Reverse stop 1
change
change
Shredder 2-Setpoint

remote 2
(D2A05)
SHB01 = 1
Shredder 2-Counter

5.2.17 Synchro
Synchro-Function
SYA01 Type of synchronisation:

(synchro)
slaved


2=External reset 2
Drive1:
2=Drive 1 start 2



SYD02 Sync time 0.1sec 1.0 0.0 600.0


2=External reset 2
Drive2:
2=Drive 2 start 2



5.2.18 Pressure 1
Pressure 1-Function


1=Local 1
2=Remote 2
3=Local/Remote 3

5.2.19 Pressure 2
Pressure 2-Function


1=Local 1
2=Remote 2
3=Local/Remote 3

5.2.20 Reading 1






5.2.21 Reading 2






* Possible register readings for display:

Drive 1 Analog in
REG101 = Remote input command (%,Actual) REG401 = Analog in 1
REG102 = Speed setpoint (%) REG402 = Analog in 2
REG103 = Input command (%) REG403 = Analog in 3
REG104 = Feed forward command (%) REG404 = Analog in 4
REG105 = Error signal (%) REG405 = Analog in 5
REG106 = Amplifier command (%) REG406 = Analog in 6
REG107 = Speed setpoint (rpm) REG407 = Analog in 7
REG108 = Feed forward command (rpm) REG408 = Analog in 8
REG110 = Speed feedback (%) REG410 = Tank temp
REG112 = Regulated pressure command Bus command in
REG114 = Master command REG502 = Bus in 2
REG115 = Emergency stop angle (°) REG503 = Bus in 3
REG504 = Bus in 4
Drive 2 REG511 = Bus digital in 1-8
REG201 = Remote input command (%,Actual) REG512 = Bus digital in 9-16
REG202 = Speed setpoint (%) REG513 = Bus digital in 17-24
REG203 = Input command (%)
REG204 = Feed forward command (%)
REG205 = Error signal (%) Diagnostic readings
REG206 = Amplifier command (%) REG901 = Control task (ms)
REG207 = Speed setpoint (rpm) REG902 = Control task max (ms)
REG208 = Feed forward command (rpm) REG903 = UI task (ms)
REG209 = Digital speed REG904 = UI task max (ms)
REG210 = Speed feedback (%) REG905 = CPU load (%)
REG211 = Pressure command REG906 = CPU load max (%)
REG212 = Regulated pressure command REG907 = Stack usage, control task (%)
REG213 = Pressure compensation REG908 = Stack usage, UI task (%)
REG214 = Offset (Synchro) REG909 = Stack usage, serial port (%)
REG215 = Emergency stop angle (°) REG911 = Calc. resistance pump 1 (ohm)
REG912 = Calc. resistance pump 2 (ohm)
Pump signals REG913 = Calc. resistance pump 3 (ohm)
REG310 = Amplifier 1 command (%) REG914 = Calc. resistance pump 4 (ohm)
REG320 = Amplifier 2 command (%) OFF =Output off
REG350 = Pump friction (%)
5.2.22 Drive log
Log function – Time/Date

Setting of time and date for the log function


RESET


RESET


RESET


RESET


RESET


RESET


RESET


RESET
* Possible register setting

REG101 = Remote input command REG310 = Amplifier 1 command (%)
REG102 = Speed setpoint REG311 = Pump 1 current (mA)
REG103 = Input command REG320 = Amplifier 2 command (%)
REG104 = Feed forward command REG321 = Pump 2 current (mA)
REG105 = Error signal REG330 = Amplifier 3 command (%)
REG106 = Amplifier command REG331 = Pump 3 current (mA)
REG109 = Digital speed REG340 = Amplifier 4 command (%)
REG110 = Speed feedback REG341 = Pump 4 current (mA)
REG111 = Pressure command REG350 = Pump friction
REG113 = Pressure compensation Analog in
Drive 2 REG403 = Analog in 3
REG201 = Remote input command REG404 = Analog in 4
REG202 = Speed setpoint REG405 = Analog in 5
REG203 = Input command REG406 = Analog in 6
REG209 = Digital speed REG410 = Tank temp
REG211 = Pressure command Bus command in
REG212 = Regulated pressure command REG501 = Bus in 1
REG214 = Offset (Synchro) REG503 = Bus in 3
REG504 = Bus in 4
OFF =Output off
Log function – Reset Time
Reset of time counters for time in use
AS-6
Contents
Introduction ............................................................................................................. 2
6.1 General system setup ....................................................................................... 3
6.2 Speed command............................................................................................... 4
6.3 Ramp ................................................................................................................ 4
6.4 Output ............................................................................................................... 5
6.5 Speed feedback ................................................................................................ 6
6.6 Power limitation................................................................................................. 9
6.7 Monitoring ....................................................................................................... 10
6.8 Analog inputs .................................................................................................. 11
6.9 Digital inputs ................................................................................................... 12
6.10 Digital outputs ............................................................................................... 19
6.11 Signal monitor ............................................................................................... 21
6.12 Shredder ....................................................................................................... 23
6.13 Synchro......................................................................................................... 24
6.14 Pressure control............................................................................................ 25
6.15 Bus Communication...................................................................................... 28
6.17 Analog outputs .............................................................................................. 35
6.18 Language selection....................................................................................... 35
6.20 Emergency stop ............................................................................................ 37
6.21 Program update ............................................................................................ 38
6.22 Hardware calibration ..................................................................................... 38
AS-6
Introduction
Settings of the basic blocks in the software. All settings are for drive 1. The same procedure is done for
drive 2 but with the parameter letter in ().
This also describes the logical order for the system set up.
The list of parameters is found in AS5 and block diagrams with parameters are found in AS7.
The choice of parameters are made by using the directional buttons (◄, ►, ▲ & ▼) (see AS5.1). After a
change, the choice must be updated with the enter button (◄┘). The parameters are updated in the
memory when going back to the Main status reading in the display.
The settings can be protected by a password (MAIN SETTINGS Æ PROTECTION: MAD01-02).
The drive monitoring function is protected by a separate password under SETUP-LOG FUNCTION.
El.m. current signal(s)

El.m. started
Starter(s) El.m. interlock
Setpoint(s)
Customer
Drive control
El.m. 1 El.m. 2 El.m. 3 Spider 2 Digital/analog
Stroker current(s)
indications
Analog indicators
Speed encoder signal(s)

Monitor switches
Pump1 Pump2 Pump3
Pump4
Function:
Drive 1 Basic
Friction
Syncro
Drive 2 Shredder
Pressure
6.1 General system setup

6.1.1 System function
In MAIN SETTINGS Æ FUNCTION: MAA01 the basic function for the drive is selected. The selectable
functions for the system are (see also block diagrams in AS1 and AS7):
• BASIC – The basic and most common function. The function includes monitoring, speed feedback
and power limitation. This is the function that also is selected for monitoring type unit.
• SHREDDER – Same as for BASIC with added functions for reversing by an overload stopped
drive.
• SYNCHRO – Same as for BASIC with two drives driven together with FRICTION ratio or position
control between the motors.
The PRESSURE function can be used with BASIC, SHREDDER and FRICTION basic function.
6.1.2 System layout configuration
The configuration is needed for the system to

know how the electric motors are connected to the El.m. 1 El.m. 2 El.m. 3
pumps and how the pumps are connected to the
drives.
Setup procedure in MAIN SETTINGS Æ

CONFIGURATION: Pump1 Pump2 Pump3
• To setup the electric motor to pump
connection, set MAB01-04 (pump1-4) to
electric motor 1, 2 or 3. Pump4
• To setup the pump to drive connection, set
MAB05-MAB08 (pump1-4) to drive 1 or 2.
• Finally set the parameter MAB09 to Drive 1
common or separate when using two
drives depending if the drive have common
function or separate. Drive 2
6.1.3 Front control button bypass
The functions for the drive buttons at the front can be bypassed by setting parameter D1A08 (D2A08)
off.
6.2 Speed command

In ANALOG INPUTS-SETPOINT1 (2): AIA(B)01 - 04 the speed
setpoint command source is selected.
yes
Remote setpoint command is a voltage or current signal connected Local/remote
switching
to the terminals. The type must be set with parameter AIA(B)01 and
with jumper SP D1(2), see AS4.5. Remote setopint can also be set no
D1(2)A01=3
via fieldbus (foe settings see AS6.15).
The local command is set with the increase and decrease buttons yes
Local command
on the front. If external increase/decrease is needed, the local
setpoint function can be paralleled by using configurable digital
no
inputs (See AS5.2.3).
The speed command can be locked to local or remote control or be D1(2)A01=1 D1(2)A01=2
switchable with the local/remote button (set with DxA01).
At local/remote switching the local setpoint command can
automatically be set to zero if DxA03 is set to yes. Otherwise the Set type of
setting will be held when switching to remote mode. The reset can command signal
D1(2)A02
also be done by using a configurable digital input
Local increase/decrease will not effect the local setpoint when
running in remote mode.
The remote input must be calibrated as described for the analog inputs (see example in AS6.8).
Inputs for fixed speed forward(set with DxA06) and reverse(set with DxA07) can be selected with
configurable digital inputs.
6.3 Ramp
The start ramp time is the time it takes for the signal to control the hydraulic pump, to go from zero to
100% if the speed setpoint is 100% and drive start is activated. The stop ramp is the time it takes to go
from 100% to zero when drive stop is activated.
Drive start and stop are ramped commands (as well as fixed forward, fixed reverse and inch reverse).
The start ramp is controlled by the parameters DxC01 in forward direction and DxC03in reverse direction.
The stop ramp is controlled by the parameters DxC02in forward direction and DxC04in reverse direction.
Example: If the ”up ramp” D1C01 is set to 10 sec. and the down ramp D1C02 is set to
5 sec. we will get the following output.
The example is based on 50 and 100% setpoint.
Speed
Drive start Drive stop
100 %
Stop ramp
50%
Start ramp
0 10 20 25 Time in sec.
6.4 Output
6.4.1 PWM frequency
The individual settings for each pump are made in PUMP OUTPUTS ( See AS5.2.2)
The outputs are Pulse Width Modulated and the PWM frequency can be set with parameters POx06.
The normal setting is 200Hz but can be set 100 to 2000Hz in steps of 100Hz. If a 5A stroker is used
(can only be controlled in one direction) the frequency must be set to 2000Hz to avoid damaging of the
stroker.
6.4.2 Coil resistance

The nominal resistance for the stroker must be set with parametr POx05. The system will measure the
current in the stroker coil and compensate for the resistance change due to increased temperature.
A typical resistance value is:
5A2 (Denison) 25ohm
9A2 (Denison) 41ohm
SP (Brueninghaus) 20ohm
KA (Sauer Sundstrand) 25ohm
6.4.3 Current setting

For output current setting it is easy to use speed indication if a speed encoder is connected (See
AS6.11 for setup).
.
D(J)07
Lower frquency then 2000Hz can destroy5A2 pump stroker
• Min current forward, parameter POx01.

Start the drive. Increase the current until the drive starts moving forward, decrease until it stops again.
Stop the drive.
• Max current forward, parameter POx02.
Start the drive. Increase the current until the right forward speed is reached. Stop the drive.
• Min current reverse, parameter POx03.

Start the drive. Increase the current until the drive starts moving reverse, decrease until it stops again.
Stop the drive.
• Max current reverse, parameter POx04.
Start the drive. Increase the current until the right reverse speed is reached. Stop the drive.
POx01-04
High current can destroy
pump stroker
6.5 Speed feedback

6.5.1 General
Speed feedback makes it possible to maintain a constant speed at the hydraulic motor shaft. The
Spider compensates for speed deviations due to load changes. To achieve this, a PID regulator is
implemented in the software. This PID regulator compares the actual speed value with the speed set-
point. Any deviation between the two signals is detected as an Error signal and transferred to the PID
regulator. The PID regulator has three different stages.
The proportional part amplifies the Error signal. The Output is proportional to the Error signal.
The Integral stage integrates the Error signal. A small Error signal will over time create a big Integral
stage output.
Derivative stage derives the Error signal. A rapid change will create a big output from the derivative
stage.
The results from the three different stages are added to the stroker output.
The following Example set-up is based on the following facts:

Analog speed encoder with output signal 4-20mA for 0-25Rpm
connected to Analog input 3.
Drive maximum speed is 22Rpm.
The setup regarding speed feedback is made in the following
parameter menus:
"Drive 1 basic - feedback" (D1E01 - D1E03)
"Analog inputs - Analog in 3" (AIH01 - AIH14)
"Pulse inputs - Drive 1" (P1I01 - PII07)
"Drive 1 basic - regulator" (D1D01 - D1D11)
The setup for Drive 2 is identical but the parameters start with "D2xx"
6.5.2 Speed encoder input signal set-up

The type of speed encoder is determined with parameter D1E02.
The possible settings are:
1. Digital feedback.
2. Analog feedback.
3. No feedback.
In this case this parameter is set to 2 -> Analog feedback.
The maximum hydraulic motor shaft speed is set in parameter
D1E01. In this case the parameter is set to 22rpm.
The speed encoder is hooked up to analog input 3, parameters
AIH01 to AIH14 is valid for the set-up. Parameters not mentioned
below are left with the factory setting.
AIH02 and AIH03 are used when calibrating the input. Zero and
span adjustment are possible to make.
AIH05 is set to 25 rpm as that is the range of the speed encoder.
AIH06 is set to rpm.
AIH07 is set to 1 as we want the signal to be presented with one
decimal
AIH09 is set to AS1 meaning Analog Speed drive 1.
AIH12 is set to AUX 1 which is set as a warning, activated when 4 mA is missing. The warning will
indicate a broken speed encoder.
If a digital speed encoder is to be used, parameters P1I01 to P1I07 must be set.

P1I01 parameter value must be the number of digital pulses that the speed encoder produces during
one rotation.
P1I06 can be set if the rotation of the hydraulic motor/encoder is giving a wrong polarity of the reading.
If 1 is set the polarity will change.
P1I07 determines the type of speed encoder used.
1= Quad. This is the standard type with two pulse trains

2= Single pulse with direction. This speed encoder gives a pulse train and in addition a directional
signal ON/OFF.
3= Single pulse without direction. This speed encoder gives one pulse train as an output.
6.5.3 Regulator set-up

The Regulator parameters are all gathered under “Drive 1 basic - Regulator”, parameters D1D01 –
D1D11. Below is a description of each parameter.
Parameter D1D11 has the following choices:
1. Non-regulated drive (Blank indication in 4’th position on display line 1)
2. Regulated drive (REG indication in 4’th position on display line 1)
3. Switching between regulated and non-regulated drive.
Parameter must be set to 2 or 3 to achieve speed feedback. In this case parameter D1D11 is set to 3.
The PID regulator is then possible to activate/deactivate from the Spider front with the predefined
pushbutton REG/UNREG.
D1D01 Sets the regulator function ON or OFF. In this case ON, the regulator is enabled.
D1D02 Feed forward function is set ON or OFF. In this case ON, the speed set-point is put to the
stroker output as an initial value and the regulator compensates for deviations in speed.
If the parameter is set OFF the regulator output will be the only signal to the
stroker output.
D1D03 Sets the Proportional regulator stage function ON or OFF. In this case select ON. The
proportional stage reacts proportional to the Error input signal. Action of this stage is
determined by parameter D1D06.
D1D04 Sets the Integrator function ON or OFF. In this case select ON. This function gives the
drive a possibility to reach set-point speed over time. Action of this stage is determined
by parameter D1D07.
D1D05 Sets the Derivative function ON or OFF. In this case select OFF. The derivative stage is
used when very quick speed changes are to be expected at the drive. It reacts on the
rate of change at the Error input signal. The D stage is seldom used due to a difficult
tuning procedure. Action of this stage is set by parameters D1D08 and D1D09.
D1D06 Proportional gain parameter sets the gain of the P-stage. In this case set to 0.5 as a start
value. P gain 0.5 means that half the Error signal input value will be transferred to the
stage output. Proportional stage however, will not make the drive reach set-point speed.
There will always be a remaining Error. The remaining Error value is though depending
on the Proportional gain setting. If the Error signal is small, close to zero, P gain will not
produce any output at this stage output. The P stage always needs an Error signal to
modify.
D1D07 Integrator time parameter sets the integration time of the I-stage. In this case set to 10
seconds as a start value. Integrator time 10 seconds means that the output value of this
stage will reach 63% of the Error signal input value in 10 seconds. Introduction of
Integration will eliminate the remaining Error signal. The actual speed will over time
correspond to speed set-point. It can be compared with a Capacitor that is charged with
the Error signal.
D1D08 Derivative time parameter sets the Derivative time of the D stage. In this case it is left at
the default value, 10 seconds. Derivative time 10 seconds means that the derivative
“gain” is a factor 10. The output from this stage is the “gain” factor multiplied with the rate
of change of the Error signal.
D1D09 Derivative decline time parameter sets the Derivative decline time of the D stage. In this
case it is left at default value, 10 seconds. Derivative decline time 10 seconds means that
the output value from this stage will decline 63 % in 10 seconds.
D1D10 Max feedback deviation is the allowed difference between command and actual speed. If
this exceeds for 10sec., the drive will switch over to unregulated drive and give the
warning ERROR TOO LARGE.
6.5.4 Regulator tuning
The above settings give in most cases a good performance of the drive. However to optimise the
parameters the following method can be used.
In short words the method is as follows:
Increase the proportional gain until the drive starts to oscillate. Note the oscillation time. Reduce the
Proportional gain with 50 %. Set the Integrator time minimum to the double oscillation time value.
This is a recommended step by step list of how to tune the PI regulator:

1 Select UNREG mode.
2 Make sure that stroker currents are correctly adjusted.
3 Deselect the Integrator stage, by setting the parameter D1D04 to Off.
4 Reduce the ramp time setting to zero or as much as the drive can tolerate.
5 Start the drive.
6 Give about 50 % speed command.
7 Select REG mode. This enables the regulator. Check performance of the drive. If the drive starts
to oscillate, stop the drive and reduce the Proportional parameter value.
8 Increase the Proportional gain in small steps. Start and stop the drive. Check the drive stability.
When the drive starts to oscillate try to determine cycle time of the oscillation (the time from one
pulse top to the next).
9 Decrease the proportional gain value to half of what set in 8.
10 Activate the Integral part by setting the parameter D1D04 to On.
11 Set the Integrator parameter to minimum the double oscillation time.
6.6 Power limitation

Power limitation function is not possible in the monitor type spider. Power limitation
Basic function or higher is needed to get the power limitation function.
Power limitation is aquired by utilizing an analog input for sensing
the electric motor current. See AS 5.2.6 for setup of the analog input.
First set the function for the analogue input in
AS5.2.6:Analog inputs -Analog in x:AIF09-AIN09 toEC1, EC2 or EC3. Set analog input
Limitation level is set with parameters Analog inputs -Power for limitation
limit:AIR01-AIR03 AIF-AIN09=ECx
Limitation function is set with parameters Drive 1(2) basic - power

limitation: D1(2)F01-D1(2)F02, See AS3.3 for connection and type of
analog input.
Set input type
for limitation
Example for power limitation setting Drive 1, Electric motor 1: AIF-AIN01
Electric motor = 163A (from data sheet or motor rating plate)
Current transformer 200A = 20mA
We want to limit electric motor 1 in drive 1. Set max
input current
AIH05, Max input = 200 AIF-AIN05
AIH06, Units for indication = A
AIH09, Function => Power limitation = EC1
Set sort of
D1F01, Delay time = the time the power is allowed to be higher reading
then the level (AIR01) before the limit function starts AIF-AIN06
DIF02, Ramp time = how fast the reaction will be for stroking
Example for power limitation setting Drive 2, Electric motor 3: Set function
Electric motor = 240A (from data sheet or motor rating plate) for input
Current transformer 400A = 20mA AIF-AIN09
We want to limit electric motor 3 in drive 2.
Set level
AIJ05, Max input = 400 for limitation
AIJ06, Units for indication = A AIR01-03
AIJ09, function => Power limitation = EC3
D2F01, Delay time = the time the power is allowed to be higher
then the level (AIR03) before the limit function starts Set filter time
D2F02, Ramp time = how fast the reaction will be for stroking D1(2)F01
Set downramp
The ramp time setting must be set by test with the drive. A too short time
time can cause oscillation in the system and a too long time will not D1(2)F02
(By test)
regulate the current to the max setting (same function as P regulation,
see AS6.5).
6.7 Monitoring
The monitoring function is available in all setups. The pre-defined digital inputs (for monitoring) must
be set to off if monitoring is not wanted. See setup of digital inputs under AS 5.2.3.
6.7.1 Functions for monitoring

The pre-programmed functions can be used on any of the 43 digital inputs that are avaliable. The pre-
programmed functions have 3 different types of indication:
Warning = indication on the display and by a digital output if this function is set (see AS6.10)
Alarm = indication on the display and by a digital output if this function is set (see AS6.10)
This function will stop the drive without ramp and after a short delay open the electric motor
interlock output to stop the motor.
Interlock = same as alarm but without stopping the electric motor.
The Warning, Alarm and Interlock indications must be reset in the Alarm/Warning list after the reason
for the indication is fixed (see AS 4.3).
The pre-programmed functions are described in AS 6.9.2.
6.7.2 Extra monitoring input

There are 20 pre-programmed auxiliary channels that can be used for different functions. One is the
monitoring function. If any of the digital inputs is configured as AUX x (see AS5.2.3, Digital inputs: 13
AUX x) the function for the input will be monitoring The function Alarm, Warning or Interlock for the
input, time delay, memory for the input and the text to be in the alarm/warning list can be set, see
AS5.2.11, Setup – Aux monitor.
Example: Digital input 25 as warning input for high temp Drive 1.
See AS 3.3 for electrical connection of digital inputs.

Set parameter Setup - Digital inputs- DIN25: AUX1.
Set parameter Setup - Aux monitor - Aux 1: AMA01 to W1 (warning drive 1).
Set AMA03 (memory bypass) to preferred function:
(If memory bypass = off: Warning indication will be activated if input is opened
Warning indication will remain if input is closed.
and must be reset in Alarm / warning menu).
(If memory bypass = on: Warning indication will be activated if input is opened
Warning indication will disappear if input is closed).
Set AMA02 to needed delay time between opened input and warning indication.
Set the text in AMA04 to HIGH OIL TEMP by using ∧, ∨ and ↵ buttons.
NOTE: The line has to be filled with blank characters by pushing ↵ until the line is filled.
Available characters are all possible characters for the display. For Chinese characters a VFD display
must be mounted and switch SW3-1 must be set to off.
Setup of this function can either be done on the spider front or via SpiderCom program.
6.7.3 Elecric motor interlock outputs

There are 3 normally high digital outputs for interlock of the electric motors (shall be connected via a
relay in the electric motor stop circuit). The interlock output will open time-delayed after an Alarm.
The delay time is set in Setup-Drive monitor-Emotor interlock: DMD01-DMD03.
See AS 3.4.2 for electrical connection. The interlock is dependent on how the configuration is done in
Setup-Main settings-Configuration, see AS6.1 for description.
The normal stop sequence at alarm:

1. The output to the pump is set to zero without ramp.
2. After a time delay (settable) the electric motor interlock is opened.
6.7.4 Monitoring outputs

There are 13 digital outputs that can be configured in Setup – Digital outputs.
They can be used for monitoring of Alarm, Warning or Interlock or monitoring of a digital input.
It is possible to use an auxiliary function only for controlling a digital output. AMx01 is then set to OFF
and a digital output must be adressed to the aux function.
See AS6.10 for possible settings and functions for the digital outputs.
6.7.5 Tank temp monitoring

The tank temperature can be monitored with digital or analog signal selected by parameter TMB01.
For digital type input functions must be selected, see AS6.9.
The choice of analog sensor can be of Pt100 type (standard) connected to prepaired inputs or
standard analog signal type connected to a configurable analog input. If a configurable analog input is
used the function is set to TANK A. Configurable input selection will disconnect the Pt100 type input.
By using an analog sensor the switch levels for Alarm, Warning, Filter interlock, Min temp, Cooling
control, Heating control and Flushing control can be set within preset limits. All switches exept filter
interlock can be monitored on digital outputs if needed.
Function Setting [°] Hysteresis [°] On [°] Off [°]

Alarm 60 (TMB03) -- 60 60 (must be reset)
Warning 55 (TMB04) -- 55 55 (must be reset)
Cooling 40 (TMB05) 3 (TMB06) 40 (rising temp) 37
Filter interlock 0 (TMB07) -- 0 0
Heating 15 (TMB08) 3 (TMB09) 15 (falling temp) 18
Min 10 (TMB10) -- 10 10
Flushing 15 (TMB11) 3 (TMB12) 30 (falling temp) 33
6.7.6 Alarm stop

As default, the command output to the pumps will be set to zero without ramp to stop the system as
fast as possible. In some applications it can cause mechanical damage to set the outputs quickly to
zero. An alarm ramp time can be set with parameter MAB10 to allow the system to do a controlled
stop.
6.8 Analog inputs

All analogue inputs can be used for current or voltage signals.
Spider has 9 analogue inputs. 2 is dedicated for speed setpoint drive 1 and drive 2.
The 7 remaining inputs are general and can be used for different purposes (see below).
Analogue input setpoint1, setpoint2 and analog in1-2 is isolated with it's own reference ground.
05-01-21, replaces 04-04-02
Analogue input 3-9 is isolated but with common reference ground with the power supply.
All analogue inputs can be connected to current or voltage signals. The function and the zero - and
maxpoint of the input must be set (see AS5.2.6).
The function settings are described for each function in AS6.5 for Analog speed feedback, AS6.6 for
power limitation AS6.12 for Shredder pressure, AS6.13 for Synchro offset and AS6.14 for
Pressure control.
Example of zero and maxpoint setting:

Speed setpoint with a 0-10V signal for drive 1. 10 V corresponds to 100% speed, parameter AIA01=0-
10V.

Connect a 0 V signal to the terminals for analog 1 (+ to terminal AI1:5 and – to terminal AI1:6).
Connect a 10V signal to the terminals.
Repeat adjustments for 0 and 10V until the right reading is achieved. As a test, check that the reading
at 5.0V (50%) is 50%.
Analog in 4 with a 4-20mA signal for power limitation drive 1. 20 mA corresponds to 200A, parameter
AII01=4-20mA and AII06=A
For settings of power limitation, see AS6.6.

Connect a 4mA signal to the terminals for analog 3 (+ to terminal AI2:7 and – to terminal AI2:8).
Connect a 20mA signal to the terminals.
Repeat adjustments for 4 and 20mA until the right reading is achieved. As a test, check that the
reading at 12mA (50%) is 100A.
6.9 Digital inputs

The digital inputs on terminal EI1, DI1, DI2, DI3, DI4, DI5 are all 24VDC functions and are
preconfigured as shown in AS3.7 terminal list.:
-Electric motor started inputs
-Input signals from power unit
-Configurable inputs
-Supply for the inputs
6.9.1 Electric motor started inputs

The electric motor started inputs are to bypass the Charge pressure alarm at electric motor stop and to
prevent against control current to the pump coils at stop. It also controls the cooling control when an
analog temperature transducer is used
6.9.2 Configurable inputs

The configurable digital inputs can be used for control and monitoring.
Function: A=Alarm, W=Warning, C=Control
Abbreviation Description Normal status for Function

input 05-01-21, replaces 04-04-02

For monitoring of pump high pressure in forward pressure
direction.
For monitoring of pump high pressure in reverse pressure
direction.
For monitoring of drive high pressure in forward direction. pressure
For monitoring of drive high pressure in reverse direction. pressure
02 H APR 12 High pressure A-side monitor function for drive 1 and 2 High, low at high W
02 H BPR 12 High pressure B-side monitor function for drive 1 and 2 High, low at high W
For monitoring of pump low charge pressure in forward pressure
direction
For monitoring of pump low charge pressure in reverse pressure
direction
03 C PRB P4 Low charge pressure B-side monitor function for pump 4 High, low05-01-21,
at low replacesA04-04-02
direction
direction
see 04 C PRA D1 pressure
see 04 C PRB D2 pressure

For monitoring of suction line indicator closed oil line



For monitoring of 3/4 clogged filter. clogged
Only applicable when using two level filter indicators.
For monitoring of fully clogged filter (must be exchanged) clogged
06 DRF 75 Monitor of drain filter clogged to 3/4 High, low on filter W

06 DRF 100 Monitor of drain filter fully clogged High, low on filter W/(A)
06 F TEMP Interlock of filter warning inputs High, low on temp W

Used when external temp interlock wanted for filter above set value
functions
07 LO LEVEL Low oil level monitor for tank High, low when W
Monitors Low oil level in PU tank below set level
07 MN LEVEL Min oil level monitor for tank High, low when A
05-01-21, replaces 04-04-02
Monitors Min oil level in PU tank below set level
08 MAX TEMP Max oil temp monitor for tank High, low when A
Monitors max set temp. in PU tank above set temp
08 HI TEMP High oil temp monitor for tank High, low when W
Monitors high set temp. in PU tank above set temp l
08 MIN TEMP Low oil temp monitor for tank High, low when A
Monitors low set temp. in PU tank below set temp
09 ALARM R Remote reset of alarms and warnings Low, High=Reset C
09 BUS R Reset of alarms and warnings via bus High=Reset via bus C
09 BUS 1 Switching to Bus command signals, Drive 1 High=Bus drive 1 C
09 BUS 2 Switching to Bus command signals, Drive 2 High =Bus drive 2 C
09 BUS M Switching to Bus command signal, External master High=Bus ext. C

master
10 SHR 1+2A Shredder forward stop, Drive 1 and 2 High, low at stop C
10 SHR 1+2B Shredder forward stop, Drive 1 and 2 High, low at stop C
10 SH RES12 External reset of Shredder blocked function, Drive 1 and High=Reset C

2
12 RES EN 1 External enable of counter reset in Synchro mode, Drive1 High=Enable of C

reset input
12 RES EN2 External enable of counter reset in Synchro mode, Drive High=Enable of C
2 reset input
12 FRICTION Friction drive in Synchro counter mode High=Friction drive C
12 INV M Inverting of master speed command in Synchro mode, High=Inverting of C

Drive 1 speed command

indication

indication

indication
05-01-21, replaces 04-04-02

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication

indication
14 START 12 Drive start in Remote mode, Drive 1 and 2 High=Start C

pulse=stop

pulse=stop
15 FORW 1 Forward drive with fixed speed, Drive 1 High=Forward

05-01-21, replacesC04-04-02
15 FORW 2 Forward drive with fixed speed, Drive 2 High=Forward C
15 FORW 1+2 Forward drive with fixed speed, Drive 1 and Drive 2 High=Forward C
15 REV 1+2 Reverse drive with fixed speed, Drive 1 and Drive 2 High=Reverse C



increase 1%

decrease 1%

increase 1%

decrease 1%

Low=Local

Low=Local
16 REM 1+2 Remote mode, Drive 1 and 2 High=Remote C

Low=Local

Low=Manual

Low=Manual
17 AUTO 1+2 Shredder Auto mode, Drive 1 and 2 High=Auto C

Low=Manual

Low=Open loop

Low=Open loop
18 REG 1+2 Closed loop speed feedback active, Drive 1 and 2 High=Active C
Low=Open loop
05-01-21, replaces 04-04-02

18ERR1+2R Reset of error too large function, Drive 1 and 2 High pulse = reset C

Low=Local

Low=Local

Low=Not used

Low=Not used
21 OFF Not used
6.10 Digital outputs

6.10.1 Electric motor interlock outputs
The electric motor interlock outputs must be connected via a 24VDC relay to the starter electric stop
circuit. The output is high when it is allowed to run the electric motor and will open by an alarm, if the
Emergency stop input is opened or by the microprocessor watchdog (controls the program function).
6.10.2 Configurable outputs

The configurable digital outputs can be used for control and monitoring, set with parameterDOx01.
The following functions are common for all outputs
1+2 Indication from drive 1 or drive 2
1*2 Indication that both drive 1 and drive 2 are affected
1...x Same function for all outputs with number 1 to x
Output function
Abbreviation Function Normal status for
output
01 A(1,2, 1+2) Monitoring of common alarm Open, closed at
alarm
01 W(1,2, 1+2) Monitoring of common warning Open, closed at

warning
01 INT(1, 2, 1+2) Monitoring of common interlock Open, closed at

interlock
02 START(1, 2, 1+2, 1*2) Drive started Open, closed at

start
03 READY(1, 2, 1+2, 1*2) Drive ready to use after start delay Open, closed when
ready
04 REMOTE(1, 2) Drive in remote mode Open, closed in
remote mode
05 AUTO(1, 2) Shredder in Auto drive mode. Open, closed in

auto mode
05 REG(1, 2) Drive with regulated speed feedback. Open, closed in

regulated mode
06 PLIM(1, 2, 1+2) Power limit active Open, closed at

active limitation
07 FORW(1, 2) Drive running with forward command Open, closed at

forward run
07REV(1, 2) Drive running with reverse command Open, closed at

reverse run
08 C ZERO Counters in Synchro counter function reset and synchro function Open, closed at
activated activated
synchronisation
08 SYNCHRO Synchronisation within the set limits. Open, closed when

within limits
09 AOUT(1...4) Register for analog output has negative sign Open, closed when
negative
10 EMOTD(1, 2, 1+2, 1*2) Electric motor(s) started Open, closed when

started
11 LOW TEMP Indication for min oil temp active Open, closed when
active
11 HI TEMP Indication for high oil temp active Open, closed when
active
11 MAX TEMP Indication for max oil temp active Open, closed when
active
11 COOL CONI Start cooling interlocked with electric motor started Open, closed for
11 COOL COND Start cooling controlled directly from temp sensor Open, closed for
11 HEAT CON Start heating (with analog temp sensor) Open, closed for
heating
11 FLUSHCON Control of flushing circuit (with analog temp sensor) Open for cooling,
closed for heating
12 P(1, 2) C ACT Pressure control of output active Open, closed at

pressure control
12 P(1, 2) HI CA High Pressure control of output active Open, closed at

pressure control
12 P(1, 2) LO CA High Pressure control of output active Open, closed at

pressure control
13 SH BLCK(1, 2) Shredder blocked in auto mode Open, closed when

blocked
14 AUX(1...20) Auxillary function active Open, closed when

active
15 OFF Output not used
6.10.3 Inverted function

An output can get inverted function to normal status by setting parameter DOx02 to yes.
6.10.4 Delayed function

An output can get a time delay by parameter DOx04. The time for the delay is set with parameter
DOx03.
The function can be set to:
ON On delay From the moment when the function for the output is activated , the output will
not be active until the delay time is passed.
OFF Off delay From the moment when the function for the output is deactivated , the output
will not be inactive until the delay time is passed.
PULSE Output pulse From the moment when the function for the output is activated , the output will
be active only during the delay time.
OFF No delay
6.11 Signal monitor

The signal monitor is the reading of the process values (REGxx) indicated with a frame in the block
diagrams, see AS7. It is possible to select and monitor 4 fixed values and a scroll list of up to 9 values
on each display. The possible settings are found in AS5.2.20 and is set in Reading 1(2).
The readings can be used to show process values during drive but can also be used for
troubleshooting. The internal values are normally indicated as a % value
6.11.1 Setpoint indication

The setpoint for the speed can be indicated as a % value with REG102(202). If the setpoint should be
indicated as a rpm value this can be monitored with REG107(207). For this indication parameter
D1(2)E01 must be set to the speed corresponding to 100% command.
6.11.2 Analog input indication

The analog inputs can be indicated with REG 40x where x stands for the input number between 1 to 9,
eg. REG 405 for analog input 5. For each input the units can be set with parameter AIx06 and the
number of decimals with parameter AIx07. The reading can also be scaled to fit eg. a conveyor speed
with parameter AIx08.
6.11.3 Analog bus input indication

The analog inputs from the fieldbus can be indicated with REG 50x where x stands for the input
number between 1 to 4, eg. REG 502 for analog input 2. For each input the units can be set with
parameter BAx03 and the number of decimals with parameter BAx04.
6.11.4 Temperature indication

A PT100 Analog temperature sensor can be indicated with REG 410. Temperature is normally
indicated as °C. If the unit is changed to °F the reading is automatically calculated.
6.11.5 Output indication

For the pump controls the current to the coil can be indicated in mA with REG3x1 where x stands for
the pump number eg. REG 321 for pump 2.
6.11.6 Internal indications

The internal indications can be used for troubleshooting or as indications during setup.
Register Function Reading
REG 101(201) Input command % or actual signal
REG102(202) Speed setpoint %
REG107(207) Speed setpoint rpm
REG103(203) Input command %
REG104(204) Ramped command %
REG108(208) Ramped command rpm
REG105(205) Speed error signal %
REG106(206) Input to output amplifier %
REG110(210) Speed signal %
REG111(211) Pressure command %
REG112(212) Regulated pressure command %
REG113(213) Pressure compensation %
REG114 Master command %
REG115(215) Stop angle °
6.11.7 Diagnostic readings

The diagnostic readings can be used for checking the load of the microcontroller.
REG 901 Time for the internal PC task (msec)
REG 902 Max time for the internal PC task (msec)
REG 903 Time for the internal UI task (msec)
REG 904 Max time for the internal UI task (msec)
REG 905 CPU load (%)
REG 906 Max CPU load (%)
REG 907 Stack usage, PC task (%)
REG 908 Stack usage, UI task (%)
REG 909 Stack usage, serial port (%)
6.11.8 Bus readings

The bus readings are used to indicate digital inputs from fieldbus.
6.11.9 Scroll menu

For each reading in the scroll list it is possible to set a text and a REG. The text and the REG will be
shown on the same line.
The scroll list is activated by ◄ for left display and by ►for right display and active list is indicated with
two arrows on the scroll list. The scrolling is done with ▲ or ▼ and only the activated indications will
be shown.
The scrolling will be active 10sec after ▲ or ▼ is used and have to be activated again for scrolling
Example:
Tank temp and a pressure transducer on analog in 3 indicated on display 2:
R2A01 - TANK TEMP
R2A02 – REG401
R2A03 – PRESSURE
R2A04 – REG403
Will give:
→ TANK TEMP 37.8ºC ←
PRESSURE 143bar
▲ or ▼ will alter between these two readings.
6.11.10 Emergency stop angle indication

The movement angle of the roll between activated emergency stop and actual stop can be indicated in
° with REG115(215). This function requires digital speed encoder.
6.12 Shredder
The selection of shredder function is made by setting parameter MAA01 to SHREDDER (see AS6.1).
The specific parameters are found in SETUP – SHREDDER 1(2).
In shredder all features described in 6.1.- 6.11 are avaliable except for the possibility to switch
between speed regulated and non-regulated drive. The selection of speed regulation has to be set
with parameter SHA(G)10.
The added functions are for the reversals by an overloaded drive.
The shredder has two drive modes, manual and auto.
In manual drive mode the forward button (or by configurable input set as L FORW1(2)) is used for
running forward and the reverse button (or by configurable input set as L REV1(2)) is used for running
reverse. The drive will run as long as the input is activated and stop when input is opened. The
reversing function is bypassed in manual drive.
In auto drive mode the start button (or by configurable input set as L START1(2)) starts the drive with
the automatic reversing function and is stopped with the stop button(or by configurable input set as L
STOP1(2)). A configurable digital input can be used for start in remote mode.
The switching between manual and auto is made with the MAN/AUT button or with a configurable
digital input (will bypass the button).
A digital output can be used for indication of auto mode.
6.12.1 Speed setpoint

The forward speed setpoint is handled as described in AS6.2 but must be a positive signal. The
reverse speed setpoint can be the inverted forward setpoint scaled with parameter SHB(H)02 (e.g.
reverse always 50% of forward speed) or a fixed command set with parameter SHB(H)01 and SETUP
– DRIVE 1(2) BASIC: D1(2)A05.
6.12.2 Overload detection

The detection of overloaded drive is made with parameter SHA(G)01. The selection can be between:
-Pressure switches that opens at high pressure
-Speed encoder to detect stopped drive
-One pressure transducer in a common pressure port for both directions
6.12.3 Reverse counter

The number of reversals within a limited time window can be set with parameter SHC(I)01 and 02 for
stopping the drive. If the function is not wanted the time window can be set to 1. If the counter setting
is reached the drive will go to manual and the warning text SHREDDER BLOCKED will appear in the
alarm/warning list. The warning must be reset before auto start is possible. The warning can also be
reset by a configurable digital input.
6.12.4 Reverse blocking

The function if the drive blocks during reverse drive can be set with parameter SHA(G)02.
If 1(Stop) is selected the same result will appear as if the counter setting is reached.
If 2(Forward) is set the drive will switch back to forward drive without stopping.
6.12.5 Interval timer

A function for a preset forward/reverse interval can be swiched on by parameter SHA(G)07 or by a
configurable digital input set to INTERV 1(2).
The forward drive time is set by parameter SHA(G)08 and the reverse drive time is set by parameter
SHA(G)09.
6.13 Synchro
The Synchro function set-up is to be found in the following parameter menus
"Synchro - Function"
"Synchro - Drive 1 reset"
"Synchro - Drive 2 indication"
"Synhcro - Drive 2 reset"
"Synchro - External Master"
See also block diagram AS7-7.

The Synchro function is divided in two parts, RATIO and COUNTER. The selection is made with
parameter SYA01.
6.13.1 Ratio drive

the synchro ratio function controls two drives with a friction ratio between the drives. Drive 1 is the
master and Drive 2 is the slave. Drive 1 speed set-point is multiplied with Drive 2 ratio set-point
creating the Drive 2 speed command. The ratio set-point can be a value between -300% and 300%.
SYC01 and SYC02 can be used to limit the span. Setpoints can be hardware signals or signals via the
bus connection. In local mode setpoints are given via the keyboard and display units.
6.13.2 Ratio drive - External master

the synchro ratio function controls two drives with a friction ratio separate for each drive. Drive 1 and
Drive 2 are slaves. An external master speed set-point is multiplied with Drive 1 ratio set-point creating
the Drive 1 speed command. The same is valid for drive 2. The ratio set-point can be a value between
-300% and 300%. SYC01 and SYC02 can be used to limit the span for Drive 2. SYG01 and SYG02
can be used to limit the range for Drive 1. A separate ramp-time, only valid for the External master set-
point, can be adjusted by setting SYF01 - SYF04.
Setpoints can be hardware signals or signals via the bus connection. In local mode setpoints are given
via the keyboard and display units.
6.13.3 Counter drive

The synchro counter function can control the relative position in-between two drives. The counter drive
function is selected with parameter SYA01 = COUNTER. The function requires digital type Speed
encoders. They must have identical number of pulses per turn. Drive 1 is the master and Drive 2 is the
slave. Drive 1 speed set-point is transferred to both drives as a basic speed set-point. Drive 1 is run in
closed loop speed control. Drive 2 is run in closed loop position control. The pulses from each encoder
are counted in two counters and compared. If there is a difference between the two counters, there is
a difference in position of the two drives. The difference signal is processed by Drive 2 regulator and
added to the speed set-point for control of Drive 2 position.
The two counters must initially be reset when the position difference is zero in-between the two rolls.
Parameter SYB02 and SYE02 determines when the counters are enabled to be reset.
1= Enable reset every time electric motor is started
2= Enable reset every time drive start is activated
3= Enable reset by a configurable digital input, set to 12 RES EN 1(2)
Parameter SYB01 and SYE01 determines when/how the counters are to be reset.
1= Reset every time drive start is activated.
2= Reset by activation of the external zero pulse input
The position control of drive 2 is activated when both counters are reset. A ramptime can be adjusted
to achieve a smoth synchronisation; this is done with parameter SYD02. The activation of the
regulator can be indicated by a digital output, set to 08 C ZERO. While operating in counter mode, the
ratio drive can be activated by a configurable digital input, set to 12 FRICTION. The input can be
either a hardware signal, or in bus mode a bus signal.
Offset between the two drives can be set in two ways:

-As a constant value by parameter SYC04.
-With an analog input, the range is maximum 0 to 180°.
-Via the bus connection.
6.14 Pressure control

The Pressure control function set-up is to be found in the following parameter menus
See block diagram AS7-8.

Pressure 1 control function is described in this section, Pressure 1 and Pressure 2 control functions
are identical. The Pressure control function is providing a possibility to compensate speed set point
depending on the pressure level in the hydraulic system. It can be used as an overload protection or
as a production improvement function, stable torque can be achieved. Digital outputs can be set -up to
indicate if pressure control is active. There are three choices available, P1 C ACT, P1 HI CA and P1
LO CA. For explanation of the outputs, see chapter Digital outputs. The below diagram describes the
pressure control function, forward action. If pressure is increasing the speed set point is increasing.
By altering a parameter, PRA02 = On, reverse action is selected. The below diagram describes the
pressure control function, reverse action. If pressure is increasing the speed set point is decreasing.
6.14.1 Pressure 1 - function

The pressure control function is selected to be active with parameter PRA01 = On. In addition high
and low control is possible to enable separately. This is done with parameters PRA03 and PRA04.
PRA05 and 06 determines the time delay for pressure control to start. It sets the delay in-between a
pressure change above or below set point and regulation start.
6.14.2 Pressure 1 - Set point

Pressure set point can be local or remote. PRB01 selects if the set point is to be Local, remote or
possible to change via a digital input. The digital input is named PR REM 1. The remote set point can
be via hardware inputs or via bus inputs. The local set point must be entered in parameter PRB02.
PRB03 and 04 defines the dead band of the pressure control. When actual pressure is within Pressure
set point - PRB03 and Pressure set point + PRB04 the speed command is not altered. PRAB05 and
06 defines the maximum influence the pressure control is allowed to have on the speed command.
The unit is % and relates to the full speed range of the drive.
6.14.3 Pressure 1 - Regulator

The PID regulator has a similar parameter set as the standard speed feedback PID control. See
chapter AS6.5 for tuning recommendations.
PRC01 Sets the Proportional regulator stage function ON or OFF. The proportional stage reacts
proportional to the Error input signal. Action of this stage is determined by parameter
PRC04.
PRC02 Sets the Integrator function ON or OFF. This function gives the drive a possibility to reach
set-point pressure over time. Action of this stage is determined by parameter PRC05.
PRC03 Sets the Derivative function ON or OFF. The derivative stage is used when very quick
pressure changes are to be expected at the drive. It reacts on the rate of change at the
Error input signal. The D stage is seldom used due to a difficult tuning procedure. Action
of this stage is set by parameters PRC06 and PRC07.
PRC04 Proportional gain parameter sets the gain of the P-stage. P gain 0.5 means that half the
Error signal input value will be transferred to the stage output. Proportional stage
however, will not make the drive reach set-point pressure. There will always be a
remaining Error. The remaining Error value is though depending on the Proportional gain
setting. If the Error signal is small, close to zero, P gain will not produce any output at this
stage output. The P stage always needs an Error signal to modify.
PRC05 Integrator time parameter sets the integration time of the I-stage. An integrator time 10
seconds means that the output value of this stage will reach 63% of the Error signal input
value in 10 seconds. Introduction of Integration will eliminate the remaining Error signal.
The actual pressure will over time correspond to pressure set-point. It can be compared
with a Capacitor that is charged with the Error signal.
PRC06 Derivative time parameter sets the Derivative time of the D stage. A derivative time 10
seconds means that the derivative “gain” is a factor 10. The output from this stage is the
“gain” factor multiplied with the rate of change of the Error signal.
PRC07 Derivative decline time parameter sets the Derivative decline time of the D stage. A
derivative decline time 10 seconds means that the output value from this stage will
decline 63 % in 10 seconds.
PRC08 Filter time for pressure feedback parameter sets the filter time for the pressure. Useful
when the pressure signal contains a lot of noise, the filter will take away pressure peaks.
6.15 Bus Communication

The bus communication is set up in the following menus
"Bus - Type & Function"
"Bus - Digital Inputs"
"Bus - Analog in 1 - 4"
"Bus - Analog out"
See block diagram AS7.2 and parameter list AS5.2.8 for further details.
6.15.1 General
The Bus function requires that a bus card is installed. The card is a profibus-DP slave following the
standard PROFIBUS-DP EN 50 170. It must be connected to a profibus-DP master. The card will only
respond to incoming commands, working as a slave.
The Bus function is activated when a digital input or a bus input is activated and remote mode is
selected via the keyboard. The digital inputs are BUS 1 and BUS 2, these inputs makes it possible to
select bus control separately for drive 1 and 2. Speed set-points are located at predefined bus
addresses. See chapter AS 6.15.9. The below sketch explains the possible mode changes.
LOC/REM button or digital input

REM 1 (Drive 1)
REM 2 (Drive 2)
Bus card not installed
(BTF01 = Off)
LOC REM BUS Bus card installed
and selected (BTF01 = Profibus)
Digital in
Bus digital in
OFF ON
BUS 1 (Drive 1)
LOC/REM button or digital input BUS 2 (Drive 2)
REM 1 (Drive 1)
REM 2 (Drive 2)
Bus fail
Bus communication fail+timedelay (BTF02)
Alarm/Interlock (selectable via BTF03)
Hardware fail
Alarm/Interlock (selectable via BTF03) Prevents Bus mode
If the bus communication is lost, an alarm or Interlock is trigged. An adjustable timer determines the
filter time for the alarm/interlock. Local mode is activated if the bus is faulty. To be able to start bus
communication again the spider must be restarted by reset or power on.
6.15.2 Bus - Type & Function

The bus communication is activated by setting the parameter BTF01 to "Profibus". BTF02 sets the
Communication drop out time. The timer range is 0 - 10 seconds. BTF03 Function at communication
drop determines if an Alarm or an Interlock is activated at a bus failure.
6.15.3 Bus - Digital inputs

A total of 24 digital input signals can be set-up in the parameters BDI01 to BDI24. The choices are
equal to the choices possible in the hardware digital input setup, see list in chapter AS5.2.3. The
following choices from that list are not valid for the bus inputs:
- START 12
- FORW 1+2
- REV 1+2
- REM 1+2
The digital inputs status is possible to monitor on the spider display. Register REG 511 to REG 513
are representing the status of the inputs. Each register contains 8 digital signals. The value of each
signal can be 0 or 1; the format is binary.
REG/BIT 8 7 6 5 4 3 2 1
6.15.4 Bus - Analog in 1 - 4

A total of 4 analog input signals can be set-up in the parameters BAAxx to BADxx. Min and Max
values are defined in BAx01 and BAx02, giving the range of the signal. BAx03 is defining the type of
unit and BAx04 defines the number of decimals for the signal. The signal is then ready to be
displayed. The signals are named REG501 to REG 504. The final step is to define the function. This is
done with the parameter BAx05, the possible settings are:
- BSO = Synchro offset.
- BMS = Master speed set-point
- OFF = Not used (Selected when signal is to be displayed only).
See AS6.15.9 for addresses on the bus.
6.15.5 Bus - Analog out

A total of 8 analog output signals can be set-up in the parameters BAK01 to BAK08. See the
parameter list for a list of selectable registers and AS6.15.10 for addresses on the bus.
6.15.6 Bus - Digital out

A total of 144 digital output signals are available for the Profibus-DP master to read. The signals are
predefined and addresses on the bus are described in chapter AS6.15.11.
6.15.7 Address table - Incoming data

In total 16 bytes are received from the Bus. Analog value data is to be in the data form "signed word"
which should be limited to a value range in-between -10 000 to +10 000. The first two words are
reserved for the set-points for drive 1 and drive 2. The following 4 words are selectable analog inputs,
as earlier described. Digital signals are represented by one bit, in total for 24 inputs, 3 bytes.

Byte
Set point 0 15 8 0001 1101
= 7500
drive 1 1 7 0 0100 1100
Set point 2 1101 1000
= -10000
drive 2 3 1111 0000
4 0010 0111
Analog IN 1 = 10000
5 0001 0000
6
Analog IN 2
7
8
Analog IN 3
9
10
Analog IN 4
11
12 7 0
Digital IN 13 15 8
14 23 16
Reserved 15 0000 0000
The analog values are in "signed word" data format. Negative numbers are the 2's complement of the
positive ones. Below is a table with some examples
Signed word value, binary format Decimal value % signal value

Most significant byte Least significant byte
0010 0111 0001 0000 10000 100
1101 1000 1111 0000 -10000 -100
0001 0011 1000 1000 5000 50
1110 1100 0111 1000 -5000 -50
0000 1001 1100 0100 2500 25
1111 0110 0011 1100 -2500 -25
6.15.8 Address table - Outgoing data

In total 38 bytes are transferred to the Bus. Analog value data is in the data form "signed word", limited
to a value range in-between -10 000 to +10 000. The first word is reserved for the protocol version, the
second for the software version. The following 8 words are the selectable analog outputs, as earlier
described. The last 18 bytes are the digital outputs. Digital signals are represented by one bit, in total
for 144 outputs, 18 bytes. Digital outputs addresses are separately described in chapter 6.15.11.

Byte
Protocol- 0 0000 0000 Reserved
version 1 3 0 3 0 0001 0000 = ver 1.0
Software- 2 3 0 3 0 0011 0001
= ver 3.1.2
version 3 7 0 0000 0010
4 15 8 0000 1001
Analog OUT 1 = 2500
5 7 0 1100 0100
6
Analog OUT 2
7
8
Analog OUT 3
9
10
Analog OUT 4
11
12
Analog OUT 5
13
14
Analog OUT 6
15
16
Analog OUT 7
17
18
Analog OUT 8
19
20 7 0
Digital OUT
21 15 8
…
…
…
37 143 136
6.15.9 Digital output address table




DB20 to DB25 are signals to be found in the list of available functions for the digital relay outputs,
described in AS6.10.
DB26 to DB37 are partly signals to be found in the list of available functions for the digital inputs,
described in AS6.9.

The drive monitoring log consists of three parts, alarm/warning lists, drive time counters and 8
scalable log channels. The alarm/warning lists and drive time counters can be indicated on drive 1
display. The total drive log information must be downloaded to a PC for examination. This requires
a null modem cable 576 00xx-801, a PC with windows XP and SpiderCom software installed.
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are DRIVE (the time with drive
started) and PUMPS (the time with started electric motor for each pump). The counters can be
reset , see RESET TIME below.
SETUP – DRIVE LOG and are protected by a password. The settings can only be done from the
front keypad.
LOG1 to LOG 8 are for setting of the eight one dinensional scalable drive monitoring log channels.
Example: 90-100
- Log channel 2
70-90
50-70
30-50
10-30
- Pressure transducer, 0-400 bar on Ain 4.

0-10
Log Total time

- 200 hours period measuring time data
Period 5
90-100
1.Analog input setting:

70-90
50-70
30-50
Time MT 10-30
AII01=4-20mA for the input signal type.

0-10
AII02,03 for zero and max adjustment of the input Period 1

When full
(see example in AS6.8) 90-100
AII04=0 to set the pressure at 4mA. Time MT 70-90

50-70
30-50
10-30
AII05=400 to set the pressure at 20mA.

0-10
Period 2
AII06=bar for the reading units. 90-100
Time MT 70-90
50-70
30-50
2.Log setting:
10-30
0-10
Period 3
SETUP – DRIVE LOG – LOG 2:
STA=ON will activate the log function Time MT
90-100
70-90
50-70
30-50
MT=200 to set the short time measuring cells Period 4

10-30
0-10
(period 1-4) to 200 hours. Period 1 cell will show

the latest up to 200 hours measurement. When this Erased
cell is full the contents will be moved to period 2 cell
and period 1 cell will start from zero again. Next time period 1 cell is full the contents of period
2 cell will be moved to period 3 cell, the contents of period 1 cell will be moved to period 2 cell
and period 1 cell will start from zero again, and so on. When all cells are full the oldest cell
contents will be erased before the next data movement.
LHI=300 to set where level 6 starts
LLO=100 to set where level 1 stops. The area between LLO and LHI will be divided into 4
equal parts. In this case the levels will be:
0-100bar drivetime
REG=REG404 to select log reading of analog in 4.
When finished setting the question RESET LOG? comes. Select with > button and push ∧ to
get a Y (yes) and then > button to reset. The questions comes if a change is done in any of
the parameters in the specific log channel setup and doesnot affect the other three channels.
The log can be set on or off with STA=OFF or ON without the need to reset the log channel.
RESET TIME for reset of the drive time counters. When the function is selected with > button
push ∧ to get a Y (yes) and then > button to reset.
6.17 Analog outputs
The spider card has four output channels. Each channel can be selected as 0-10V or 2-10V
voltage output or as 0-20mA or 4-20mA current output. The selection between current and
voltage is made by jumpers on the card and by using different terminals.
The selection between 0-10V and 2-10V or between 0-20mA and 4-20mA is made with
parameters in the setup menu.
The outputs can be zero and maxpoint adjusted.
Example for channel 1, 4-20mA for 0-20rpm speed from digital speed encoder.
1. Set parameter D1E01 to 20.0rpm (the speed that corresponds to 100%).
2. Connect a current meter in series with the output signal.
3. Parameter AOA02 must be ON for 4mA output.
4. Select parameter AOA03. The system gives 0% to the card. Adjust the parameter until
closest to 4mA output.
5. Select parameter AOA04. The system gives 100% to the card. Adjust the parameter
until closest to 20mA output.
6. Repeat 4 and 5 until the best result is achived.
6.18 Language selection

A language selection for the alarm/warning list texts and in some cases indication texts on the
main display can be done in the menu (SETUP – MAIN SETTINGS - LANGUAGE :MAC01).
The selectable languages are: English (Default language)
German
French
Spanish
Italian
Japanese (Requires the standard LCD display type)
Dutch
Finnish
Swedish
Short form (abbreviations)
Chinese (Requires a VFD display type)

The system saves the log on a separate memory card (shared with paramterer memory).
The drive monitoring log consists of four parts, alarm/warning lists, drive time counters, six
scalable log channels and two scalable 3D-log channels. The alarm/warning lists and drive time
counters can be indicated on drive 1 display. The total drive log information must be downloaded
to a PC for examination. This requires null-modem cable 576 3521-003, a PC with windows XP
and SpiderCom2 software installed.
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are PUMP (the time with started
electric motor) and DRIVE (the time with drive started). The counters can be reset , see RESET
TIME below.
SETUP – LOG FUNCTION and are protected by a password.
LOG1 to LOG 8 are for setting of the eight scalable drive monitoring log channels.
RESET TIME will reset the time counters for total drive time.
6.20 Emergency stop

The Emergency stop circuit consist of two parallel systems. The main system is a monitoring channel
configured as Alarm. The time delay between opening of the emergency stop input and the shutdown
of the electric motors is set with parameter DMD01-03.
The backup system is a hardware timer on the board with possibility to set the delay between 2 and 32
sec with SW1 (see AS4.5).
The timer must be set 0 - max 4sec longer then the main system. A time set more then 4 sec longer
will give a warning. If setting is shorter or 5sec longer the system will shutdown at hardware test.
Setting Time delay

0 2 sec
1 4 sec
2 6 sec
3 8 sec
4 10 sec
5 12 sec
6 14 sec
7 16 sec
8 18 sec
9 20 sec
A 22 sec
B 24 sec
C 26 sec
D 28 sec
E 30 sec
F 32 sec
At each power up and each time all electric motors are stopped, the system will check that the relays
for the electric motor interlock outputs not are stucked in closed position.
The emergency stop alarm is as default with memory and must be reset but can be set to automatic
reset with MAB11:ON.
6.21 Program update

The program version can be updated by using the cable used for SpiderCom (576 3521-003) and the
software program Loader.exe (Spider flash loader).
Run Loader.exe. Select the file for download Start the procedure
Reset the Spider board by pushing the reset button or by switching on and off the power to the card to
start the download procedure.
When the download is ready, reset the Spider system and set new parameters.
6.22 Hardware calibration

When the software is updated a hardware calibration is needed. This calibration is needed to
compensate for the offset in the measuring channels for the stroker current feedback. This calibration
must be done without stroker coils connected.
Disconnect contact PO1, PO2, PO3 and PO4.

In the main menu there is a choice for this calibration
HW CALIBRATION
↵ ⇒ PWM OFFSET
↵ ⇒ CAL. OFFSET NO
∧ ⇒ CAL. OFFSET YES
↵ will start the calibration. Calibration OK and the calibration settings will be indicated when the
procedure is ready. This adjustment will be stored in an EEProm on the main board.
AS-7.1
Spider Digital inputs
AS-7.2
Spider Analog in- and outputs
AS-7.3
Spider Pump outputs
AS-7.4
Spider Monitor
AS-7.5
Spider Basic function
AS7.5, Basic function, Engineering manual 04-04-02
AS-7.6
Spider Shredder function
AS7.6, Shredder function, Engineering manual 04-04-02
AS-7.7
Spider Synchro function
AS7.7, Synchro function, Engineering manual 04-04-02
AS-7.8
Spider Pressure function
AS-7.9
AS-7.9

M-020 Volume 2 Manual Belt Feeders

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Aker Kvaerner

San Cristobal Project

Purchase Order 0 507 001 57 27

Sales Order 2 005 302 2

(2/2001) Engineering Group-Hägglunds North America www.hagglunds.com

Phone: (614) 527-7400

United States Regional Offices Canadian Regional Offices

(2/2001) Engineering Group-Hägglunds North America www.hagglunds.com

Page 1 of 4 Form No.: F10400-4 | Release Date: 04-Nov.-04 l Revision: F

Page 2 of 4 Form No.: F10400-4 | Release Date: 04-Nov.-04 l Revision: F

Page 3 of 4 Form No.: F10400-4 | Release Date: 04-Nov.-04 l Revision: F

Page 4 of 4 Form No.: F10400-4 | Release Date: 04-Nov.-04 l Revision: F

* - Indicates Items supplied loose to be installed by Customer

TOTAL: 26268.42 1868.50

* - Indicates Items supplied loose to be installed by Customer

CB2005033.xls Form No.: F10203-2 | Release Date: 4/12/2000 | Revision: ORIG

Job Number: 2005 033 Serial Number: 517-2-21190

Type of Control Device

Power Unit Switch Indications

PWM Driver Soft Stop Emergency Stop

Jupiter 500 Driver Card (S20-11712)

REMOTE VOLTAGE & CURRENT INPUT CONFIGURATION

Inputs and Outputs

Job Number: 2005 033 Serial Number: 517-2-21190

Electric Motor No. 1

Does Motor Have Space Heater: Yes No

Does Motor Have bearing RTD’s: Yes No

Does Motor Have stator RTD’s: Yes No

Does motor have grease fittings installed: Yes No

Mechanical Centering: OK, Re-center

Compensator Setting: Port A: 4200 psi, Port B: 4200 psi

Pump Shaft Seal Leak Check OK

Power Unit Hydraulic Components

Hoses, couplings, and fittings checked for oil leaks: OK

Power Unit Electrical Function Check

Tested By:WK Date:16SEP05

*TT-1 / LS-1,LS-2 :FLUID LEVEL TEMP. SENSOR / Version 2.03

This manual provides necessary information for installation and maintenance

This Installation and Maintenance Manual is valid

2. TECHNICAL DATA .......................................................................................................... 7

4. OPERATING INSTRUCTIONS .................................................................................... 28

DANGER is used to indicate the presence of a hazard

WARNING is used to indicate the presence of a hazard

CAUTION is used to indicate the presence of a hazard

1.2 Motor data

1.3 Functional description

Fig. 1 The COMPACT CB motor

7 9 A = inlet or outlet port »A«

In hanging load applications, charge

Table 2.1a Charge pressure

Recommended charge pressure [psi]

RECOMMENDED CHARGE PRESSURE - COMPACT CB MOTORS

Recommended charge pressure [psi]

2.2 Sound from a complete installation

Pump Pipe Hydraulic Noise from

Foundation and construction noise

2.3 Choice of hydraulic fluid

Viscosity limits Nitrile seals (std motor) -35°C to +70°C

** Low viscosity gives reduced service life for "COMPACT CB".

Fire resistant fluids

HFD synthetic fluids

Environmentally acceptable fluids

Fluid Approved Seals Internal paint