Manual Triturador CPM

CPM PAGE ONE ITEMS
SERIAL NUMBER: 442753

CUSTOMER: CPM Europe (Van Aarsen)
MODEL: CMX120072DS W/Roll Feeder
CUSTOMER PO: 02/16/15
QUANTITY PART NUMBER DRAWING PART DESCRIPTION

1.00 3457005 Filter,Air
1.00 3834482 Gearmtr,FT47GDRE80M4 1HP IP55 79.7:1 3/60/380 1800 1.25"Bore
2.00 71921 Bushing,QD SF 42mm
2.00 7241700E1B Roll,Stationary CMX1200-72 8 Groove,RBV,2.5 Degree
2.00 7241750E1B Roll,Adjustable CMX1200-72 8 Groove,RBV,2.5 Degree
4.00 8118150 8118100 Disc Spring Stack Belt Drive CMX Crumbler (50 Springs)
1.00 8129913 NONE Safety Label Kit (Portuguese) SP&DP1000/1200 W/Roll Feeder
1.00 8161700 NONE Assy,Emergency Stop (No Tag) E-Stop Switch,Stahl 1 NO\1 NC
2.00 GA-16279-3 16279-3 Roll Assembly Comp. XPB1000/1200 Roll Mills
1.00 GA-16285-4 16285-4 Lubrication Components CMX1200 DS Crumbler
1.00 GA-16361-22 16361-22 Feed Gate Adjust AA, CMX1200 2-Position,24 Volt
1.00 GA-16364-14 16364-14 Main Drive Comps. CMX1200DS 1500 RPM,3 Groove,30HP,778,SF
1.00 GA-16420-17 16420-17 Frame Components CMX1200-72DS
1.00 GA-16421-12 16421-12 Guard Components CMX1200DS Crumbler
1.00 GA-16459-7 16459-7 Divider, Comp. CMX1200-72 Double Stand W/Wide Doors
1.00 GA-16539-14 16539-14 IRD Components 1.5:1,3 Groove CMX1200DS Crumbler
1.00 GA-16737-97 16737-97 Roll Feeder Comps. w/Magnet CMX1200-72DS Crumbler SEW FT47
1.00 GA-16926-39 16926-39 Roll Adjust Comp, Air Actuated CMX1200-72DS 24V
MAIN DRIVE: ILLUSTRATIONS:

ELECTRICAL: 3/60/380 GENERAL DIMENSION: A36065
CONTROL: 24 VDC CONTROL SCHEMATIC: A31378
NEMA: TEFC HYDRAULIC SCHEMATIC:
HP: 18.5 KW (25 HP)
RPM: 1800 RPM
FRAME: 160L
Page 1 of 1
GENERAL ASSEMBLY 8118150
DRAWING # 8118100
Disc Spring Stack Belt Drive
CMX Crumbler (50 Springs)
02/16/15
ITEM QUANTITY PART NUMBER PART DESCRIPTION

50.00 3772401 Spring, Disc 2.760 Od X 1.398"
X .118" Am703630
Page 1 of 1
DRAWING # NONE
Safety Label Kit (Portuguese)
SP&DP1000/1200 W/Roll Feeder
02/16/15

1.00 5246900BR Label,Brazil Port/see note
Rotation
1.00 5280100P Label,(Portugs) Relocate
Emergency Stop Switch
1.00 7295103 Nameplate, Serial Number
Roskamp
1.00 8064210 Container Assy/Roller
Mills/Crumblers
2.00 3302933 Decal,(Portges) Operation
Manuals/Warning-Vinyl
2.00 3303025P Decal,(Portugese) Rollers
Rotating Warning-Vinyl
5.00 3309333 Decal,(Portgse)-Belt Driv
Rotate Prts Warning-Vinyl
1.00 3309553 Decal,(Portgse)(Dischrge)
Rotng Prts/Warning-Discrg
2.00 3309563 Decal, (Portgse) (Inlet)
Rotng Parts/Warning-Vinyl
1.00 3764250P Notice,(Portugese) Sheave
Alignment
1.00 3802500 Label,Use Genuine Roskamp
Parts
1.00 3809100P Decal,(Portuguese) Flying
Material/Warning-Vinyl
1.00 3811000P Decal,(Portugese) Feeder
Rotating Parts/Warn-Vinyl
1.00 3824213 Label,Lubrication Portgse
(Portuguese)
Page 1 of 1
DRAWING # NONE
Assy,Emergency Stop (No Tag)
E-Stop Switch,Stahl 1 NO\1 NC
02/16/15

2.00 12200 Washer,Flat #10
1.00 3817502 Switch,Emergency Stop Stahl

2 Contacts,1NO,1NC
2.00 3922400 Nut,Nylok M6 X 1.0
Din 985
2.00 3922401 SHCS,M6 X 1.0 X 25mm
1.00 7202304 Bracket, 'E' Stop Switch

8040 Stahl Switch
Page 1 of 1
GENERAL ASSEMBLY GA-16279-3
DRAWING # 16279-3
Roll Assembly Comp.
XPB1000/1200 Roll Mills
02/16/15

001 4.00 8120000 Hsg,MTO SAF217 W/75mm Seal
2 Bolt Mount W/Stab Ring
005 4.00 4677000 Bearing,Spherical
22217 EK W33
010 4.00 4677002 Adapter,H317 X 75mm W/Nut
& Lockwasher SKF Or Equal
Page 1 of 1
DRAWING # 16285-4
Lubrication Components
CMX1200 DS Crumbler
02/16/15

8.00 3821450 Label,Zerk (Red)
Main Bearings
4.00 3821452 Label,Zerk (Yellow)
Idler Bearings
001 8.00 109730 Clamp,Support
Aeroquip 900729-4
005 12.00 109850 Elbow,M 90 1/4" OD X 1/8" Pipe
Self Align Parker X269CA-4-2
010 12.00 109855 Connector,M 1/4" OD X 1/8"Pipe
Self Align Parker X68CA-4-2
015 435.00 3159600 Tubing,Plastic 1/4"OD
Imperial 44-Nsr-1/4 Black
020 8.00 3784555 Adapter,1/4-28,1/8Ptf
025 12.00 3784552 Nut,Panel Lube
030 12.00 3784557 Zerk,Straight 1/4-28 5010

Lincoln Lube
035 4.00 3784558 Elbow,90 Deg Street 13155
Lincoln Lube, Grease Fit
Page 1 of 2
DRAWING # 16361-22
Feed Gate Adjust AA, CMX1200
2-Position,24 Volt
02/16/15

1.00 3388550 Muffler,AC980 Gast 1/4"
for 4AM-NRV-70C Air Motor
005 1.00 0595902 Handwheel, Remote Feed
Gate XPB 1000/1200
010 1.00 0596410 Air Motor Adapter Housing
015 1.00 0630100 Bellows,9-1/4 Lg 1000

Grinder
020 1.00 3110606 Coupling,Jaw Type 1/2 X 5/8
025 2.00 3114100 Cotter Pin - 1/8 D. X 1"
030 1.00 3116514 Valve,1/4" 4W XP Dbl Sol 24VDC

L2003CBWDW-Dby Aumotatic
035 1.00 3388500 Motor,Air 4AM-NRV-70C 8-Vane
Reversible,
040 1.00 3413506 Jack,Acton-Jac 2.5MSJ-I-6
CCW C-Face 24:1
045 1.00 3413550 Clevis,End 1000/1200 Roll
Mill Grinders Jacks
050 2.00 3413554 Collar,Stop 1-4 ACME 3C
1/4-20 Tapped B4511-01-00
055 1.00 3413800 Pin,Clevis - 5/8D X 2-11/32 Lg
060 1.00 3756501 Pin, Clevis 1/2" X 2-1/4"

MCM# 98306A389
065 1.00 3764160 Valve,1/4" NPT Lockout Air
UCI,Valve Sel-2
070 2.00 4649800 Switch,Limit See Note
075 1.00 5325201 Key - 3/16 Sq. X 1" Long
080 1.00 7155000 Washer, Bellows Retainer

Series 1000/1200 Roll Mill
085 1.00 7155100 Plate,Clamp - Bellows
Series 1000/1200 Roll Mill
090 1.00 7232030 Bracket, Jack Mount
Full Feature/Air Actuated
095 1.00 7232043 Linkage, Feed Gate Aa
CMX 1200 Roll Feeder
100 1.00 7245601 Lever, Adjust Feed Gate
Clamp-On XPB 1000/1200
Page 2 of 2
DRAWING # 16361-22
Feed Gate Adjust AA, CMX1200
2-Position,24 Volt
02/16/15

105 2.00 7245671 Actuator, Limit Switch
CMX 1200 Air Act Feedgate
110 2.00 7245672 Retainer, Actuator
115 1.00 7245674 Mount, Limit Switch
120 1.00 7292600 Key,8mm X 7mm X 20mm Long
Feed Gate
125 1.00 7333995 Guard,Stub Shaft 2.5 Ton Jack
Roskamp Roller Mills
Page 1 of 1
DRAWING # 16364-14
Main Drive Comps. CMX1200DS
1500 RPM,3 Groove,30HP,778,SF
02/16/15

001 2.00 16701 Key,18 X 11 X 100 Metric
005 6.00 3016726 Belt,5VX750
010 2.00 3793901 Sheave,Qd 3-5V8.5"Od Sf
015 2.00 3793903 Sheave,QD 3-5V16.0" OD E
020 2.00 73604 Bushing,QD E 60mm
025 2.00 8118301 Base,Motor Single/Top 3 Pair

RM, and All CMX, SPX
Page 1 of 2
DRAWING # 16420-17
Frame Components
CMX1200-72DS
02/16/15

16.00 15025 Pin,Dowel 1/2" X 2-1/2"
1.00 3376600 Sealant,RTV
001 4.00 0605910 Bracket,Pressure Spring

Make From (06059103)
005 1.00 3763900 Wrench,Spanner 4" 5475A24
McMaster,Pin Style,Fixed Head
010 4.00 3772800 Handle,Pull
015 8.00 3786600 Bolt,Eye M24 X 3.0 X 75mm

Threaded Metric W/Shoulder
020 28.00 7162100 Washer,Thrust
2-1/2" OD X 1-1/16" ID X 1/4"
025 1.00 7210203 Scoop, Sample, Large Aluminum
Flaker/1000/1200
030 8.00 7225821 Guide,Spring MS
035 4.00 7242610 Plate,Cheek 1000/1200

3/8"UHMW 11-3/8"X12"
040 4.00 7242631 Plate, Cheek- CMX1200 3/8"
045 4.00 7243152 Insert,Wear Standard FP

1/4 X 1 X 30 1/2" Lg
050 4.00 7243542 Cover,Sample Port 1200-72
055 4.00 7244304 Pressure Member Rear Cast
060 4.00 7244324 Pressure Member Front Cast

XP1000/1200 Roll Mill
065 8.00 7244334 Tension Member Top/Bottom Cast
XPX1200 Roll Mill
070 2.00 7244350 Support,Bearing RH Rear
SPB DPB TPB 1200 Mills
075 2.00 7244360 Support,Bearing LH Rear
SPB DPB TPB 1200 Mills
080 1.00 7244370 Gauge,Tram
XPB1000/1200 Roll Mill
085 8.00 7244375 Screw,Hex Head M24X3.0 X 140mm
Grade 8.8 DIN933 (See 3915533)
090 4.00 7244606 Seal,7.5 X 7.5 Shaft1"Halstead
XPB1200 Roll Mill
Page 2 of 2
DRAWING # 16420-17
Frame Components
CMX1200-72DS
02/16/15

095 4.00 7244607 Seal,10 X 7.5 Shaft 1"Halstead
CMX1200 Only
100 8.00 7244613 Retainer,Shaft Seal
1000/1200
105 4.00 7244652 Cover,Slot - Inner
Series 1200 Roll Mill
110 4.00 7244656 Seal,Slot Inner - UHMW
Series 1200 Roll Mills
115 4.00 7244670 Seal,Slot - 5" UHMW
XPB1200 Roll Mill
120 1.00 7244821 Lug,Lifting W/(1) Hole
XPX1000/1200 Roll Mill
125 4.00 7309100 Holder,Shaft Seal1000/12
RM,XP,CMX For 7-1/4"Seal
130 4.00 7309102 Holder,Shaft Seal 1000/12
RM,XP,CMX For 9-3/4"Seal
135 2.00 7313110 Frame Weldment - Flat Top
CMX1200-72 Crumbler
140 4.00 7313200 Rail,Bearng Side Sheet
CMX1200 Crumblers
145 2.00 7313310 Door Front CMX1200-72
150 1,000.00 87255 Seal,Trim 3100-B3X1/8A

Black Trim-Lok
155 4.00 7315350 Baffle,Adjstbl CMX1200-72
160 2.00 7315400 Cover,Frnt Slot 12 CMX RH

Right Side
165 2.00 7315450 Cover,Frnt Slot 12 CMX LH
Left Side
170 4.00 7315490 Seal,Slot - 5" UHMW
CMX1600 Crumbler
Page 1 of 1
DRAWING # 16421-12
Guard Components
CMX1200DS Crumbler
02/16/15

2.00 7245390 Cover,IRD Tension Access
XPB 1000/1200 Roll Mill
2.00 7311200 Cover,Access-Tension Member
4.00 3772800 Handle,Pull
005 1.00 7315000 Plate,Backing - IRD (RH Drive)

CMX1200 Crumbler
010 1.00 7315001 Cover,Guard - IRD (RH Drive)
CMX1200 Crumbler
015 1.00 7315010 Plate,Backing - IRD (LH Drive)
CMX1200 Crumbler
020 1.00 7315011 Cover,Guard - IRD (LH Drive)
CMX1200 Crumbler
025 1.00 7315080 Plate, Backing-Main Dr RH
Guard, CMX1200 RH Drive
030 1.00 7315081 Cover,Guard - RH Main Drive
CMX1200 Crumbler
035 1.00 7315082 Cover,Rear Guard - RH Drive
CMX1200 Crumbler
040 1.00 7315090 Plate, Backing-Main Dr LH
Guard, CMX1200 LHDrive
045 1.00 7315091 Cover,Gd LHMain Dr CMX
CMX1200 LHDrive
050 1.00 7315092 Cover,Rear Guard,LHDrive
CMX1200
055 4.00 7244335 Cover,Top Tension Member
XPB Roll Mills
Page 1 of 1
DRAWING # 16459-7
Divider, Comp. CMX1200-72
Double Stand W/Wide Doors
02/16/15

001 1.00 7315210 Divider, CMX1200-72 DS
005 2.00 7315270 Door, Maint. - CMX1200-72

Divider
010 445.00 87255 Seal,Trim 3100-B3X1/8A
Black Trim-Lok
Page 1 of 1
DRAWING # 16539-14
IRD Components 1.5:1,3 Groove
CMX1200DS Crumbler
02/16/15

4.00 99800 Collar,Steel Set 2-3/16"
4.00 7244730 Tube,Spacer - Idler Arm

XPX & XPRM Roll Mills
001 4.00 16701 Key,18 X 11 X 100 Metric
005 4.00 3384800 Spring,Die 2"OD X 1"ID X 6"

Blue Danly 9-3224-21
010 4.00 3773800 Bushing,TL 2517 X 60mm
Steel Construction Only,No Sub
015 2.00 3781602 Sheave,TL 3A6.0/B6.4 2517
020 2.00 3781603 Sheave,TL 3A9.0/B9.4 2517
025 8.00 3783701 Brg,ER35 2-3/16" Bore

W/O Inner Seal & Snap Ring
030 6.00 3785510 Belt,BB92
035 2.00 3789300 Label,IRD Belt Tension Gauge

XPB1200 Roll Mill
045 4.00 7243722 Sheave,Idler 6.0"PD 3 Groove
050 2.00 7244615 Tension Arm Pivot Bar

6 Groove IRD
055 2.00 7244622 Tension Arm Pivot 6-Groove IRD
1000/1200
060 2.00 7244625 Pin,Idler Bracket-6 Groove IRD
065 2.00 7244635 Bolt,Idler Pivot Tension
070 2.00 7244690 Scale,IRD Tension XPB
075 2.00 7244710 Shaft,Main Idler 6-Groove IRD
080 2.00 7244715 Shaft,Idler 6 Groove IRD

XPB1200 Roll Mill
085 4.00 7244720 Spacer,IRD - 6 Groove
XPB1200 Roll Mill
090 2.00 7244750 Idler Plate, RH (Outside)
Double Bird
095 2.00 7244751 Idler Plate, LH(Inside)
Double Bird
Page 1 of 2
DRAWING # 16737-97
Roll Feeder Comps. w/Magnet
CMX1200-72DS Crumbler SEW FT47
02/16/15

001 1.00 0617103 Shaft, Magnet 1000/1200
005 2.00 3060900 Collar,Set 1" Steel
010 2.00 3772800 Handle,Pull
015 2.00 3782000 Bearing,FY45FM,45mm 4-B Flange

Eccentric Lock,SKF or Equal
020 4.00 3785600 Knob,Hand 1X2-1/2 X 2-1/4
Tap M10 x 1.5
025 4.00 3786600 Bolt,Eye M24 X 3.0 X 75mm
Threaded Metric W/Shoulder
035 2.00 4675800 Bearing,Flanged 2B
SKF FYTB 25FM, SKF or Equal
040 2.00 7243537 Lever,Tip Out Magnet
XPX1200-72
045 1.00 7245622 Gate,Feed
XPX1200-72 Roll Mill
050 1.00 7245660 Cheek Plate Roll Feeder - RH
XPX1200 Roll Mill
055 1.00 7245661 Cheek Plate Roll Feeder - LH
XPX1200 Roll Mill
060 2.00 7300902 Magnet, Plate 34" OAL
065 2.00 7316831 Door, Inspection FDR-72

Series XP 1000/1200-72
070 2.00 7316841 Seal, Inspection Door-72
Series XP 1000/1200-72
075 2.00 7318115 Cover,Slot Modular Roll Feeder
CMX1200 Crumbler (Mild Steel)
085 1.00 7245698 Arm,Torque-Roll Fdr,FT37 FT47
XPX1200 Roll Mill
095 1.00 7345101 Housing Weldment-Roll Feeder
CMX1200-72 Crumbler
100 1.00 7345111 Door,Rear Maint. 1200-72
CMX1200-72 Roll Feeder
105 1.00 7345121 Door, Front Maintenance
CMX 1200 72 Roll Feeder
110 1.00 7316175 Roll,Feeder DPX1200-72
1.25 SEW (Torque Lock)
115 1.00 7352302 Slide Adj,Feed Gate 72 Ms
CMX 1200 Crumbler
Page 2 of 2
DRAWING # 16737-97
Roll Feeder Comps. w/Magnet
CMX1200-72DS Crumbler SEW FT47
02/16/15

120 1.00 7352362 Baffle,Adj Roll Feeder Ms
CMX 1200-72
125 1.00 8160081 Exposed Shaft Guard Components
CMX1200 Modular Roll Feeder
Page 1 of 2
DRAWING # 16926-39
Roll Adjust Comp, Air Actuated
CMX1200-72DS 24V
02/16/15

001 4.00 0630100 Bellows,9-1/4 Lg 1000
Grinder
005 2.00 3110604 Coupling - Lovejoy L-075*
5/8" Bore X 3/4" Bore
010 2.00 3116524 Valve,1/2" 4W XP Dbl. solenoid
24 VDC Grimstad Supply IP65
015 4.00 3385853 Collar, Stop 1-1/2" Acme
2-2/3,40 Deg Thrd,3/8"Tap
020 2.00 3388501 Motor,Air 6AM-NRV-22A 8-Vane
Reversible,Gast Mfg
025 2.00 3388551 Muffler,Exhaust AC990
Gast 1/2" NPT
030 2.00 3761001 Caplug,BPF 5/8"
035 1.00 3764150 Valve,1/2"Npt Lockout Air

Uci, Valve Sel-4
040 2.00 3793000 Jack,Machine Screw-Nook 5MSJ-I
24:1,3" Travel
045 2.00 3793002 Jack,Machine Screw-Nook 5MSJ-I
W/56C Position 1,24:1,3"Travel
050 4.00 3808600 Switch,Limit Square D
9007CR53B2MA17
055 2.00 5325201 Key - 3/16 Sq. X 1" Long
060 4.00 7157701 Collar Thrust Nook Jack

Fine Adjust
065 4.00 7158550 Nut,Retaining
CM1272 Crumbler
070 2.00 7243700 Coupling,Self Locking
SPB,DPB & TPB 1200
075 2.00 7243701 Hub,Spline-Jack Side
SPB,DPB & TPB 1200
080 2.00 7243703 Shaft,Stub Coupling
SPB,DPB & TPB 1200
085 2.00 7243712 Shaft,Coupling 1200-72
XPB1200 Roll Mill
090 4.00 7378520 Mount,Back Plate Roll Adj Shft
XP1200 Roll Mills
095 2.00 7243780 Bracket, Switch Mount CMX
100 2.00 7378505 Back Plate, Roll Adjust Shaft

Page 2 of 2
DRAWING # 16926-39
Roll Adjust Comp, Air Actuated
CMX1200-72DS 24V
02/16/15

105 2.00 7378515 Cover,Guard Coupling Shaft
110 4.00 7244395 Plate,Bellow Clamp XPX
Series 1200 Roll Mills
115 4.00 7244632 Bolt,Roll Stop - 4-1/2"
CMX1200 Crumbler
120 4.00 4504700 Nut,Hex
M16 Din 934 Steel Galv.Verz.
125 2.00 7243783 Bracket, Mount - Actuator
CMX 1200/1600 Crumbler
130 4.00 7243784 Actuator, Limt Switch CMX
135 4.00 7243785 Rod,Actuator Adjustment

CMX Crumbler
140 4.00 3794222 SHSB,12mm X 16mm X 10mm Thread
Socket Head Shoulder Bolt
145 2.00 3809070 Decal,Do Not Step On Guards
English-Vinyl
150 2.00 7244685 Guard,Stub Shaft 5 Ton Jack
Roskamp Roller Mills
CMX
Trituradora
Manual do Operador
e Peças
Copyright © 2011 da California Pellet Mill Company. Todos os direitos
reservados. Nenhuma parte desta publicação pode ser reproduzida,
armazenada em sistema de recuperação de dados, ou transmitida, sob
qualquer forma ou por quaisquer meios, eletrônicos, mecânicos,
fotocópia, disquete ou de outra natureza, sem a autorização prévia, por
escrito, da California Pellet Mill Company. Impresso nos Estados
Unidos da América.
California Pellet Mill Co. - WL0138.2PTBR

Prefácio
Gostaríamos de aproveitar esta O desempenho duradouro e trituradora da CPM. Antes de
oportunidade para agradecê-lo adequado deste equipamento é colocar a trituradora em
pela sua preferência e para dar- possível somente com a funcionamento, faça as
lhe as boas vindas à requintada colaboração e atenção de verificações preliminares
família de proprietários de operadores adequadamente descritas na Seção "Instalação"
equipamentos da CPM. Você treinados e um pessoal de para certificar-se de que a
selecionou uma das muitas manutenção bem informado. É operação começa sem problemas.
máquinas de qualidade fabricadas essencial que haja treinamento Leia atentamente este manual de
com precisão que a CPM tem antes da operação deste instrução antes de começar a usar
para oferecer. equipamento. Esse treinamento a trituradora. Estude os
deve incluir a familiarização com procedimentos corretos de
Este manual de instrução contém os recursos de segurança do operação e familiarize-se com
informações específicas sobre a equipamento, localização dos todo o processo de operação e os
operação, manutenção e peças interruptores de travamento da equipamentos relacionados.
que o ajudarão a obter o melhor máquina e intertravamentos
desempenho possível do seu elétricos com outros X Nota: Leia este manual antes
equipamento da CPM. Este equipamentos. de operar a trituradora.
manual descreve a operação, Preste atenção especial à
manutenção e conserto do seu A fábrica montou e inspecionou Seção "Segurança".
equipamento. com bastante cuidado a
ATENÇÃO
Leia e compreenda
os itens abaixo antes de operar este equipamento
Manutenção
Antes de inspecionar, ajustar ou reparar a trituradora:
• Desligue todos os motores no painel de controle com os botões de pressão.
• Desligue e trave/etiquete os interruptores de desconexão de todos os motores.
• NÃO remova tampas ou proteções antes de todas as peças em movimento terem
parado.
• Os equipamentos e as peças da trituradora são grandes e pesados; levante e manuseie
apenas com equipamentos projetados e homologados para as cargas indicadas.
Operação
• Operação e manutenção apenas por pessoal qualificado.
• As proteções, tampas e portas de acesso devem estar seguramente instaladas antes de operar esta
trituradora.
ATENÇÃO
A não observância deste aviso pode resultar em lesões físicas ou morte.
WL0138.2PTBR - Manual do Operador e Peças i

Como entrar em contato conosco Escritórios da California Pellet Mill Company
California Pellet Mill Co. Roskamp/Champion

P.O. Box Box 647 2975 Airline Circle
Crawfordsville, IN 47933 – EUA Waterloo, IA 50703 – EUA
Telefone: (800) 428-0846 Telefone: (319) 232-8444
Fax: (317) 362-7551 Linha de chamadas gratuitas: + (800) 366-2563
Fax: (319) 236-0481
Sedes internacionais
CPM/Europe B.V. CPM/Europe ltd.
Rijder 2 1507 DN West March,
Zaandam, Países Baixos Daventry Nothants NN11 4PQ, Inglaterra
Telefone: +31-[0]75 6512 611 Telefone: + (44) 0327 704721
Fax: +31-[0]75 6512 600 Fax: + (44) 327 71831
CPM/Pacific (Private) Ltd.

17 Liu Fang Road
Jurong Town, Cingapura 2262
Telefone: + (65) 265 0701
Fax: + (65) 268 6428
Informações sobre encomendas de peças

1. Encomendar peças de reposição por intermédio de seu representante ou direto da CPM, Crawfordsville,
Indiana, + (800) 428-0846
2. Indique o número de série e o número do modelo da trituradora para o qual está encomendando peças (veja
a Figura H-1 abaixo).
3. Utilize os números de referência e as descrições apresentadas no fim deste livro, na Seção "Peças". Ao
encomendar peças ou inserir correspondência relativa à esta unidade, consultar sempre a plaqueta com o
número de série, localizada na parte dianteira da trituradora, na direção do centro do conjunto principal (ver
Figura H-1 abaixo).
Número de série: Data da compra:

Número do modelo:
Representante: Telefone: ( ) -
Placa
de série Peças de manutenção que é recomendável manter em estoque:
N°. de referência Descrição N°. de referência Descrição
1. 6.
Figura H-1: Localização do número de série da trituradora e itens a serem lembrados ao encomendar peças.
ii California Pellet Mill Co. - WL0138.2PTBR

Como utilizar este manual
Este manual é o resultado da colaboração de vários funcionários da CPM. Ele reflete os conhecimentos, o trabalho
dedicado e a experiência dessas pessoas. O tempo que dispensamos na elaboração deste manual demonstra o esforço
que empregamos para fornecer produtos de qualidade aos nossos clientes. Na CPM, acreditamos que o melhor
operador é o operador mais bem informado. Caso tenha alguma sugestão a fazer ou necessite de mais informações
para comunicar aos seus operadores, entre em contato conosco pelo telefone (800) 366-2563 (nos EUA).
Organização
Este manual foi elaborado com o objetivo de facilitar a sua utilização. Dividimos o manual em várias seções,
procurando assim facilitar a localização da informação necessária. Embora algumas seções possam não se aplicar à
sua situação, recomendamos que dedique algum tempo para familiarizar-se com cada uma das seções,
especialmente a Seção "Segurança". Acidentes e desgastes desnecessários em geral podem ser evitados se o
operador tiver conhecimento de tudo o que se relaciona com a operação, manutenção e ajustes da trituradora.
O objetivo da divisão deste manual em seções é fornecer instruções específicas para o operador e para o pessoal de
manutenção. Recomendamos que as operações descritas em cada seção sejam executadas por pessoal devidamente
treinado. O pessoal devidamente treinado deve estar equipado com as ferramentas apropriadas.
Símbolo
Incluímos neste manual símbolos especiais para alertá-lo sobre situações especiais, tais como, possíveis falhas
mecânicas se a etapa não for cumprida e/ou lesão corporal, que pode ocorrer se o operador não seguir as instruções.
Familiarize-se com estes símbolos e tome um cuidado especial sempre que os mesmos aparecerem nas instruções
contidas neste manual.
O símbolo de alerta de segurança

O alerta quando uma determinada área apresenta um possível perigo. Este símbolo
encontra-se tanto no manual como na máquina, e as instruções que o acompanham devem
ser seguidas.
As seguintes palavras podem acompanhar este símbolo, chamando a atenção do operador
para que este obedeça à importante mensagem de segurança:
PERIGO: A palavra “Perigo” é utilizada para indicar a existência de um perigo que
causará lesões físicas graves, morte ou danos materiais consideráveis se a
advertência for ignorada.
ATENÇÃO: A palavra “Atenção” é utilizada para indicar a existência de um perigo que
poderá causar lesões físicas graves, morte ou danos materiais
consideráveis se a advertência for ignorada.
AVISO: A palavra “Aviso” é utilizada para indicar a existência de um perigo que
causará ou poderá causar lesões físicas leves ou danos materiais se a
advertência for ignorada.
Símbolo de travamento/etiquetagem – Desligar a alimentação

Este símbolo foi criado pela CPM para informar o operador ou o pessoal de manutenção
que eles devem desligar a energia no disjuntor principal, travar o interruptor da corrente e
colocar uma etiqueta no fecho, com o nome da pessoa que está realizando a manutenção
ou os ajustes. A pessoa que está fazendo a manutenção ou os ajustes deve ser a única
pessoa a ficar com a chave da trava, devendo mantê-la consigo ao fazê-los.
x
Nota
Este símbolo é seguido de uma "Nota: ". A nota serve para chamar a atenção do pessoal
para informações de instalação, operação ou manutenção que são importantes, mas não
acarretam perigos.
WL0138.2PTBR - Manual do Operador e Peças iii

Índice Segurança......................................Seção 1 Ajustes pelo operador ..................Seção 5
Práticas gerais de segurança.......................................1 Ajuste do alimentador de rolos ..................................1
Perigo de abertura de entrada/descarga......................1
Ajuste da comporta de alimentação......................1
Perigo com os acionadores das correias.....................1
Ajuste dos defletores ............................................1
Perigo de rolos em movimento ..................................1
Ajuste do atuador da porta de alimentação...........1
Interruptor de Parada de Emergência.........................1
Tremonha de admissão .........................................1
Perigo de presença de matérias estranhas ..................2
Riscos elétricos ..........................................................2 Ajustes de manutenção................Seção 6
Proteção dos olhos .....................................................2 Ajuste do alimentador de rolos ..................................1
Proteção da cabeça.....................................................2 Ajuste da placa lateral do alimentador de rolos....1
Instruções de ativação ................................................2
Ajuste opcional do ímã do alimentador do rolo ...1
Proteção dos ouvidos .................................................2
Ajustes da trituradora.................................................1
Instruções gerais de segurança..................Suplemento
Ajuste dos defletores ............................................1
Introdução......................................Seção 2
Placas laterais .......................................................1
Descrição da trituradora.............................................2
Ajustes do acionador ............................................2
Ajuste manual dos cilindros.......................................2
Requisitos de tensionamento das correias em V ..2
Opção de ajuste automático dos cilindros..................2
Alimentadores ............................................................3 Instalação do acionador principal .........................2
Alimentadores de cilindros...................................3 Ajuste da correia do acionador entre rolos ...........3

Flat Top ................................................................3 Ajuste dos rolos e mancais ...................................3
Flat Top com desviador ........................................3 Procedimento de ajuste dos rolos...............................3
Recursos de segurança ...............................................3 Procedimento para rolos paralelos – Com ajuste ..
Instalação.......................................Seção 3 manual dos rolos...................................................3
Disposição geral.........................................................1 Procedimento para rolos paralelos – com ajuste ...

automático dos rolos.............................................3
Inspeção do material recebido ...................................1
Processo de reposição a zero dos rolos ao ajuste ..
Instruções para a instalação .......................................1
zero – com ajuste automático dos rolos...............5
Planejamento e projeto do local de instalação......1
Re-corrugação dos rolos .......................................5
Detalhes dos chumbadores ...................................2
Remoção dos rolos ...............................................5
Espaço ao redor da trituradora..............................2
Almofada amortecedora da vibração....................3 Instalação dos rolos ..............................................7
Fixação com argamassa........................................3 Ajuste do alinhamento..........................................8
Proteção contra ação magnética ...........................3 Lubrificação...................................Seção 7

Peneiramento do material .....................................3 Normas...........................................Seção 8
Verificação de outros aspectos da instalação.............3
Especificações de torque dos parafusos ...............1
Interruptor de Parada de Emergência.........................4
Normas CPM – Prendedores métricos .................1
Instruções de operação................Seção 4
Peças..............................................Seção 9
Sequência de ativação ................................................2
Sistema de ajuste manual dos cilindros .....................2 Apêndice ......................................Seção 10
iv California Pellet Mill Co. - WL0138.2PTBR

Segurança
Atenção: Leia e equipamento de içamento em entre os rolos. Mantenha as partes
compreenda as seguintes boas condições e NÃO do corpo e qualquer objeto
práticas de segurança. permaneça debaixo de objetos afastados desta área. NÃO coloque
Estude o Livreto de sendo içados. Mantenha a área nenhuma parte do corpo nem
Instruções Gerais de de trabalho desobstruída para ferramentas na área dos rolos
Segurança da CPM, que os empregados tenham quando o motor está ligado.
incluído no Manual do uma boa superfície de apoio
para os pés.
Operador (a partir da Interruptor de Parada
página 2 desta Seção).
Familiarize-se com as Perigo de Emergência
instruções gerais de
operação e manutenção. de abertura de O Interruptor de Parada de
Emergência (veja a Figura S-1,
Não se esqueça de entrada/descarga página 2) ficam facilmente ao
travar/etiquetar a fonte de alcance dos operadores quando
alimentação antes de 1. A trituradora possui uma
abertura de entrada e descarga. estes estão próximos à trituradora.
realizar qualquer Mude o Interruptor de Parada de
manutenção ou ajuste. A Lesões físicas podem ocorrer
Emergência para um local mais
Seção 1 -
pessoa que realizar a se alguma pessoa ou objeto
cair na abertura. Há um grande acessível, se necessário. Conecte
manutenção deve manter esta chave puxa-empurra ao
consigo a única chave da perigo se uma pessoa colocar
um braço ou qualquer objeto circuito de controle da trituradora
trava. para parar o motor.
dentro da área de entrada ou
descarga com a trituradora em X Nota: Este interruptor serve
Familiarize-se com as instruções funcionamento.
gerais de operação e manutenção. para parar a trituradora
Não se esqueça de travar/etiquetar a 2. Instale proteções permanentes apenas em caso de
fonte de alimentação antes de ao redor das aberturas de emergência. Reative o
realizar manutenção na trituradora. entrada e de descarga para interruptor apenas depois de
impedir que uma pessoa entre resolvida a emergência.
Práticas gerais de nessas áreas possivelmente Atenção: Visto que o
perigosas. Não remova as Interruptor de Parada de
segurança proteções. Emergência abre apenas
1. Siga sempre as práticas Atenção: Mantenha as o circuito de controle,
seguras de operação na partes do corpo sempre NÃO o utilize como
presença de qualquer máquina. afastadas das aberturas de interruptor de desconexão
A maioria dos acidentes ocorre entrada ou descarga ao fazer manutenção ou
devido à falta de cuidado ou devido ao possível risco reparos após uma
por negligência. Qualquer de esmagamento. emergência. Desligue e
máquina com peças giratórias trave/etiquete o
é potencialmente perigosa. interruptor de desconexão
Proteja e opere máquinas com da alta tensão na fonte de
peças giratórias de acordo com
Perigo com os alimentação antes de
as leis e os regulamentos acionadores das realizar qualquer
aplicáveis e seguindo as boas correias manutenção ou reparos.
práticas normais de segurança. Etiquete o interruptor de
Verifique se as proteções das desconexão travado com
2. Antes de realizar qualquer correias cobrem completamente as o nome da pessoa que o
manutenção em máquinas com correias. A instalação incorreta das travou. Essa pessoa deve
acionamento motorizado, proteções das correias transforma manter consigo a única
desligue a fonte de os acionadores das correias nas chave de travamento do
alimentação do motor extremidades da trituradora em um interruptor de
desligando o interruptor de possível perigo. Desligue o desconexão.
desconexão da linha de alta fornecimento de energia trifásica e
tensão do arranque do motor. feche/coloque etiquetas nos
Trave o interruptor de motores antes de retirar as Perigo de presença
desconexão na posição proteções das correias. (Veja outras
desligada, com um cadeado, e informações sobre correias na
de matérias
coloque uma etiqueta com o Seção "Apêndice".) estranhas
nome da pessoa em posse da
chave. A pessoa que está Remova todas as matérias estranhas
fazendo a manutenção deve Perigo de rolos em do material sendo processado.
manter consigo a única chave movimento Pedras, metais ferrosos, metais não
da trava do interruptor de ferrosos, etc. podem provocar risco
desconexão. Os rolos em movimento constituem de ignição por faísca ou o
um perigo grave. Os rolos giram a engripamento da máquina. É
3. Use as ferramentas altas velocidades e funcionam com aconselhável utilizar uma peneira e
apropriadas para cada tarefa de uma ação de trituramento e uma armadilha magnética antes de
manutenção. Mantenha o esmagamento que puxa objetos por alimentar material na trituradora.
WL0139.2PTBR - Manual do Operador e Peças 1

2. Utilize somente dispositivos Instruções de
Segurança industriais de alta qualidade
destinados ao serviço ativação
pretendido. Use arranques de Após instalar a trituradora e rever
motor equipados com este manual de instruções, preencha
interruptores de sobrecarga o cartão fornecido com a trituradora
térmica com restabelecimento e envie à CPM para registrar a
manual. instalação. Contate o seu
representante para receber
Proteção dos olhos treinamento sobre a operação
correta da trituradora.
1. Use óculos de proteção
aprovados ao trabalhar ao
Figura S-1: Parada de Emergência; redor do equipamento. Proteção dos
se houver um local melhor para o Máquinas em movimento ouvidos
interruptor de Parada de podem projetar objetos
Emergência, mude-o para esse inesperadamente. Em condições normais de operação
local. esta máquina não produz ruídos
2. Use óculos de proteção ao perigosos. Contudo, algumas
Seção 11 --
fazer um serviço de aplicações especializadas deste

Riscos elétricos manutenção no equipamento a equipamento podem produzir
Seção
fim de proteger-se contra níveis de ruídos superiores a 85

1. Siga o diagrama esquemático objetos projetados. dBA. Outros equipamentos
fornecido na Seção "Peças" instalados próximos ou ao redor
como modelo de circuito para desta máquina (tais como motores
a instalação elétrica da Proteção da cabeça de acionamento) podem aumentar
trituradora. Estude o circuito e Use um capacete enquanto estiver os níveis de ruído para acima de 85
os componentes listados para trabalhando ao redor do dBA. Use proteção aprovada para
assegurar o cumprimento de equipamento. Objetos em queda ou os ouvidos, conforme necessário,
todas as normas elétricas e de espaços baixos acima da cabeça ao trabalhar ao redor deste
segurança. podem causar lesões. equipamento.
2 California Pellet Mill Co. - WL0139.2PTBR

®
Instruções Gerais
de Segurança
Esta publicação contém Instruções Gerais de Segurança
para a operação de equipamento fabricado pela Roskamp/Champion
Etiquetas de instruções de segurança importantes e diagramas da colocação das

etiquetas
Sugerimos que esta publicação seja colocada junto ao equipamento

Roskamp/Champion para consulta dos operadores e de outras pessoas que
venham a lidar com as máquinas
– Trabalhe sempre com atenção

à segurança –
divisão da Consolidated Process Machinery

Copyright © 1999 da California Pellet Mill Company. Todos os direitos
reservados. Nenhuma parte desta publicação pode ser reproduzida,
armazenada em sistema de recuperação de dados, ou transmitida, sob
qualquer forma ou por quaisquer meios, eletrônicos, mecânicos, através
de fotocópia, disquete ou de outra natureza, sem o consentimento
prévio por escrito da California Pellet Mill Company.
Impresso nos Estados Unidos da América.
Champion - EF-WL0073.3PO
Introdução
AVISO
• Leia e obedeça os avisos de perigo contidos nesta
publicação. A não observação desta precaução poderá
resultar em lesões pessoais ou em danos ao
equipamento.
• Inspecione o equipamento para verificar se todas as

máquinas possuem etiquetas com avisos de segurança.
Caso contrário, peça as etiquetas ou kits de etiquetas
necessários e a Roskamp/Champion as enviará
gratuitamente. Encontram-se em anexo etiquetas com
instruções (Ver Seção "Etiquetas com Instruções de
Segurança e Instruções, Processos de Aplicação").
Escritórios da California Pellet Mill Company

Roskamp/Champion
2975 Airline Circle
Waterloo, IA 50703
Tel.: (319) 232-8444
Linha de chamadas grátis: (800) 366-2563
Fax: (319) 232-4040
Vendas Internacionais
CPM/Europe B.V. CPM/Europe Ltd.

Distelweg 89 West March,
1031 HD Amsterdã, Países Baixos Daventry Nothants NN11 4PQ, Inglaterra
Tel.: (011) (31) 204946111 Tel.: (011) (44) 327704721
Fax: (011) (31) 206364294 Fax: (011) (44) 32771831
CPM/Europe S.A.
CPM/Pacific (Private) Ltd.
BP 35, 34 Avenue Albert 1
17 Liu Fang Road
92502 Rueil, Jurong Town, Cingapura 2262
Mailmaison, França Tel.: (011) (65) 2650701
Tel.: (011) (33) 147492999 Fax: (011) (65) 2686428
Fax: (011) (33) 147518411
EF-WL0073.3PO - Instruções Gerais de Segurança i

Índice Instruções de Segurança ............................Seção 1
Diagrama de Colocação das Etiquetas

com Instruções de Segurança ..................Seção 2
Etiquetas com Instruções de Segurança ..............................1, 2, 3, 4 & 5
Interruptor de Parada de Emergência......................................................6
Tensão Perigosa.......................................................................................6
Moinho a Cilindros 1000/1200 ...............................................................7
Moinho a Cilindros 900 ..........................................................................8
Trituradora CMX-DS 1200 855DS/SS ...................................................9
Lascadoras SP-2400/SP-2800 ...............................................................10
Moinho de Cabeça a Cilindro ...............................................................10
Lascadoras SP-1600/SP-1800/SP-2000 ...............................................11
Moinho a Martelo / Percussor...............................................................12
Britateiras e Desfibradora/Laminadora Acabadora...............................13
Britateira................................................................................................14
Alimentador Rota’ Feed .......................................................................14
Câmaras a Vapor ...................................................................................15
Gyro Sifter ............................................................................................15
Refrigerador Horizontal ........................................................................16
Alimentadores (Cilindro, Tremonha, Balso).........................................17
Cabeça de Britateira CHHD / Alimentador de Rosca Sem-fim ...........18
Moinho a Cilindros Modelo 650...........................................................19
Etiquetas com Instruções de Segurança,

Processos de Aplicaçõe ..............................Seção 3
Instalaçõe ................................................................................................1
Formulário de Encomenda de Segurança

..............................................................Contra-capa
ii Roskamp Champion - EF-WL0073.3PO

Instruções de Segurança
Símbolo de instrução para
Aviso: Leia todas as instruções antes de
travar/colocar etiqueta - desligar a
operar o equipamento. Ao operar
máquinas, deverá seguir sempre as regras eletricidade
de precaução, descritas a seguir, a fim de Este símbolo foi criado pela Roskamp
reduzir o risco de lesão pessoal e de danos Champion para avisar o operador ou o pessoal
ao equipamento. de manutenção que é necessário desligar a
eletricidade no disjuntor principal, travar o
interruptor da corrente e colocar uma etiqueta
1. Observe as instruções no fecho com o nome da pessoa que efetuou a
dos avisos das etiquetas manutenção ou os ajustes. A pessoa que
efetuar a manutenção ou os ajustes deverá
As etiquetas colocadas nas máquinas advertem o ser a única a ter a chave da trava e deverá
operador da existência de determinados perigos e manter a chave consigo enquanto estiver a
indicam como evitá-los. Obedeça sempre a esses avisos manutenção ou os ajustes.
e siga as instruções.
7. Tenha cuidado com os
2. Leia o Manual de arranques automáticos
Instruções Algumas máquinas são instaladas e conectadas
Todos os equipamentos da Roskamp Champion vêm eletricamente para ligarem automaticamente.
acompanhados de um manual de instruções. Todos os Mantenha-se afastado das máquinas quando a sua
operadores desta máquina deverão estar totalmente presença junto delas não for necessária. Siga as normas
familiarizados com o conteúdo do manual antes de adequadas de travamento e etiquetagem, ao trabalhar
iniciar o funcionamento, operar ou fazer a manutenção com a máquina.
da mesma.
8. Não remova os
3. Mantenha as pessoas dispositivos de proteção e
presentes afastadas as tampas
NÃO PERMITA que pessoal não autorizado opere a Antes de operar a máquina, verifique se todos os
máquina. Assegure-se de que todas as pessoas que dispositivos de proteção, portas de acesso, tampas e
trabalhem com o equipamento ou se encontrem na sua grades protetoras estão nos seus devidos lugares.
proximidade foram avisadas dos perigos inerentes e
9. Proteja todas as peças
receberam as devidas instruções sobre a sua operação.
4. Use equipamento de móveis

segurança adequado Se a máquina não estiver equipada com um dispositivo
de proteção do acionador de fábrica, cubra quaisquer
Proteja seus olhos com óculos de proteção. Use também peças ou membros giratórios expostos antes de operar a
equipamento de proteção apropriado, tal como máquina. Compre ou construa dispositivos de proteção
capacetes, tampões dos ouvidos, luvas (do tamanho de reposição.
certo e sem folgas), protetores do rosto e máscaras
10. Dê uma boa manutenção
contra o pó.
Seção 1 -
5. Use vestimenta às máquinas
apropriada NUNCA opere o equipamento se o mesmo necessitar de
assistência, lubrificação ou conserto.
NÃO vista roupas soltas nem use jóias; estas podem
ficar presas nas peças móveis. Deve-se usar touca
protetora sobre cabelos compridos. 11. Inspecione
semanalmente os
6. Trave/Coloque etiquetas interruptores de limite
nos interruptores das
máquinas
Se a máquina estiver equipada com portas ou painéis de
acesso que incorporem quaisquer interruptores de limite
de bloqueio, o interruptor de limite deve ser travado
Institua programas de aplicação das normas referentes a com todos os controles elétricos para que a máquina não
travamento e etiquetagem dos dispositivos de opere quando a porta ou o painel estiverem abertos.
acionamento exigidas pela OSHA. Assegure-se de que
todos os funcionários receberam treinamento adequado Teste e faça um registo semanal da função do interruptor
quanto aos procedimentos de travamento e etiquetagem de bloqueio de limite.
e os seguem constantemente.
EF-WL0073.3PO - Instruções Gerais de Segurança 1

12. Verifique se existem 17. Mantenha-se afastado de
Instruções de Segurança
peças danificadas peças móveis
Antes de uma máquina continuar a ser utilizada, um NUNCA MANTENHA NENHUMA PARTE DO SEU
dispositivo de proteção ou qualquer outra peça que CORPO DEBAIXO OU PRÓXIMO A MEMBROS
esteja danificada devem ser cuidadosamente ROTATIVOS OU PEÇAS MÓVEIS.
inspecionados, para se determinar se esse dispositivo ou
peça funcionarão apropriadamente e realizam as
operações a que se destinam. 18. Preste atenção!!!
Inspecione o alinhamento das peças móveis, a PRESTE ATENÇÃO ao que estiver fazendo.
existência de peças quebradas e qualquer outra condição
que possa afetar a operação da máquina. Use de senso comum.
13. Use o equipamento de 19. Acessórios e

maneira correta modificações
NUNCA sobrecarregue nem faça mau uso do O uso de acessórios ou modificações ao equipamento
equipamento. Use as máquinas apenas de acordo com a que não tenham sido os recomendados podem constituir
sua finalidade e segundo as suas características técnicas. um risco.
14. Não deixe nenhum 20. Peças de reposição

objeto dentro da máquina Ao prestar assistência à máquina, use exclusivamente
NUNCA permita que algum objeto de metal ou outro peças sobresselentes idênticas, fornecidas pela
corpo estranho entrem na máquina, uma vez que isso Roskamp Champion.
poder provocar incêndio ou outros danos.
21. Tensão perigosa
15. Utilize os aparelhos de Um equipamento munido de um painel de comandos
elevação de maneira correta opcional pode causar acidentes graves. Não permita
Se a máquina estiver equipada com um aparelho de mais do que uma fonte de potência. Trave e coloque
elevação, use-o de maneira correta, de modo a levantar uma etiqueta no interruptor de alimentação da corrente,
apenas as peças para as quais ela está adaptada. antes de prestar assistência à máquina.
NUNCA utilize um aparelho de elevação que se
encontre danificado ou desgastado ou que necessite de
conserto.
16. Mantenha a área de

trabalho limpa e
desobstruída
Áreas em desordem podem ser a causa de lesões. O
1 --
acúmulo de pó pode constituir risco de explosão.

Seção 1
Seção
2 Roskamp Champion - EF-WL0073.3PO

Segurança
de Segurança
Etiquetas com instruções de
segurança
A ilustração das etiquetas com instruções de segurança na Seção "Diagrama de colocação das etiquetas com
instruções de segurança" destina-se a mostrar as etiquetas em mais detalhes com indicação do número de
referência para encomenda de etiquetas suplementares, se necessário.
Etiquetas com
das Etiquetas Instruções de
com Instruções
CPM P/N 3-3029-20 CPM P/N 3-3030-25 CPM P/N 3-3030-26
Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co.
Número de referência 3-3029-20 Número de referência 3-3030-25 Número de referência 3-3030-26

Ilustrada nas páginas: 7,8,9,10, Ilustrada nas páginas: Ilustrada na página: 13.
11,12,13,14,15,16,17,18 e 19. 7,8,9,10,11 e 19.
Diagrama de
Seção 22 -- Diagrama Colocação das
de Colocação
Número de referência 3-3030-27 PNúmero de referência 3-3093-21 Número de referência 3-3094-18

Ilustrada nas páginas: 14 e 17. Ilustrada nas páginas: 7,8,9,10, Ilustrada na página: 6.
11,12,13,14,18 e 19.
Seção

Seção 22 -- Diagrama de Colocação das Etiquetas com Instruções de Segurança

segurança

Número de referência 3-3095-22 Número de referência 3-3095-23 Número de referência

Ilustrada nas páginas: Ilustrada nas páginas: máquina de 1500 rpm - 3-3097-14
7,8,9,10,11, 7,8,9,10,11,
12,13,14,15,16,17,18 e 19. máquina de 1800 rpm - 3-3097-13
12,13,14,15,16,17,18 e 19. máquina de 3000 rpm - 3-3097-16
máquina de 3600 rpm - 3-3097-15
Ilustrada na página: 12.
CPM P/N 3-4234-02 CPM P/N 3-8087-00

Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co.

Ilustrada na página: 9. Ilustrada na página: 15. Ilustrada na página: 12.
Seção

Segurança
de Segurança
segurança
Etiquetas com
das Etiquetas Instruções de
com Instruções
CPM P/N 3-8088-00 CPM P/N 3-8089-00

Ilustrada na página: 15. Ilustrada na página: 15. Ilustrada na página: 12.
Diagrama de
Seção 22 - - Diagrama Colocação das
de Colocação
CPM P/N 3-8091-00 CPM P/N 3-8093-00
Copyright © 1995 California Pellet Mill Co. CPM P/N 3-8092-00
CPM P/N 3-8090-00

Copyright © 1995 California Pellet Mill Co.

Ilustrada nas páginas: 7,8 e 17. Ilustrada nas páginas: 13, 16 e Ilustrada nas páginas: 13 e 19.
Seção
18.


segurança
NOTICE
Key Lock Switch Modes: Maintenance During Operation:
• “ON” -Turns on green
light and maintenance
•Key Lock Switch
normally “OFF”.
door interlock
switches. Opening any If it is essential to perform
maintenance door shuts internal inspection or
off flaking mill, maintenance on flaking mill
feeder, roll pressure, during operation, authorized
green light and turns personnel must:
on red warning light. • Before - Set Key Lock
Switch to “OFF” mode.
• “OFF” - Turns off green
light and bypasses
• After - Set Key Lock
Switch to “ON” mode.
maintenance door
interlock switches. The internal inspection or
Opening any maintenance maintenance is to be
door turns on red performed by qualified and
warning light. authorized personnel only.
Maintenance door interlock
switches and warning lights
to be tested weekly.
Maintenance During Shut Down:
Flaking Mill Operation: • Key Lock Switch
• Key Lock Switch
normally “ON”.
normally “ON”.
Read instruction manual Before adjusting or repairing

before operating or flaking mill:
maintaining flaking mill. • Turn off all motors.
• Turn off and lockout
Operate flaking mill with disconnect switches
qualified personnel only. for all motors.
Guards, covers and Do not remove maintenance doors

maintenance doors must be or guards until all moving parts
secured before operating have stopped.
flaking mill.
Wear safety glasses around

operating equipment.
CPM P/N 3-7642-01

Número de referência 3-7642-01 Ilustrada nas páginas: 6 e 10.

Nota: Mude de lugar a etiqueta com o interruptor de parada de emergência e feche-o à chave.
Rotating parts. Rotating parts.

Can cause severe injury. Can cause severe injury.
s s
Seção


Ilustrada nas páginas: 7,8 e 17. Ilustrada nas páginas: 18 e 19. Ilustrada nas páginas: 14 e 18.

Segurança
de Segurança
segurança
Instruções de
NOTICE
com Instruções
BEFORE BOLTING MOTOR BASE TO FLOOR
USE STRAIGHT EDGE OR LINE TO ALIGN SHEAVES
(LEFT-HAND DRIVE MOTOR WITH C-FLOW AND Z-FLOW POSITIONS SHOWN)
MILL MILL
STRAIGHT EDGE
Etiquetas com
C-FLOW MOTOR C-FLOW MOTOR
das Etiquetas
MILL MILL
STRAIGHT
LINE
Z-FLOW MOTOR Z-FLOW MOTOR
Colocação das
RIGHT WRONG
de Colocação
CPM P/N 3-7642-50
Número de referência 3-7642-50

Ilustrada nas páginas: 7,8,9,10 e 11.
Diagrama de
Seção 22 - - Diagrama
Seção

Ilustrada na página: 12. Ilustrada nas páginas: 14 e 15. Ilustrada na página: 12.

Interruptor de Parada de Emergência

(Número de referência da etiqueta: 5-2801-00)
O Interruptor de Parada de Emergência encontra-se em todos os equipamentos

Roskamp Champion. Algumas máquinas funcionam em ação recíproca com outras
NOTICE máquinas e, consequentemente, usam um único Interruptor de Parada de
Emergência.
If possible, relocate
emergency stop switch
to the most accessible O Interruptor de Parada de Emergência deve ficar em um ponto de fácil alcance
location for operators of this
machine. para os operadores, quando esses estiverem junto à máquina. Mude o Interruptor
Switch must be near
de Parada de Emergência para um local mais acessível. Ligue este interruptor para
machine that it stops. empurrar-puxar ao circuito de comandos da máquina para parar o motor.
CPM P/N 5-2801-00
X Nota: Este interruptor destina-se a ser usado apenas para parada de
emergência do equipamento. Volte a acionar o interruptor apenas depois de
resolver o problema da emergência.
Aviso: Uma vez que o Interruptor de Parada de Emergência abre apenas o circuito de comandos, NÃO o
utilize com o interruptor de desligamento ao realizar um serviço de manutenção ou de conserto após uma
emergência. Desligue e trave/coloque uma etiqueta no interruptor de desligamento da alta tensão na fonte
de eletricidade antes de realizar qualquer manutenção ou conserto. Coloque uma etiqueta no interruptor
de desligamento da trava, com o nome da pessoa que tenha desligado o interruptor. Essa pessoa deve
manter consigo a única chave do trinco do interruptor de desligamento.
X Nota: Nos modelos SP-2400 e SP-2800 da lascadora o Interruptor de Parada de Emergência está localizado junto
a um fecho e a uma etiqueta especial (Número de referência 3-7642-01); estes três elementos devem estar situados
Tensão Interruptor da trava à

Perigosa chave
( Número de (Número de referência: 3-7642-01)
referência: 3-3094-18)
NOTICE
• Key Lock Switch
normally “OFF”.
door interlock
light and bypasses
maintenance door
interlock switches. The internal inspection or
Flaking Mill Operation: • Key Lock Switch
• normally
Key Lock Switch
“ON”.
normally “ON”.
Read instruction manual Before adjusting or repairing

CPM P/N 3-3094-18
As máquinas da Roskamp Champion maintenance doors must be

secured before operating
flaking mill.
or guards until all moving parts
have stopped.
podem estar equipadas com um Wear safety glasses around

CPM P/N 3-7642-01
painel de comandos opcional. Os

painéis de comando podem tornar-se
altamente perigosos se a potência
elétrica for originada de mais de uma
fonte.
Aviso: Desligue a corrente
e trave/coloque uma
etiqueta em todas as fontes O Interruptor da trava à chave está presente nas lascadoras da Roskamp
de alimentação, antes de modelos SP-2400 e SP-2800. O Interruptor de Parada de Emergência
operar a máquina. está localizado junto ao Interruptor da trava à chave, num suporte
especial situado no lado da frente das máquinas.
Seção
O Interruptor da trava à chave deve encontrar-se ao alcance dos

X Nota: Siga as instruções das operadores quando estes estiverem próximo da máquina. Mude o lugar
do Interruptor da trava à chave, do Interruptor de Parada de Emergência
etiquetas. Leia e siga as
instruções do manual.

Segurança
de Segurança
Moinho a Cilindros 1000/1200
(Número de referência do kit 8-1299-00-SP e SD, com
alimentador de cilindro;
8-1299-20-SP e DP com/sem alimentador de cilindro; 8-
1299-40-TP com
Instruções de
alimentador de cilindro; 8-1299-60TP com/sem
com Instruções
alimentador de cilindro;)
Rotating parts.
Can cause severe injury.
s
Etiquetas com
CPM P/N 3-3093-21 CPM P/N 3-8091-00 CPM P/N 3-8110-00 CPM P/N 3-3095-22 CPM P/N 3-3029-20 CPM P/N 3-3030-25
Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co.
*Outros pontos de *** Alimentador de

localização Cilindro
Ver abaixo Ver abaixo
das Etiquetas
Colocação das
de Colocação
NOTICE
MILL MILL
STRAIGHT EDGE
Diagrama de
MILL MILL
STRAIGHT
LINE
CPM P/N 3-3093-21

CPM P/N 3-3030-25 CPM P/N 3-3029-20 CPM P/N 3-3095-23 Copyright © 1995 California Pellet Mill Co.
RIGHT WRONG
** Lados da *Outros pontos de CPM P/N 3-7642-50
máquina localização
X Nota: Todos os moinhos de cilindros estão equipados com um Interruptor de Parada de Emergência. Ver informação sobre
o Interruptor de Parada de Emergência na página 6.
X Nota: Os moinhos de cilindros podem estar equipados com um Painel de Comandos opcional. Ver informação sobre Tensão
Perigosa na página 6.
Seção
*Outros pontos de localização: A etiqueta 3-3093-21 está também colocada na área dentro dos dispositivos de proteção,
próximo da correia de transmissão.
**Lados da máquina: A etiqueta 3-3095-23 está colocada em ambos os lados da máquina.
***Modelo com alimentador de cilindro apenas: Ver outras opções de alimentadores na página 17.

Moinho a Cilindros 900

(Número de referência da etiqueta 8-1300-00-SP e SD
com alimentador dos cilindros; 8-1300-20-SP e DP com
agitador da tremonha; 8-1300-40-SP e DP com
alimentador do vibrador 8-1300-60-TP com alimentador
dos cilindros; 8-1300-80-TP com agitador da tremonha;
8-1300-90-TP e DP com alimentador do vibrador;)
Rotating parts.
s
CPM P/N 3-3093-21 CPM P/N 3-8091-00

CPM P/N 3-8110-00 CPM P/N 3-3095-22 CPM P/N 3-3029-20 CPM P/N 3-3030-25
*Outros pontos de ***Alimentador

localização de Cilindro
NOTICE
MILL MILL
STRAIGHT EDGE
MILL MILL
STRAIGHT
LINE
CPM P/N 3-3093-21

RIGHT WRONG
** Lados da *Outros pontos de CPM P/N 3-7642-50
máquina localização
X Nota: Todos os moinhos de cilindros estão equipados com um Interruptor de Parada de Emergência. Ver informação sobre
o Interruptor de Parada de Emergência na página 6.
X Nota: Os moinhos de cilindros podem estar equipados com um Painel de Comandos opcional. Ver informação sobre
Tensão Perigosa na página 6.
Seção
**Lados da máquina: A etiqueta 3-3095-23 está colocada em ambos os lados da máquina.
***Modelo com alimentador de cilindro apenas: Ver outras opções de alimentadores na página 17.

2 -- Diagrama de Colocação das Etiquetas com Instruções de Segurança
TRITURADORA CMX-DS 1200 E 855DS
(Número de referência do kit 8-1301-00)
NOTICE
MILL MILL
STRAIGHT EDGE
MILL MILL
STRAIGHT
LINE
RIGHT WRONG
CPM P/N 3-7642-50
*Outros pontos de localização

Ver abaixo
NOTICE
MILL MILL
STRAIGHT EDGE
MILL MILL
STRAIGHT
LINE

CPM P/N 3-3030-25 Copyright © 1995 California Pellet Mill Co.
RIGHT WRONG
** Lados da máquina *Outros pontos de CPM P/N 3-7642-50
Ver abaixo localização

Ver abaixo
TRITURADORA CMX-SS 1200 e 855SS

NOTICE
MILL MILL
STRAIGHT EDGE
MILL MILL
STRAIGHT
LINE
CPM P/N 3-3093-21

RIGHT WRONG CPM P/N 3-3030-25
CPM P/N 3-3029-20
CPM P/N 3-3095-23
CPM P/N 3-3093-21
CPM P/N 3-3095-22
CPM P/N 3-7642-50
*Outros pontos de localização ** Lados da máquina** Lados da máquina*Outros pontos de localização

Ver abaixo Ver abaixo Ver abaixo Ver abaixo
X Nota: Todas as trituradoras estão equipadas com um Interruptor de Parada de Emergência. Ver informação sobre o
Seção 2
Interruptor de Parada de Emergência na página 6.

Seção
X Nota: As trituradoras podem estar equipadas com um Painel de Comandos opcional. Ver informação sobre Tensão
**Lados da máquina: Essas etiquetas estão localizadas em ambos os lados da máquina.
Roskamp Champion - EF-WL0073.3 9

LASCADORAS SP-2400/SP-2800
NOTICE NOTICE
• Key Lock Switch
normally “OFF”. (LEFT-HAND DRIVE MOTOR WITH C-FLOW AND Z-FLOW POSITIONS SHOWN)
door interlock
MILL MILL
STRAIGHT EDGE
light and bypasses
maintenance door
interlock switches. The internal inspection or C-FLOW MOTOR C-FLOW MOTOR
CPM P/N 3-3095-22 Flaking Mill Operation: • Key Lock Switch
CPM P/N 3-3095-23
• normally
Key Lock Switch
“ON”.
normally “ON”. Copyright © 1995 California Pellet Mill Co.
CPM P/N 3-3095-22
Read instruction manual Before adjusting or repairing MILL MILL

STRAIGHT
LINE

maintenance doors must be or guards until all moving parts Z-FLOW MOTOR Z-FLOW MOTOR
secured before operating have stopped.
flaking mill.
Wear safety glasses around
RIGHT
CPM P/N 3-7642-01

WRONG
CPM P/N 3-7642-50
CPM P/N 3-3029-20

Copyright © 1995 California Pellet Mill Co. CPM P/N 3-3093-21 Copyright © 1995 California Pellet Mill Co.
*Outros pontos de *Outros pontos de

localização localização
MOINHO DE CABEÇA A CILINDRO

X Nota: Todas as lascadoras estão equipadas com um Interruptor de Parada de Emergência. Ver informação sobre o Interruptor de Parada
de Emergência na página 6.
Seção
X Nota: As lascadoras podem estar equipadas com um Painel de Comandos opcional. Ver informação sobre Tensão Perigosa na página 6.
X Notice: Nas lascadoras modelos SP-2400 e SP-2800, o Interruptor de Parada de Emergência está localizado ao lado da trava e de uma
etiqueta de segurança especial (número de referência 3-7642-01). Estes três elementos devem ser localizados no mesmo lugar.

Segurança
de Segurança
LASCADORAS SP-1600/SP-1800/SP-2000
Instruções de
com Instruções
Etiquetas com
das Etiquetas
Colocação das
de Colocação
NOTICE
Diagrama de
MILL MILL
STRAIGHT EDGE
CPM P/N 3-3093-21 CPM P/N 3-3095-23 CPM P/N 3-3029-20 CPM P/N 3-3030-25 CPM P/N 3-3093-21
Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co.
*Outros pontos de
MILL
*Outros pontos de
MILL
STRAIGHT
LINE
localização localização Z-FLOW MOTOR Z-FLOW MOTOR

RIGHT WRONG
CPM P/N 3-7642-50
X Nota: Todas as lascadoras estão equipadas com um Interruptor de Parada de Emergência. Ver informação sobre o
X Nota: As lascadoras podem estar equipadas com um Painel de Comandos opcional. Ver informação sobre Tensão
Seção
Roskamp Champion - EF-WL0073.3 11

Segurança
de Segurança
Moinho a Martelo
(Número de referência do kit - 8-1303-00/1500 rpm; 8-1303-
20/1800 rpm
8-1303-40/3000 rpm; 8-1303-60/3600 rpm)
Instruções de
com Instruções

CPM P/N 3-3029-20
CPM P/N 3-3095-23 CPM P/N 3-3095-22 Copyright © 1995 California Pellet Mill Co.
** Lados da ** Lados da ** Lados da

máquina máquina máquina
Ver abaixo Ver abaixo Ver abaixo
Etiquetas com
das Etiquetas
Percussor
Colocação das
(Número de referência do kit 8-1304-00/1500 rpm; 8-1303-

20/1800 rpm
de Colocação
8-1304-40/3000 rpm; 8-1304-60/3600 rpm)
CPM P/N 3-8090-00 CPM P/N 3-3097-14

Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. CPM P/N 3-3093-21
Diagrama de
**Lados da máquina **Lados da **Lados da *Outros pontos de localização

Ver abaixo máquina máquina Ver abaixo
Seção 22 -- Diagrama
X Nota: Todos os moinhos a martelos e percussores estão equipadas com um Interruptor de Parada de Emergência. Ver
Seção
informação sobre o Interruptor de Parada de Emergência na página 6.

**Lados da máquina: Essas etiquetas estão localizadas em ambos os lados da máquina, nas portas.

Segurança
de Segurança
Britateiras e Desfibradora/Laminadora-
Acabadora
(Número de referência do kit 8-1305-00 Gladiator; 8-
1303-20-Titan e /1800 rpm 8-1304-40/3000 rpm; 8-
1304-60/3600 rpm)
Instruções de
com Instruções
Britateiras Gladiator
e Gladiator II
Etiquetas com
CPM P/N 3-3093-21
Gladiator II
*Outros pontos de
das Etiquetas
CPM P/N 3-8093-00
CPM P/N 3-3095-22
CPM P/N 3-3029-20
CPM P/N 3-3030-26
CPM P/N 3-3095-23
CPM P/N 3-8092-00
localização
Gladiator Ver abaixo
**Lados da máquina **Lados da máquina
*Outros pontos de
Ver abaixo Ver abaixo localização
Ver abaixo
Titan Crusher
Colocação das
de Colocação
CPM P/N 3-3093-21
*Outros pontos de
localização
Ver abaixo

CPM P/N 3-3030-26
Diagrama de
Desfibradora/Laminadora
-acabadora
CPM P/N 3-3093-21
*Outros pontos de
localização
Ver abaixo
X Noa: Todas as britateiras Gladiator/Titan e Desfibradora/Laminadoras-Acabadoras estão equipadas com um

Interruptor de Parada de Emergência. Ver informação sobre o Interruptor de Parada de Emergência na página 6.
X Nota: As britateiras Gladiator/Titan e Desfibradora/Laminadoras-Acabadas podem estar equipadas com um Painel de
Seção
Comandos opcional. Ver informação sobre Tensão Perigosa na página 6.

*Outros pontos de localização: A etiqueta 3-3093-21 está também colocada na área dentro dos dispositivos de
proteção, próximo da correia de transmissão.
**Lados da máquina: Essas etiquetas estão localizadas em ambos os lados da máquina.

Segurança
de Segurança
Britateira
X Nota: Todas as britateiras estão equipadas com um Interruptor de Parada de
Emergência. Ver "Interruptor de Parada de Emergência", na página 6.
Instruções de
*Outros pontos de localização: A etiqueta 3-3093-21 está também localizada na

área interna dos dispositivos de proteção destacáveis, junto à correia de
transmissão.
com Instruções
**Lados da máquina: Esta etiqueta está localizada em ambos os lados da

máquina.
CPM P/N 3-3095-22

CPM P/N 3-3093-21
Etiquetas com
*Outros pontos de
localização
Ver acima
das Etiquetas
CPM P/N 3-3095-23

Rotating parts.
s
CPM P/N 3-8113-00

Colocação das
**Lados da máquina
CPM P/N 3-3029-20
Ver acima
Alimentador Rota' Feed

de Colocação

Diagrama de
CPM P/N 3-3030-27

CPM P/N 3-3095-22

CPM P/N 3-3029-20

CPM P/N 3-3095-23

Seção
X Nota: Os Alimentadores Rota' Feed são equipados com um Interruptor de Parada de Emergência quando vendidos como
unidade independente. Se vendidos em conjunto com um Moinho a martelos Champion são conectados ao Interruptor de
Parada de Emergência da máquina principal. Ver "Interruptor de Parada de Emergência", na página 6.
X Nota: Os alimentadores Rota' Feed podem ser equipados com um Painel de Comandos opcional. Ver "Tensão Perigosa", na
página 6.

Segurança
de Segurança
Câmaras a Vapor
Instruções de
com Instruções
CPM P/N 3-8088-00
Etiquetas com
CPM P/N 3-4234-02
das Etiquetas
Gyro Sifter
Colocação das
(Número de referência do kit 8-1308-00; com Um ímã
A-A 8132800)
de Colocação
X Nota: Todas
as Gyro Sifter são
Diagrama de
equipadas com um
Interruptor de
Parada de
CPM P/N 3-3095-22
CPM P/N 3-8089-00
CPM P/N 3-3029-20
CPM P/N 3-3095-23
Emergência. Ver
Apenas ímã de entrada **Lados da máquina**Lados da máquina "Interruptor de
pneumática opcional Ver coluna à direita Ver coluna à direita Parada de
Emergência", na
página 6.
** Lados da
máquina: Estas
etiquetas estão situadas
nas portas, em ambos
os lados da máquina.
Seção

Segurança
de Segurança
Refrigerador Horizontal HDHC-7D

Instruções de
com Instruções
Etiquetas com
Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co.
**Lados da máquina **Lados da máquina **Lados da máquina

Ver abaixo Ver abaixo Ver abaixo
de Colocação
Diagrama de
Seção 22 -- Diagrama das Etiquetas
Colocação das
CPM P/N 3-8092-00 CPM P/N 3-3095-23

**Lados da máquina **Lados da máquina

X Nota:Todos os refrigeradores horizontais são equipados com um Interruptor de Parada de Emergência. Ver "Interruptor
de Parada de Emergência", na página 6.
X Nota: Os refrigeradores horizontais podem ser equipados com um Painel de Comandos opcional. Ver "Tensão Perigosa",
Seção
na página 6.
**Lados da máquina: Estas etiquetas estão localizadas em ambos os lados da máquina.

Segurança
de Segurança
Alimentadores
(Número de referência do kit 8-1306-20-alimentador de
cilindro; 8-1306-40- alimentador da tremonha; 8-1306-
60-alimentador de bolso;)
Instruções de
com Instruções
Rotating parts.
s

**Lados da máquina
Ver abaixo
Alimentador de
Cilindro
Etiquetas com
das Etiquetas
CPM P/N 3-3095-22
Alimentador da
Colocação das
tremonha
de Colocação
CPM P/N 3-3029-20 CPM P/N 3-3095-22
CPM P/N 3-8091-00 Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co.
Diagrama de
Alimentador de
bolso
X Nota: Quando comprados separadamente, os alimentadores são equipados

com um Interruptor de Parada de Emergência. Ver "Interruptor de Parada de
Emergência", na página 6.
**Lados da máquina: Estas etiquetas estão localizadas em ambos os lados da
Seção
máquina.
CPM P/N 3-3029-20 CPM P/N 3-3030-27
**Lados da máquina
Ver coluna esquerda

Segurança
de Segurança
Cabeça de Britateira CHHD

X Nota: Todas as cabeças de britateira estão equipadas com um Interruptor de
Instruções de
Parada de Emergência. Ver informação sobre o Interruptor de Parada de

Emergência na página 6.
com Instruções
*Outros pontos de localização: A etiqueta 3-3093-21 está também colocada na área

dentro dos dispositivos de proteção, próximo da correia de transmissão.
Rotating parts.
s
Etiquetas com
*Outros pontos de
localização
Ver acima
das Etiquetas
Alimentador de Rosca Sem-fim

Colocação das

de Colocação
X Nota: Todos os alimentadores

de rosca sem-fim são
equipados com um
Interruptor de Parada de
Emergência. Ver "Interruptor
CPM P/N 3-8092-00
de Parada de Emergência",
na página 6.
*Outros pontos de
Diagrama de
localização X Nota:Os alimentadores de

Ver coluna à direita rosca sem-fim podem ser
equipados com um Painel de

Comandos opcional. Ver
"Tensão Perigosa", na página
6.
*Outros pontos de localização:
CPM P/N 3-3095-23
A etiqueta 3-8092-00 está
também colocada na área

**Lados da máquina
interna dos dispositivos de
Ver coluna à direita
proteção destacáveis,
próximo da correia de
transmissão.
Seção
**Lados da máquina: Estas

etiquetas estão localizados
CPM P/N 3-8112-00
em ambos os lados da
CPM P/N 3-3095-22
**Lados da máquina máquina.
**Lados da máquina Ver coluna à direita
Ver coluna à direita

Segurança
de Segurança
Moinho a Cilindros Modelo 650
(Número de referência do kit 8-1310-00-SP, DP e TP; 8-
1310-20-XP com broca horizontal; 8-1310-40-XP com
broca e correia de transmissão verticais; 8-1310-60-XP
Instruções de
com broca e correia de transmissão verticais;)
com Instruções
CPM P/N 3-3093-21
CPM P/N 3-3095-22 CPM P/N 3-3029-20
*Outros pontos de localização Copyright © 1995 California Pellet Mill Co.

CPM P/N 3-3030-25
Ver abaixo
de Colocação
Diagrama de
Seção 22 - - Diagrama Etiquetas com
das Etiquetas
Colocação das
Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. Copyright © 1995 California Pellet Mill Co. CPM P/N 3-8112-00
**Localizações opcionais **Localizações opcionais

X Nota: Todos os moinhos a cilindros estão equipados com um Interruptor de Parada de Emergência. Ver informação sobre o
X Nota: Os moinhos a cilindros podem estar equipados com um Painel de Comandos opcional. Ver informação sobre Tensão
Seção
**Localizações opcionais: As etiquetas 3-8093-00 e 3-8112-00 destinam-se a ser utilizadas na broca e estão colocadas nesse
equipamento.

Aplicação
de Aplicação
É importante seguir este a primeira etiqueta vai ser secagem para evitar o
procedimento para afixar aplicada. A área limpa acúmulo de pó.
etiquetas com instruções de deverá ser muito maior do
segurança adesivas de vinilo nas que o tamanho da etiqueta. 7. Retire o revestimento
suas máquinas. Evite raspar a tinta, a protetor do reverso da
menos que haja lascas de etiqueta. Dobre
Esse procedimento assegura que
as etiquetas fiquem afixadas com tinta aderidas ao raspador. ligeiramente a etiqueta de
a maior aderência possível às maneira a que o seu centro
Processos de
máquinas e, portanto, 3. Lixe ligeiramente a área de toque na superfície da

permaneçam coladas por muito aplicação com uma lixa máquina primeiro e depois
tempo.
Segurança, Processos
fina, de modo a tornar a alise-a, evitando a

Materiais necessários: superfície um pouco mais formação de bolhas. Faça
grossa e de mais fácil pressão sobre as bolhas
• Diagrama de colocação de aderência. formadas para fazer sair o
etiquetas com instruções ar retido e pressione a
de segurança.* 4. Limpe bem com um agente etiqueta contra a superfície
de limpeza de uso para fixá-la no lugar.
• Etiquetas com instruções doméstico e toalhas
de segurança.* descartáveis. 8. Verifique se a etiqueta está
de Segurança,
firmemente afixada à
• Raspador de tinta. 5. Enxugue com toalhas máquina. Repita as etapas
descartáveis limpas até a de 1 a 7 com as etiquetas
• Lixas finas. superfície estar restantes.
• Agente de limpeza para completamente seca.
uso doméstico que não Nota: A superfície deve ficar
contenha óleos (por completamente seca e sem
exemplo as marcas 409 ou quaisquer sinais de óleo.
Fantastic).
6. Aguarde quinze (15)
Instruções de
• Toalhas descartáveis. minutos para que os

últimos vestígios de
Instalação líquido de limpeza tenham
com Instruções
secado. Esta etapa é

1. Determine, com base no importante. Se for
diagrama, os locais onde as colocada antes da
etiquetas com instruções superfície estar
de segurança irão ser completamente seca, a
colocadas. etiqueta irá se destacar
com facilidade, devido à
2. Remova com um raspador umidade residual no seu
a sujeira e o pó reverso. Cubra a área limpa
Etiquetas com
acumulados na superfície durante o período de

da máquina, no lugar onde
3 -- Etiquetas
*As etiquetas com instruções de segurança e os Diagramas de Colocação das Etiquetas são fornecidos em kits de etiquetas.
A página a seguir contém Na sua maioria, as etiquetas são Podem ser remetidas etiquetas
ilustrações dos kits de etiquetas de vinilo adesivo. Algumas delas avulsas caso não necessite de um
com instruções de segurança, que são produzidas exclusivamente kit completo. Consulte o(s)
a Roskamp Champion fornece sob a forma de letreiros de número(s) de referência do(s)
Seção 3
gratuitamente. Poderá obter o alumínio com rebites. Aplique as kit(s) de etiquetas de substituição
número de referência do kit etiquetas de vinilo seguindo as apropriado(s) para a sua máquina
Seção
apropriado para a sua máquina instruções da seção "Etiquetas consultando os diagramas

consultando os diagramas de com Instruções de Segurança, contidos nesta publicação.
etiquetas de substituição contidos Processos de Aplicação".
nesta publicação.

Segurança
de Segurança
Envie a sua encomenda por fax ou pelo correio para:
Roskamp/Champion
2975 Airline Circle
Waterloo, IA 50703
™
®
Tel.: (319) 232-8444
Linha de chamada grátis (nos EUA): (800) 366-2563
Fax: (319) 232-4040
Instruções de
Remeter etiquetas para:
com Instruções
À atenção de:
Nome e endereço da empresa: Data:
Etiquetas com
Modelo(s)/Número(s) de série da(s) máquina(s) (Necessário indicar)
de Etiquetas
Descrição No. de Referência Quantidade Página
Kit de Etiquetas com Instruções de Segurança para o Moinho a Cilindros
Encomenda de
1000/1200 (Indicar tipo) 8-1299- 7
Kit de Etiquetas com Instruções de Segurança para o Moinho a
de Encomenda
Cilindros 900 (Indicar tipo) 8-1300- 8
Kit de Etiquetas com Instruções de Segurança para a Trituradora CMX (Indicar tipo) 8-1301- 9
Kit de Etiquetas com Instruções de Segurança para a Lascadora (Indicar tipo) 8-1302- 10&11
Kit de Etiquetas com Instruções de Segurança para o Moedor de Cabeça a Cilindro 8-1302- 10
Kit de Etiquetas com Instruções de Segurança para a Moinho a martelos
(Indicar tamanho e rpm) 8-1303- 12

Kit de Etiquetas com Instruções de Segurança para o Percussor (Indicar tamanho e rpm) 8-1304- 12
Kit de Etiquetas com Instruções de Segurança para o Britateira (Indicar tipo e rpm) 8-1305- 13,14 &18 Formulário de
Formulário
Kit de Etiquetas com Instruções de Segurança para o Alimentador (Indicar tipo) 8-1306- 14,17 &18
Kit de Etiquetas com Instruções de Segurança para a Câmara a Vapor (Indicar altura) 8-1307- 15
Kit de Etiquetas com Instruções de Segurança para o Peneira Giroscópica (Indicar tamanho) 8-1308- 15
Kit de Etiquetas com Instruções de Segurança para o Refrigerador (Indicar tipo) 8-1309- 16
Kit de Etiquetas com Instruções de Segurança para o Moinho a Cilindros Modelo 650 (Indicar tipo) 8-1310- 19
*Para garantir que seja remetido o kit de etiquetas com instruções de segurança correto,
preencha, no espaço reservado, em cada Número de Referência, o código que corresponde à sua máquina.
Se necessário, faça cópias adicionais deste formulário.

Introdução
J M
Seção 2 -
A
K
I C
L B
E
D
H
G F
B
J
E
A
D K
I
F
L
H
G
Figura I-1: Trituradoras (CMX-DS com desviador e CMX-SS exibido).
A trituradora reduz o material a da distância intercalar dos referem à trituradora do ponto de

partículas ao fazê-lo passar por cilindros, do volume do material vista de alguém voltado para a
cilindros corrugados em contra- alimentado para os cilindros. sua parte dianteira. Os eixos
rotação. O grau de redução intermediários de ajuste de rolo
depende do material, do Sempre que forem utilizados os estão sempre localizados na parte
diferencial de velocidade dos termos esquerdo/direito e dianteira.
cilindros, do tipo de corrugação, traseiro/dianteiro, estes se

Introdução Descrição da cilindros. A disposição em
serpentina da correia também
Opção de ajuste
trituradora muda o sentido da rotação dos automático dos
cilindros. Um parafuso de ajuste cilindros
(Todas as letras contidas nas com mola mantém a tensão
referências se referem à Figura I- correta nas correias de O sistema com ajuste automático
1 acima, salvo indicação em acionamento entre cilindros. dos cilindros dispõe de um leitor
contrário). Os cilindros padrão digital que indica a abertura dos
(A) são fabricados de ferro A manutenção e os ajustes podem cilindros. Um kit de anel em
fundido com uma superfície ser facilmente realizados quadratura (veja a Figura I-3),
funcional em aço temperado. Os removendo a porta de acesso para montado na extremidade de um
cilindros possuem munhões manutenção (K). macaco de rosca, mantém um
(eixos) (B) que rodam em registro do movimento do eixo de
mancais de roletes esféricos de Para inspecionar o tamanho das acoplamento e converte esse
fila dupla de auto-alinhamento partículas, existem as portas de movimento na distância da
preciso (C). O cilindro rápido amostragem (L). abertura. O leitor digital LED
está fixado ao corpo da exibe a distância da abertura com
trituradora e o cilindro lento
Seção 2 -
movimenta-se de forma a ajustar Ajuste manual dos uma precisão de ± 0,001

polegada (veja a Figura I-5,
a abertura dos cilindros. cilindros página 3).
O corpo da trituradora é uma Com o sistema de ajuste manual Um motor pneumático, montado
soldadura feita de chapa de aço dos cilindros, o usuário ajusta os no macaco de rosca, ajusta a
pesado com corrediças dos cilindros na trituradora. A distância da abertura do cilindro.
mancais fresadas (D) após a trituradora de ajuste manual é Um interruptor seletor ou botões
soldadura para assegurar um ideal para funcionamento por operam uma válvula solenóide
perfeito alinhamento dos longos períodos de tempo que que orienta o ar de maneira a
cilindros (cilindros no mesmo requeiram poucos ajustes, ou afastar ou a aproximar os
plano horizontal, veja a Figura I- quando o operador estiver perto cilindros.
2). A construção do corpo da do equipamento.
trituradora permite uma fácil O modelo com opção de ajuste
instalação e assistência aos O sistema de ajuste manual usa automático dos cilindros dispõe
cilindros. A trituradora possui um os macacos de roscas instalados de dois sistemas integrados que
acionador de correia principal em na trituradora para deslizar o protegem os cilindros contra
V (E) que permite maior cilindro móvel nas trilhas de danos. Porcas de retenção
rendimento, baixa manutenção e rolamento. Os macacos de rosca
operação silenciosa. A base do são conectados com um eixo de
motor (F) adapta-se a todas as acoplamento.
caixas de motor NEMA padrão.
Uma roda manual, com um
O cilindro lento está montado indicador analógico de posição
sobre placas de apoio fresadas montado no macaco de rosca,
com precisão (G) que deslizam aciona um macaco de rosca. A
nas corrediças dos mancais roda permite o percurso rápido do
fresadas. Macacos de rosca (H), cilindro em ambos os sentidos.
conectados Ã s placas de apoio Ao fechar os cilindros, colares de
deslizantes, ajustam a abertura bloqueio dos cilindros evitam que
dos cilindros. Um eixo de os cilindros se toquem. Pinos de
acoplamento (I) conecta os retenção controlam a abertura
macacos de rosca de ajuste do máxima do cilindro (veja a Figura I-4: Kit de anel em
cilindro para garantir ajustes Figura I-4). quadratura
precisos e completos da abertura
dos cilindros. Bloqueadores dos
cilindros fixam a distância C
A
mínima e abrem a abertura dos
B
cilindros. Uma roda manual (J)
ou um codificador é conectado no
macaco de rosca da máquina. Isto E
possibilita ao usuário alterar a F
abertura dos cilindros em
pequenos incrementos para
atingir a redução de partícula
desejada.
D
Um acionador de correia em V
entre cilindros, com polias de
diversos tamanhos nos dois
cilindros, proporciona as Figura I-3: Ajuste manual dos cilindros – (A) Roda; (B) Trava de regulagem;
velocidades diferenciais dos (C) Eixo de acoplamento; (D) Tampa do macaco de rosca; (E) Acoplamento;
(F) Indicador analógico.

Introdução
corretamente ajustadas no O acionador do alimentador de superior. Esta tremonha permite
cilindro garantem uma proteção cilindros é um redutor de operar duas trituradoras juntas e
positiva, impedindo o contato engrenagens montado sobre um ter uma única entrada. Também
entre os rolos e evitando que eixo acionado por um motor é usada, principalmente, como
estes se afastem muito um do elétrico que faz girar o cilindro um refrigerador horizontal e
outro. Um bloqueio programado de alimentação. Os acionadores vertical.
no leitor digital também limita o do alimentador de cilindros têm
percurso dos cilindros. uma configuração TEFC ou são à
prova de explosão. Recursos de
Alimentadores Uma porta de alimentação
segurança
ajustável controla o volume de Todas as trituradoras da CPM
A trituradora pode estar equipada material alimentado na vêm com os recursos de
com um dos dois seguintes trituradora. A porta de
alimentadores: Os alimentadores segurança padrão, que ajudam os
alimentação padrão é operada operadores em situações de
ajudam a obter um fluxo através de uma roda (existem
uniforme de material ao longo do emergência e mantêm a
outras opções). trituradora inoperante durante
comprimento dos cilindros e
Seção 22 --
orientam o fluxo desse material procedimentos de manutenção e
A estrutura modular da ajuste.
para a área de atrito entre os trituradora incorpora os
cilindros, assegurando
Seção
mecanismos dos cilindros e da O Interruptor de Parada de
rendimento máximo da porta de alimentação que formam Emergência destina-se a
trituradora. uma tremonha que recebe o interromper todas as operações
material a ser moído. Há uma da trituradora a martelos no caso
Alimentadores dos porta de acesso para manutenção de uma emergência. Este
cilindros: aparafusada através da qual é interruptor deve estar localizado
prestada assistência à máquina, e em local de fácil acesso.
O alimentador do rolo é são feitos o ajuste das placas
aparafusado sobre a trituradora e defletoras e a limpeza do Atenção: O Interruptor
consiste de um rolo de conjunto opcional do ímã. Uma de Parada de
alimentação rotativo, uma porta de inspeção está montada Emergência NÃO deve
unidade de acionamento, uma na máquina para permitir a ser usado como
porta de alimentação, um ímã inspeção visual do dispositivo de parada
opcional de proteção e carcaça. funcionamento do alimentador. de segurança para fazer
manutenção ou ajuste
O cilindro de alimentação gira na trituradora.
sobre mancais de rolamentos Flat Top
montados externamente. O O flat top é uma trituradora
cilindro de 9 polegadas de padrão, sem alimentador. É As trituradoras floculadoras da
diâmetro possui uma corrugação usado principalmente como um CPM foram projetadas com uma
grosseira que alimenta refrigerador horizontal e vertical. blindagem resistente para evitar
positivamente material da acidentes e para cumprir todas as
tremonha e fornece um fluxo normas de segurança padrão.
uniforme de material para os Flat Top com desviador
cilindros da trituradora. (Todas as letras referem-se à Todos os dispositivos de ajuste
Figura I-1, na página 1, salvo com a máquina em
Os defletores de fluxo devem ser indicação em contrário). O Flat funcionamento foram
instalados de maneira a que o Top com desviador (M) é uma posicionados em locais
material a ser triturado seja trituradora padrão, com uma convenientes para facilitar o
orientado para a área de atrito dos tremonha desviadora na parte trabalho do operador e dar-lhe
cilindros. segurança.
Figura 1-5: Leitor digital LED.

Introdução
Seção 22 --
Seção

Instalação
Atenção: Leia e funcionamento da máquina. • Inspecione o equipamento
compreenda as O dispositivo de medição para verificar se ocorreram
instruções gerais sobre deve ser instalado antes de o danos no transporte. Caso
instalação abaixo, e material entrar na área da tenha ocorrido qualquer
lembre-se de empregar armadilha magnética. O dano, notifique a empresa
sempre boas práticas dispositivo de medição t r a n s p o r t a d o r a
de oficina ao instalar a evitará o acúmulo de imediatamente e apresente
t r i t u r a d o r a . material nos rolos. Isto um pedido de indenização
Trave/etiquete a fonte evitará cargas excessivas do junto a essa empresa para a
de alimentação antes motor e o desgaste dos compensação de quaisquer
de instalar a máquina mancais. perdas ou danos.
(veja a Seção Instale a trituradora deixando um • Localize o manual do
"Segurança"). espaço adequado de acesso para operador, a lista de peças, os
sua manutenção e para o ajuste e diagramas de dimensões
manutenção do motor de gerais e os diagramas de
Disposição geral acionamento principal. Deixe um instalação elétrica.
Seção 3 -
mínimo de 24 polegadas de
Consulte o diagrama das espaço livre nas laterais e traseira
dimensões gerais para obter as da trituradora e espaço adicional Instruções para a
dimensões das aberturas de
entrada e saída e as dimensões
na parte dianteira da trituradora instalação
para a remoção dos cilindros.
gerais (esse diagrama foi enviado (Veja o diagrama com as Siga as seguintes instruções
no momento da encomenda da dimensões gerais na Seção gerais para a instalação da
máquina e também está incluído "Peças"). trituradora:
na Seção "Peças" deste livro). As
especificações do modelo são Equipe as instalações com meios Planejamento e projeto
apresentadas na página um da para elevar os cilindros, as polias
encomenda. do local de instalação
do acionador e o conjunto do
acionador entre cilindros. Visto • O projeto do piso deve ser
As trituradoras podem ter sido que as peças da trituradora são feito por um engenheiro de
enviadas com um alimentador pesadas, utilize equipamentos construção civil qualificado.
instalado na entrada da elevadores de capacidade
trituradora. Para o melhor • O piso deve ser projetado
nominal e roldanas para consertar tendo em conta a sua rigidez
funcionamento da trituradora, o os cilindros.
operador deve proporcionar um e não o peso morto.
fluxo uniforme do material ao
longo de toda a largura da Inspeção do • Coloque vigas profundas ao
trituradora. O desempenho da longo da base da trituradora,
trituradora pode ser inadequado e
material recebido ao longo do menor
os rolos podem desgastar-se • Localize a lista de materiais. comprimento da área da
irregularmente quando o fluxo de Essa lista identifica todas as trituradora (veja a Figura IN-
alimentação para os rolos é peças que foram enviadas 2, página 2).
irregular. (Veja a Figura IN-1 soltas.
para o fluxo adequado do ? Nota: NÃO bloqueie
material). • Compare as peças recebidas nenhuma parte da abertura
com as indicadas na lista de de descarga com vigas
? Nota: A CPM recomenda a materiais. Se houver profundas.
utilização de um ímã e uma discrepâncias, contate o seu
peneira antes que o material • As cargas descarregadas pela
representante da CPM. trituradora variarão de
seja colocado na trituradora.
É também aconselhável ? Nota: A CPM não é acordo com o modelo e a
utilizar um dispositivo de responsável por perdas ou configuração (veja o
medição capaz de fazer uma danos ocorridos no processo diagrama de dimensões
interrupção completa do de remessa. gerais na Seção "Peças").
• A estrutura do piso deve ter
uma frequência natural
superior a 8 Hz.
• O piso deve ter resistência
suficiente para suportar o
equipamento de manuseio de
materiais.
• O piso sob a base da
Figura IN-1: Fluxo do material - (A) rolos - vista da extremidade; (B) rolos - trituradora a martelos deve
vista superior; (C) fluxo do material; (D) a área entre os rolos (setas) é a área
de esmagamento. Para melhor desempenho, o material (C) deve fluir
ser liso e com uma espessura
diretamente para a área de esmagamento (D) e deve cobrir a área de de até 1/16 pol.
esmagamento de uma extremidade à outra dos rolos (parecerá uma cortina).

Instalação
Seção 3 -
Figura IN-2(a): Suporte com viga profunda para uma base única (vista inferior) – (A) Vigas profundas; (B) Paredes; (C)
Plataforma da trituradora; (D) Base do motor (fluxo “Z”); Nota: Nunca cubra a abertura de descarga (E).
Figura IN-2(b): Suporte com viga profunda para uma base dupla (vista inferior) – (A) Vigas profundas; (B) Paredes; (C)
Plataforma da trituradora; (D) Base do motor (fluxo “Z”); Nota: Nunca cubra a abertura de descarga (E).
orifícios e conforme número de orifícios

dimensionado no diagrama existentes na estrutura.
de dimensões gerais que se
encontra na Seção "Peças". Espaço ao redor da
trituradora
• Leve em consideração o
roteamento do conduto do
motor. Este pode ser passado
pelo piso próximo à base da
trituradora. Determine a
Figura IN-3: Chumbadores - (A) Figura IN-4: Trituradora
localização da caixa do
chumbador; (B) cano; (C) concreto; aparafusada na base. conduto do motor. A
(D) profundidade de 4 a 6 pol. localização da caixa do
conduto em certos motores de
Detalhes dos • Prenda a trituradora na grandes dimensões não é
respectiva base, utilizando os ajustável (considere a
chumbadores remoção dos rolos, a remoção
orifícios de parafusos
• (Veja a Figura IN-3, página perfurados na estrutura (veja das proteções e a
2, que contém detalhes sobre a Figura IN-4). Use manutenção).
chumbadores típicos). chumbadores que
Posicione os chumbadores correspondam ao tamanho e
de acordo com o padrão de

Instalação
Almofada amortecedora A CPM oferece placas de ímãs da Existem vários sistemas de
da vibração série Magnum. No entanto peneiramento no mercado. A
lembre-se de que se o produto CPM recomenda o uso da peneira
• Posicione a almofada estiver se movimentando muito Champion Gyro Sifter, mas a
amortecedora da vibração depressa pelo ímã, nenhuma maioria das peneiras é adequada
opcional embaixo da borda placa magnética na entrada será para o trabalho.
da trituradora de acordo com capaz de realizar o trabalho.
as dimensões fornecidas no
diagrama de dimensões À medida que aumenta o Verificação de outros
gerais, na Seção "Peças". problema de contaminação de aspectos da instalação
resíduos de ferro, será necessário • Verifique a tensão e o
Fixação com argamassa instalar outro tipo de proteção alinhamento das correias.
• Será necessário fazer o magnética. Certifique-se de que as
enchimento de espaços na polias e as chaves estão
base da trituradora se não for Todos os ímãs requerem limpeza apertadas nos eixos.
utilizada uma almofada regular para manter a eficiência.
X Nota: Consulte as
Seção 3 -
amortecedora da vibração X Nota: Todas as placas
opcional e/ou se o piso não especificações de
magnéticas necessitam de manutenção dos motores e
for plano em até 1/16 pol. limpeza de manutenção
debaixo da base da correias na Seção "Ajustes
muito regular para de manutenção".
trituradora. assegurar a sua eficácia.
• Use argamassa de epóxi que Devem ser estabelecidas • Verifique os parafusos de
não encolha. Ventile a área programações de inspeção e montagem dos motores.
enquanto estiver trabalhando limpeza. Essas inspeções Certifique-se de que todas as
com argamassa. Siga as devem ser assinadas em uma montagens de motor a motor
instruções do fabricante para lista de verificação, e os parafusos de montagem
manusear a argamassa. (Veja diariamente ou após cada dos motores estejam
a Seção "Apêndice" para turno. apertados.
obter instruções típicas para Nas aplicações onde ocorram • Antes de fazer qualquer
a aplicação de argamassa, grandes problemas com limalha ligação elétrica, inspecione o
que são apresentadas apenas de ferro ou quando é necessário interior da trituradora para
como referência.) um sistema de auto-limpeza, verificar se há peças soltas
pode-se usar uma correia ou materiais estranhos.
Proteção contra ação magnética de alimentação. Essas
magnética correias magnéticas de • Ligue a eletricidade.
alimentação não somente limpam (Confira os requisitos de
X Nota: É um requisito automática e continuamente o tensão e corrente indicados
absoluto assegurar uma boa produto de entrada, mas, quando na placa de identificação).
proteção contra a ação equipadas com um acionador
magnética antes de se fazer variável, atuam também como • Instale interruptores de
a instalação de uma alimentador da trituradora, com intertravamento para o
trituradora! uma alimentação ao longo de sistema de alimentação de
toda a largura, a velocidades material e retirada do
É necessária a colocação de ímãs produto acabado para evitar
antes de se fazer a instalação de controladas.
qualquer dano ao
uma trituradora a fim de a Armadilhas magnéticas bem equipamento ou acúmulo de
proteger contra metais ferrosos, desenhadas são um elemento material em caso de
resíduos de ferro e limalha, que essencial do sistema de interrupção de algum outro
são comuns em qualquer fluxo de trituração. Caso necessite de componente.
grande volume de material. Estas algum esclarecimento sobre
matérias devem ser retiradas da proteção magnética, contate seu • Quando a instalação elétrica
corrente do material antes destas representante CPM. estiver concluída, verifique
entrarem para a trituradora ou a se a velocidade de rotação do
temperatura poder elevar-se motor está correta. Verifique
extremamente em poucos Peneiramento do material se os interruptores de
segundos, em resultado do atrito O material deve ser peneirado travamento e todos os
contra o cilindro da trituradora. antes de entrar para a trituradora interruptores de
Essa matéria incandescente e passar pela área do ímã. O intertravamento à jusante
material pode chegar ao ponto de peneiramento separa pedras, estão funcionando
ignição e causar incêndio ou metais não magnéticos, pedaços corretamente.
explosão. No mínimo, quaisquer de materiais, etc. que podem
partículas de ferro que entrem na causar ignição por faísca, • Proteja as aberturas de
trituradora podem danificar as contaminar o produto acabado e admissão e de descarga da
peças da máquina e contaminar o causar o desgaste prematuro do trituradora a fim de evitar a
produto acabado. equipamento. entrada acidental de alguma
pessoa na máquina.

Instalação • Instale todas as proteções.
Verifique se as proteções das
conveniente e acessível
na trituradora de modo a
correias estão instaladas e que o mesmo possa ser
bem fixas. alcançado em caso de
emergência.
• Ajuste os cilindros conforme
descrito na Seção “Ajuste de • Faça a instalação elétrica de
manutenção” (Procedimento acordo com os diagramas
de ajuste do cilindro) ou elétricos, que se encontram
consulte o pôster na Seção "Peças".
“Procedimento de ajuste do
cilindro” remetido • Veja se este interruptor
juntamente com a desliga todo o equipamento
trituradora. TA
móvel na área da trituradora.
NO
• Verifique o alinhamento dos

cilindros, observando a
Seção 3 -
colocação dos pares de Atenção: O

cilindros (veja a Seção interruptor de parada
"Ajustes de manutenção"). de emergência não
se destina a servir de
• Destrave e ligue a Figura IN-5: Interruptor de Parada
interruptor de
alimentação no interruptor de Emergência
travamento. É
de desconexão principal.
Interruptor de necessário proceder
• Faça um teste de ao travamento/
funcionamento da trituradora Parada de colocação de etiqueta
e corrija quaisquer Emergência no interruptor de
problemas que necessitem de desconexão de
atenção. • O Interruptor de parada energia (veja a Seção
de emergência está "Segurança").
montado na estrutura da
base. Coloque este
interruptor no local mais

Instruções de operação
Uma operação cuidadosa da X Nota: NÃO ultrapasse a corrugação, entre em
máquina assegura o desempenho amperagem máxima do contato com seu
ideal e uma vida útil mais motor, uma vez que isso representante CPM).
prolongada para os rolos. Siga as pode causar danos aos
regras gerais descritas abaixo ao componentes de • Verifique o alinhamento dos
operar este equipamento. acionamento do rolo rolos, examinando as
principal e do rolo interno. amostras de produto
• Inicie sempre a trituradora coletadas em ambas as
com os cilindros afastados. • Verifique o produto que sai extremidades dos rolos.
Em caso de dúvida, abra os da trituradora, obtendo Tamanhos de partículas
cilindros até pelo menos amostras através das portas diferentes do material
0,500 pol., de modo a de obtenção de amostras retirado das extremidades
permitir a passagem de (veja a Figura O-1). Se um dos cilindros indicam um
qualquer material presente produto mais fino for problema de alinhamento ou
na área de atrito entre os necessário, aproximar os uma alimentação excessiva
cilindros. rolos; para um produto mais em uma das extremidades.
grosso, abra-os. Siga o "Processo de ajuste
• Ajuste os cilindros com Normalmente, é necessário dos cilindros" descrito na
cuidado. Verifique um ajuste de 0,005 Seção "Ajustes de
regularmente o ajuste do polegadas ou mais para manutenção".
bloqueio dos cilindros para mudar o aspecto do produto.
assegurar uma proteção X Nota: O ajuste para colocar
positiva contra o atrito dos Atenção: NÃO os cilindros paralelos é uma
cilindros. coloque as mãos nem operação de manutenção.
qualquer outro objeto, Permita que esta tarefa seja
• Mantenha uma tremonha com exceção do coletor efetuada somente por
cheia no alimentador ao de amostras, para pessoal qualificado.
operar o equipamento a fim coletar amostras na
de garantir uma alimentação área dos rolos, já que • Verifique visualmente,
uniforme ao longo dos isso pode resultar em através da porta de inspeção,
cilindros. lesões físicas. se o material alimentado está
passando diretamente pelos
• Aumente cuidadosamente a cilindros. NÃO deixe o
velocidade de alimentação. X Nota: Se não conseguir material se acumular na área
Deixe a máquina passar obter partículas do tamanho de atrito entre os cilindros
normalmente para a desejado para a sua (veja as Figuras O-2, página
capacidade máxima do aplicação, poderá ser 1 e O-3, página 2). O
motor em vez de engatar o necessário mudar a processamento de materiais
alimentador a altas corrugação dos cilindros
Seção 4 -
diretamente através dos
velocidades. (para se informar sobre as cilindros confere uma
especificações de capacidade e rendimento
ótimos à máquina e uma
duração prolongada aos
cilindros.
• Nunca tente ligar a máquina
com material retido na área
de atrito entre os cilindros.
• Não permita que os cilindros
se amolem; isso pode
resultar em um desgaste
rápido da corrugação.
Figura O-1: Porta de obtenção de amostras
• Nunca deixe a máquina
funcionar com cargas de
intensidade superiores à
carga nominal total do motor
a fim de evitar a danificação
dos componentes de
transmissão.
• Nunca permita que materiais
alimentados se acumulem na
área de atrito entre os
Figura O-2: Fluxo do material (forma correta do fluxo do material) - (A) rolos - cilindros, visto tal poder
vista da extremidade; (B) rolos - vista superior; (C) fluxo do material; (D) área
entre os rolos (setas) é a área de esmagamento. Para melhor desempenho, o
resultar em um desgaste
material (C) deve fluir diretamente para a área de esmagamento (D) e deve excessivo dos cilindros e na
cobrir essa área de uma extremidade a outra.

Instruções de operação Atenção: NÃO Sistema de ajuste
coloque as mãos
nem qualquer outro manual dos
objeto, com exceção cilindros
do coletor de
amostras, para O sistema de ajuste manual (veja
coletar amostras na a Figura O-4) dispõe de macacos
área dos rolos, já de rosca montados na dianteira da
que isso pode trituradora, que fazem deslizar o
resultar em lesões cilindro ajustável sobre o
físicas. respectiva trilha de rolamentos.
Os macacos de rosca são
conectados com um eixo de
5. Verifique as amostras acoplamento.
retiradas dos rolos,
Figura O-3: O acúmulo de material colocando uma colher de
(processo incorreto de operar a
Os colares ajustáveis de bloqueio
trituradora) - (A) Cilindros - vista
amostra através das portas de dos cilindros evitam que os
da extremidade; (C) Fluxo/acúmulo obtenção de amostras, cilindros se toquem. Os parafusos
do material (incorreto); (D) A área localizadas na parte dianteira de bloqueio dos cilindros
entre os cilindros (setas) é a área da trituradora. Examine as determinam a abertura máxima
de atrito. amostras recolhidas de cada do cilindro.
uma das extremidades da
redução da capacidade da trituradora para determinar Uma roda manual no macaco de
máquina (veja a Figura O-3). seu rendimento. Ajuste os rosca permite ao operador ajustar
rolos conforme necessário manualmente a abertura dos
para obter os resultados cilindros a fim de fazer um ajuste
Sequência de desejados. fino do tamanho das partículas.
ativação Cada revolução da roda resulta
6. Verifique a operação da em movimentos de 1/64 pol.
Use a sequência abaixo para dar trituradora através da porta (0,0156 pol.) dos cilindros (isto
início à operação de de inspeção, montada na pode ser observado no indicador
processamento: porta de acesso para da roda). Solte o parafuso de
manutenção dianteira. retenção analógico e coloque o
1. Ative o sistema de retirada Verifique visualmente para indicador a zero quando os
do produto. se certificar de que a cilindros estiverem fechados.
2. Limpe os cilindros (abra-os corrente de alimentação é
uniforme ao longo de todo o X Nota: Não aperte
até 0,500 polegadas) e ligue excessivamente o parafuso
o motor da trituradora. comprimento dos cilindros e
Seção 4 -
de que o material não está se de retenção analógico.

3. Ajuste cuidadosamente os recuando na área de atrito Aperte com a mão e em
cilindros até à sua posição de entre os cilindros (veja a seguida gire 1/8 de volta.
operação normal. Figura O-3).
4. Aumente lentamente a
velocidade de alimentação,
abrindo a porta do A C
alimentador. NÃO ultrapasse B
a amperagem nominal do
motor da trituradora.
E
F
Figura O-4: Ajuste manual dos cilindros – (A) Roda; (B) Trava de regulagem;
(C) Eixo de acoplamento; (D) Tampa do macaco de rosca; (E) Acoplamento;
(F) Indicador analógico.

Ajustes pelo operador
Esta seção destina-se a facilitar o
trabalho do operador. As etapas
descritas nesta seção são
operações que o operador deve
ser capaz de realizar a fim de
obter a melhor produtividade da
trituradora.
X Nota: O operador deve
também estar familiarizado
com as outras seções deste
manual, especialmente a
Seção "Segurança". O
melhor operador é um
operador bem informado. Figura OA-1: Ajuste do defletor (removidas as proteções para ajuste).
A trituradora saiu da fábrica com Pode-se inspecionar visualmente limite de três posições ou ajuste
as configurações e ajustes a posição dianteira do defletor automático. Estes reguladores
corretos. Pode ser necessário através das portas de inspeção, podem ser ajustados pelo cliente
alguns ajustes finais após sua montadas na porta de acesso de acordo com seus requisitos
instalação. dianteira para a manutenção (veja específicos.
a Figura O-2). Os defletores são
Siga as instruções abaixo para verticais ou ligeiramente cônicos Para regular o colar de bloqueio
determinar se são necessários na base, quando posicionados da porta de alimentação, retire a
ajustes e faça os ajustes corretamente. Se a abertura na tampa do parafuso do macaco.
necessários de acordo com as base do defletor na trituradora for Solte o parafuso com uma roda
mesmas instruções. muito estreita, poderá ocorrer manual e solte os parafusos de
Atenção: Antes de uma restrição do fluxo do retenção do colar, coloque o colar
fazer qualquer ajuste, material, bem como uma redução para dentro ou para fora na
verifique se a energia da capacidade da máquina. posição necessária, aperte os
está desligada e se o parafusos de retenção e coloque a
painel de desconexão tampa de volta no macaco (veja a
do interruptor Figura OA-3).
principal está
travado/etiquetado
(veja a Seção
Seção 5 -
"Segurança").
Ajuste do
alimentador de rolos
(Siga as instruções desta etapa se Figura OA-2: Portas de inspeção.
a trituradora estiver equipada
com um alimentador de rolos).
Para ajustar os defletores, solte os Figura OA-3: Ajuste da porta de
Ajuste da comporta de parafusos de aperto no lado do alimentação (tampa descoberta
acionador do cilindro interno da para ajuste).
alimentação
trituradora e gire os defletores
A dimensão da abertura da porta com uma chave inglesa. Aperte
determina as quantidades de os parafusos de aperto para Tremonha de admissão
material que podem entrar na prender os defletores.
trituradora; ajuste a taxa de A tremonha de alimentação no
admissão de material de acordo alimentador de cilindros conterá
com as suas necessidades. Ajuste do atuador da acúmulos de: bolas de umidade,
porta de alimentação madeira, pedras, etc...; é uma boa
A porta de alimentação é ajustada A posição da porta de ideia limpá-la periodicamente a
girando a roda manual, se esta alimentação é ajustada pelo fim de manter o máximo
tiver sido instalada no motor pneumático ou roda, desempenho da trituradora.
equipamento, ou mudando o passando através de um macaco
ajuste do codificador. de rosca em ângulo reto. A
ligação entre o macaco de rosca
Ajuste dos defletores de ângulo reto e a porta de
Há dois defletores (veja a Figura alimentação pode ter um de
OA-1) instalados na estrutura que quatro tipos de reguladores:
se destinam a restringir o fluxo ajuste manual, remoto –
de material que entra na porta de interruptor de limite de duas
alimentação. posições, remoto – interruptor de

Operator Adjustments
Section 5 -
2 California Pellet Mill Co. - WL0143.1

Ajustes de manutenção
Aviso: A seção abaixo
foi elaborada para o
pessoal de manutenção.
Todos os ajustes
A
descritos abaixo devem A
ser feitos por pessoal
qualificado. B B
X Nota: Os operadores devem

familiarizar-se também com
esta seção a fim de
verificarem se há a
necessidade de possíveis Figura MA-1: Ajuste das placas laterais (A) e dos ímãs (B) do alimentador de
ajustes de manutenção. rolos (removidas as proteções para manutenção).
A trituradora saiu da fábrica com para baixo, de modo a que estes

as configurações e ajustes Ajuste opcional do ímã
do alimentador do rolo toquem no rolo. Levante os
corretos. Podem ser necessários defletores ligeiramente para obter
alguns ajustes finais após sua O ímã opcional do alimentador um espaço livre (recomenda-se
instalação. do rolo é fixo e não tem ajuste, de 1/32 a 1/16 polegada de
mas é uma boa ideia ao realizar a espaço livre). Depois de ajustar
Siga as instruções abaixo para manutenção regular, limpar este
determinar se são necessários os defletores, desaperte os
ímã de detritos (ver figura parafusos Nylock (veja a Figura
ajustes e faça os ajustes MA-1).
necessários de acordo com as MA-2).
mesmas instruções.
Ajustes da Placas laterais
Atenção: Antes de fazer
qualquer ajuste, trituradora As extremidades dos rolos ficam
verifique se a energia chanfradas durante a corrugação
Atenção: Verifique se e a chanfra restante deixa uma
está desligada e se o a energia está
painel de desconexão do pequena abertura por onde o
desligada e se foi material passa sem ser triturado.
interruptor principal travada/etiquetada
está travado/etiquetado A placa lateral veda essa abertura
antes de realizar com eficácia para impedir que o
(veja a Seção qualquer manutenção
"Segurança"). material passe além da
ou ajuste na extremidade do rolo sem ser
trituradora (veja a processado.
Seção 6 -
Seção "Segurança").
Ajuste do As placas laterais, com a forma
alimentador de rolos de blocos em "V", são feitas de
Ajuste dos defletores polietileno UHMW. Esse
(Siga as instruções desta etapa se Remover a porta dianteira e/ou material é relativamente macio e
a trituradora estiver equipada remover quaisquer itens que evita que as extremidades dos
com um alimentador de rolos). bloqueiam a entrada do moinho rolos sejam danificadas em caso
(moinhos equipados com de contato entre os rolos (veja a
Ajuste da placa lateral do desviadores ou alimentadores de Figura MA-3).
alimentador de rolos rolo, remover a porta de As placas laterais requerem uma
manutenção). Para ajustar os manutenção periódica à medida
O alimentador possui placas defletores, mova os rolos para
laterais em ambas as que a ponta do "V" se desgastar
colocá-los na posição com o uso. As placas laterais são,
extremidades. Essas placas completamente fechada.
proporcionam uma vedação normalmente, submetidas à
positiva, que evita o escoamento Desaperte os três parafusos manutenção quando os rolos são
do material pelas extremidades Nylock em cada defletor corrugados. Caso o desgaste
da porta de alimentação. ajustável. Deslize os defletores
Para ajustar as placas laterais do
alimentador, desaperte a porca de
fenda em T na estrutura da
máquina e deslize as placas
laterais para cima ou para baixo
(veja a Figura MA-1). Aperte as
porcas depois de ajustar as placas
laterais do alimentador.
Figura MA-2: Ajuste do defletor;
Defletor (A), Parafuso com Nylock Figura MA-3: Placas laterais
(B) (proteções removidas para (removidas as proteções para
manutenção). manutenção).

Ajustes de manutenção exija, preste assistência Ã s
placas laterais antes de remover
O motor do acionador de correia
principal não é instalado na
Instalação do acionador
principal
os rolos. fábrica. Instale e a juste o
acionador de correia principal no Coloque o motor sobre os
Siga as etapas descritas a seguir local da instalação. parafusos da base ou dos trilhos
para prestar assistência Ã s placas do motor e instale as arruelas e
laterais. X Nota: Veja as informações porcas. Não aperte os parafusos
detalhadas sobre ajuste na do motor completamente.
Acessar as placas laterais através da Seção "Apêndice".
porta de manutenção dianteira do Verifique se a proteção do motor
alimentador do rolo ou remover a está instalada. Coloque a polia e a
Requisitos de bucha de pressão cônica no eixo.
porta de manutenção do desviador.
Retire as tampas do acionador entre tensionamento das Aperte até atingir o torque
rolos e do acionador principal para correias em V indicado para os parafusos de
obter acesso aos parafusos de fenda O acionador de correia principal pressão cônicos. (Veja
em T da placa lateral, localizados da trituradora utiliza correias de informações detalhadas sobre
entre os blocos de apoio, no lado do seção 5VX e polias (veja a ajustes na Seção "Apêndice").
acionador entre rolos e do acionador Figura MA-5). As polias do
principal (veja a Figura MA-4). Aviso: Não aperte as
acionador entre rolos são buchas de pressão
secionadas em "B" e as correias cônicas em demasia
são correias duplas secionadas para não danificar as
em "V". buchas ou a polia.could
Aviso: Nunca instale result.
correias de seção em
"B" em polias de seção Certifique-se de que a polia do
5V. motor e as polias da trituradora
estejam alinhadas (veja a Seção
"Apêndice"). Meça o alinhamento
das polias com um fio de prumo
ou uma corda.
Figura MA-4: Ajuste das placas Deslize o motor suficientemente
laterais (removidas as proteções para a frente para que as correias
para manutenção). possam ser colocadas sobre as
polias manualmente. Instale as
Para ajustar as placas laterais, correias no acionador.
mova os rolos para a posição
Seção 6 -
completamente fechada. Desaperte Aviso: Nunca "role"

a porca (veja a Figura MA-4) do uma correia em V sobre
parafuso da placa lateral e segure uma polia, pois isso pode
na placa lateral mantendo-a resultar em danos Ã s
Figura MA-5: Correias do cordas da correia.
diretamente apoiada na área de acionador principal (removidas as
atrito enquanto a porca é apertada. proteções para manutenção).
Qualquer dano à s
cordas reduzirá sua vida
Para reinstalar a placa lateral, útil e resultará no
retire a porca do parafuso de Apenas na instalação inicial, desempenho inadequado
fenda em T da placa lateral e puxe tensione o novo conjunto de das correias.
a placa lateral para fora. Insira o correias 1/3 a mais do que a
parafuso da nova placa lateral na tensão máxima recomendada.
fenda existente e no orifício da Deslize o motor para trás fazendo
estrutura da trituradora. Reinstale Verifique novamente a deflexão com que as correias fiquem
a porca e aperte. das correias depois de terem sido tensionadas. Aperte o motor na
assentadas nos entalhes da polia e respectiva base.
Examine as placas laterais depois de aplicar força e
cuidadosamente depois de retirar velocidade máximas ao motor. Girar os parafusos de ajuste na
os rolos para fazer a manutenção. base do motor para ajustar as
Substitua as placas laterais se Continue verificando a tensão das correias (ver figura MA-6, página
apresentarem sinais de desgaste. correias regularmente durante as 3).
primeiras 48 horas de operação e
ajuste-as conforme necessário. Para manter as polias devidamente
Ajustes do acionador As correias em V normalmente se alinhadas, o parafuso de ajuste
A trituradora possui dois esticam de 7 a 10% e devem ser oposto Ã s correias deve ser
acionadores de correia. A fábrica devidamente tensionadas para desapertado para compensar a
instala e regula a tensão do alcançar o seu potencial máximo. tração das correias quando a tensão
acionador entre rolos. O acionador é aplicada sobre elas.
entre rolos requer ajustes depois X Nota: Veja as informações
detalhadas sobre ajuste na Depois de tensionar as correias,
da operação inicial. aperte as porcas para fixar o motor.
Seção "Apêndice".

Alinhamento e tensionamento das
correias - (A) moinho de rolos; (B)
motor na posição "C"; (C) base do
motor; (D) correias; (E) proteção da
correia; (F) motor na posição “Z”; (G) A
posição dos parafusos de
tensionamento/ alinhamento para um
motor na posição "Z"; (H) posição dos
parafusos de
tensionamento/alinhamento para um
motor na posição "C"; as linhas
pontilhadas mostram o fluxo em "C" e
"Z".
Figura MA-7: Acionador de correia
Para obter a melhor tensão das entre rolos; (A) tensionador de
correias e para fins de alinhamento, é correia (removidas as proteções
boa prática colocar os parafusos de para manutenção).
tensionamento em lados opostos e
em extremidades opostas da base do 1. Gire manualmente o eixo de
motor. acoplamento do macaco de rosca
Quando as trituradoras são posicionados juntos com um desviador, a com a roda manual e aproxime
montagem dos motores na posição “C” não está disponível. A posição os rolos até entrarem em contato.
“F” vai usar correias mais curtas para condensar a área necessária. (O
fluxo “C” é disponível apenas em máquinas de base única.) 2. Verifique o alinhamento do rolo
de ponta a ponta após chegar à
Figura MA-6: Suporte do motor - posicionamento correto
posição zero. Se houver um
desvio de mais de 0,005 pol. no
Verifique novamente o paralelismo entre os rolos, ajuste
Ajuste dos rolos e mancais os rolos da seguinte maneira:
alinhamento das polias.
X Nota: Veja as informações
Depois de ajustar a tensão correta, detalhadas sobre ajuste na 3. Solte o acoplamento no eixo de
trave os parafusos de ajuste da base Seção "Apêndice". acoplamento do macaco de
do motor e instale a tampa das rosca. Dependendo da
extremidade a ser movimentada,
proteções do acionador principal. Procedimento de gire o eixo de acoplamento ou o
Para apertar as correias do motor, ajuste dos rolos acoplador do eixo de
as etapas descritas abaixo devem acoplamento até que os rolos
ser seguidas. Procedimento de rolos fiquem paralelos com um desvio
paralelos – com ajuste inferior a 0,005 pol. no espaço
X Nota: Veja as informações livre de ponta a ponta. Prenda o
detalhadas sobre ajuste na manual dos rolos acoplador do eixo de
Seção 6 -
Seção "Apêndice". Siga o procedimento abaixo para acoplamento.
1. Monte a base do motor em um ajustar o alinhamento paralelo
sentido no qual os parafusos dos rolos (veja a Figura MA-8). “Procedimento de rolos
de ajuste tensionem as correias paralelos - com ajuste
em vez de afrouxá-las. Atenção: Ao realizar automático dos rolos”
manutenção ou ajustes,
2. Não aperte os parafusos de trave/etiquete sempre a Usar o procedimento seguinte
montagem do motor antes de fonte de alimentação para definir o alinhamento
ajustar a tensão das correias. principal (veja a Seção paralelo dos rolos.
"Segurança").
3. Não utilize chaves inglesas de
impacto para apertar as
correias.
4. Aperte os parafusos de ajuste C
alternadamente, com três (3) A
voltas em cada um com B
ferramentas manuais.
E
Ajuste da correia do F
acionador entre rolos
X Nota: Veja as informações
detalhadas sobre ajuste na
Seção "Apêndice". É fornecido D
um aparelho de teste da
correia.
Figura MA-8: (ACIMA) Ajuste manual dos cilindros – (A) Roda; (B) Trava de
regulagem; (C) Eixo de acoplamento; (D) Tampa do macaco de rosca; (E)
Acoplamento; (F) Indicador analógico.

Ajustes de manutenção Atenção: Ao realizar
manutenção ou
em fechamento, para reduzir o
efeito de retrocesso nos
do calibre. Se os rolos
estiverem demasiado
ajustes, trave/etiquete macacos. apertados, abra-os.
sempre a fonte de X Nota: Ajuste sempre no
alimentação principal sentido dos rolos em
(veja a Seção fechamento, para reduzir o
"Segurança"). efeito de retrocesso nos
l.
,010 po
de 0 macacos.
ssura 0
1. Ajuste o(s) contador(es) da Espe 3-8023-0
Peça 7. Aperte o acoplamento e
abertura dos rolos para 0,025
pol. e, em seguida, reinstale a respectiva proteção
trave/etiquete a fonte de Figura MA-11: Etapa 3 - calibre (veja a Figura MA-14).
alimentação principal dos apalpador
motores da trituradora (veja a
Figura MA-9).
Figura MA-9: Etapa 1 - ajuste o(s)

contador(es) para 0,025 pol. Figura MA-12: Etapas 3 e 6 -
verifique a abertura dos rolos com
Figura MA-14: Etapa 5 – remova a
o calibre apalpador.
2. Retire a(s) porta(s) de proteção do acoplamento e solte o
manutenção dos rolos para acoplamento e Etapa 7 – aperte o
expor os rolos (veja a Figura acoplamento e reinstale a proteção
MA-10). do acoplamento.
Seção 6 -
Figura MA-15: Etapa 6: Os rolos

ilustrado acima não estão
paralelos. Quando a distância é
maior na extremidade esquerda,
Figura MA-13: Etapa 3 - gire os ajuste o macaco de rosca
eixos de acoplamento. esquerdo, e quando a distância é
Figura MA-10: Etapa 2 - retire a(s) maior na extremidade direita,
porta(s) de manutenção e etapa 8 – ajuste o macaco de rosca direito
reinstale a(s) porta(s) de 4. Se a distância da abertura conforme ilustrado.
manutenção entre os rolos for igual em
ambas as extremidades
(paralelos), passe para a etapa 8. Se a trituradora tiver mais de
3. Insira um calibre apalpador de 8. Se a distância da abertura um suporte de rolos, repita as
0,010 pol. (No. de referência não for a mesma nas duas etapas 3 a 7 para os outros
3-8023-00, incluída com a extremidades (não paralelos), suportes. Após ajustar todos
trituradora) (veja a Figura passe para a etapa 5. os suportes, passe para a etapa
MA-11) entre os rolos (veja a 9. Nota: Todos os
Figura MA-12) enquanto os 5. Retire a proteção do controladores devem ter sido
rolos estiverem sendo acoplamento e solte-o (veja a regulados com antecedência
fechados à mão (gire o eixo de Figura MA-14). para uma abertura de 0,025
acoplamento entre os pol. entre os rolos.
macacos) (veja a Figura MA- 6. Gire um macaco de rosca para
13). Movimente o calibre fechar a distância da abertura 8. Reinstale a(s) porta(s) de
apalpador de uma à outra entre os rolos na extremidade manutenção dos rolos (veja a
extremidade da abertura entre larga (veja a Figura MA-15). Figura MA-10).
os rolos até sentir um ligeiro Movimente o calibre
apalpador até sentir um ligeiro 9. Opere a(s) válvula(s)
aperto em uma das solenóide(s) para fechar os
extremidades da abertura entre aperto no calibre (veja a
Figura MA-12). Deverá ser rolos contra os colares de
os rolos. Se estiver muito bloqueio dos rolos (veja a
apertado, abra os rolos e repita possível movimentar o calibre
apalpador de uma extremidade Figura MA-16,’página 5).
esta etapa. Nota: Ajuste
sempre no sentido dos rolos à outra com um ligeiro aperto

Figura MA-16: Etapa 9 - feche os
rolos com uma válvula solenóide. Figura MA-19: Etapa 5 - (traseira do
controlador) remova e reinstale a
11. Ir para “Procedimento para Figura MA-17: Etapa 1 - desaperte ponte elétrica entre 7 e 8.
zerar o rolo” abaixo ou ver o o parafuso de retenção e gire o
pôster fornecido com a colar de impulso. Etapa 3 – gire o seguida, aperto o botão "R"
trituradora. colar de impulso e aperte os (veja a Figura MA-20). Ao
parafusos de retenção. terminar, volte a instalar a
Procedimento de ponte elétrica (veja a Figura
MA-19).
reposição dos rolos ao
ajuste zero - com ajuste X Nota: Depois de repor o rolo no
automático dos rolos ajuste zero, talvez seja
necessário ajustar a abertura
Atenção: Ao realizar máxima da porta de
manutenção ou ajustes, alimentação. Reajuste o colar
trave/etiquete sempre a de bloqueio no atuador do
fonte de alimentação macaco da porta de
principal (veja a Seção alimentação para que o motor
"Segurança"). principal da trituradora possa
funcionar com amperagem
máxima.
Para obter um ajuste zero exato Figura MA-18: Etapa 2 - gire os
para os rolos, estes devem estar eixos de acoplamento.
paralelos. Se estiver em dúvida,
verifique o ajuste dos rolos o efeito de retrocesso nos
conforme descrito no macacos. (veja a Figura MA-
“Procedimento de paralelização 18).
dos rolos”, a partir da página 3,
ou no pôster fornecido com a 3. Com os rolos em contato,
Seção 6 -
trituradora. recue o bloqueio dos rolos
(colares de impulso), girando
1. Desaperte o parafuso de o colar o máximo possível no Figura MA-20: Etapa 5 – aperte o
retenção dos colares de sentido anti-horário. Em botão "R" no controlador.
impulso e gire o colar de seguida, abra os rolos com
impulso (bloqueio dos rolos) meia volta do eixo de
pelo menos duas voltas no acoplamento. Recue os Re-corrugação dos rolos
sentido horário (veja a colares mais 1/8 de volta (no O grau de desgaste dos rolos
Figura MA-17). sentido anti-horário) e fixe- depende do material que está
Atenção: Certifique-se os. Fixe os colares de sendo processado, das toneladas
de que todas as impulso apertando o processadas, da redução obtida
proteções estejam parafuso de retenção contra o do material, da exatidão do ajuste
instaladas antes de macaco (veja a Figura MA- dos rolos e de quaisquer
operar a trituradora. 17); aperte o parafuso com a impurezas presentes no fluxo do
Tenha cuidado ao ligar contraporca fornecida. material. A manutenção de um
e ajustar a trituradora. fluxo uniforme de material limpo
4. Feche os rolos operando a ao longo da largura dos rolos
válvula solenóide para assegura sua vida útil máxima.
2. Com a trituradora em verificar se não está sendo
funcionamento, ajuste os feito nenhum contato e para Os rolos padrão são fabricados
rolos manualmente até ouvir reduzir o efeito de retrocesso em ferro fundido com uma
o contato entre os mesmos (veja a Figura MA-16). Se os superfície funcional endurecida
ou sentir a vibração do eixo rolos fizerem contato, abra- com coquilha. As corrugações
de acoplamento. Esse os e repita o processo a partir são cortadas nessa área do rolo
contato deve ser apenas leve. da etapa 1. enrijecida a frio. A re-corrugação
Se os rolos se tocarem com prolonga a vida útil dos rolos.
intensidade, abra-os e volte a 5. (Ajuste a calibragem para Com cada re-corrugação ocorre
fechá-los. Nota: Ajuste zero no controlador) retire a uma redução do diâmetro do rolo
sempre no sentido dos rolos ponte elétrica entre 7 e 8 e da espessura da coquilha
em fechamento, para reduzir (veja a Figura MA-19) e, em endurecida. O número de re-

Ajustes de manutenção corrugações possíveis depende do
número de entalhes por polegada,
2. Desligue e trave/etiquete a
fonte de alimentação da
7. Retire as correias e as polias
diferenciais do acionador.
do estilo de corrugação, das trituradora. Anote a localização de cada
condições dos rolos antes da re- polia para assegurar a
corrugação e do equipamento de 3. Retire a tampa das proteções velocidade diferencial
corrugação do usuário. Os rolos do acionador principal (veja correta dos rolos depois da
normalmente podem ser re- a Figura MA-21). remontagem (veja a Figura
corrugados de 4 a 8 vezes antes MA-24).
de se tornarem demasiado 4. Desaperte os parafusos de
pequenos ou macios para reajuste do motor do acionador
corrugamento. principal e retire as correias
do acionador principal.
Ao devolver os rolos à CPM para Retire as polias da
re-corrugação, não é necessário extremidade do acionador
remover os mancais dos rolos. Se principal da trituradora (veja
o proprietário tiver rolos de a Figura MA-22).
reposição, o tempo de ociosidade
da trituradora será minimizado se Aviso: Nunca "role" uma
o rolo de reposição for correia em V sobre uma
substituído já com mancais e polia, pois isso pode
carcaças instalados em vez de Figura MA-24: Ajuste da correia do
passar os mancais de um para o resultar em danos Ã s acionador entre rolos
outro. cordas da correia.
Qualquer dano às cordas
Verifique se a embalagem em que a A
máquina vai ser remetida é adequada reduzirá sua vida útil e
para o peso e o manuseio ao qual os resultará no desempenho
rolos estarão sujeitos durante o inadequado das correias.
transporte.
Remoção dos rolos

Figura MA-25: Porta dianteira
Atenção: Nas Figuras removida (A) Eixo do acoplamento.
MA-21 a MA-35, as
proteções foram
removidas para a 8. Retire a porta dianteira (veja
manutenção. a Figura MA-25).
9. Retire as graxeiras (veja as
Seção 6 -
Siga o procedimento abaixo para setas nas Figuras MA-22 e

retirar os rolos da trituradora. Figura MA-22: Correias removidas MA-23). Há quatro graxeiras
na unidade de acionamento por suporte no lado do
Atenção: Ao remover principal. Setas apontam para as acionador entre rolos e dois
ou instalar os rolos, linhas de graxa. por suporte no lado do
use ferramentas acionador principal.
adequadas para o
trabalho. Use um 5. Retire a tampa das proteções 10. Remover a parte inferior das
mecanismo de do acionador entre rolos proteções das correias.
elevação de (veja a Figura MA-23).
capacidade suficiente. 11. Remover o eixo de
6. Desaperte o parafuso de acoplamento (ver figura
Use sempre boas ajuste sem removê-lo. Gire o
práticas de oficina. MA-25). Para remover os
parafuso para diminuir a parafusos Allen soltos em
tensão das correias (veja a uma extremidade do eixo de
1. Movimente os rolos até a sua Figura MA-23). acoplamento (ver figura
posição completamente MA-26, página 7). Em
aberta. seguida, deslizar o acoplador
novamente, na outra
extremidade, e remover os
parafusos Allen (ver figura
A
MA-27, página 7).
12. Remover as tampas das
fendas dianteiras em ambos
os lados da trituradora (ver
figura MA-28).
Figura MA-23: Removida a tampa 13. Remover os parafusos de
Figura MA-21: Removida a tampa do acionador entre rolos. (A) – travamento e as arruelas de
do acionador principal. parafuso de ajuste. Setas apontam tensão (ver figura MA-26 e
para as linhas de graxa. MA-29).

16. Remover os parafusos da
placa de rolamento.
A Remover a placa de suporte
do membro de pressão
inferior (ver figura MA-30).
17. Retire o rolo dianteiro
utilizando uma barra
espaçadora (veja a Figura
MA-31).
Figura MA-33: Remoção das
Figura MA-26: Remoção da chave tampas das fendas interiores.
Allen para liberar o eixo do
A
acoplamento. Conjunto do macaco 21. Retire os parafusos do
de rosca (A) suporte dos mancais (rolo
traseiro).
22. Retire o rolo traseiro
A utilizando uma barra
espaçadora (veja a Figura
C
MA-35).
B
Figura MA-30: A – Membro de

pressão dianteiro; B – Parafuso do
carro; C – Membro de tensão
Figura MA-27: Deslizamento do inferior.
acoplador para trás (A) e remoção
dos parafusos Allen na extremidade
oposta.
Figura MA-34: Ressalto de

levantamento.
Seção 6 -
Figura MA-31: Remoção do
primeiro rolo.
18. Retire as placas laterais (veja

a Figura MA-32).
Figura MA-28: Remoção das tampas 19. Remover as tampas das Figura MA-35: Levantamento da
das fendas, uma de cada lado de fendas internas (ver figura segunda barra espaçadora com um
cada base/máquina. MA-33). ressalto de levantamento em uma
extremidade.
Instalação dos rolos

Siga o procedimento abaixo para
instalar os rolos de reposição.
Perigo: Ao remover ou
instalar os rolos, use
f e r r a m e n t a s
adequadas para o
Figura MA-29: Arruelas de tensão.
trabalho. Use um
Figura MA-32: Remoção das placas mecanismo de elevação
14. Retire os elementos laterais. de capacidade
dianteiros (veja a Figura suficiente. Use sempre
MA-30, página 7). 20. Instale o ressalto de boas práticas de
levantamento fornecido pela oficina.
15. Desaperte os parafusos de CPM no eixo do rolo curto
alinhamento (veja a Figura (rolo traseiro) (veja a Figura
MA-30). 33). 1. Com os mancais montados
no rolo traseiro, instale o

Ajustes de manutenção ressalto de levantamento na
extremidade do mancal
12. Instale as graxeiras (veja as
setas nas Figuras MA-22 e
Perigo: Nunca aperte
as correias usadas
correspondente ao eixo do MA-23, página 6). Há quatro além da tensão
rolo (veja a Figura MA-34). graxeiras por suporte no lado máxima recomendada.
do acionador entre rolos e As correias novas
2. Levantar o rolo até a fenda dois por suporte no lado do
(ver figura M-35). devem ser tensionadas
acionador principal. 30% a mais do que o
3. Ajuste o rolo, instale os 13. Ajuste os defletores ajuste máximo de
parafusos do suporte dos ajustáveis em relação ao fábrica.
mancais, verifique a posição rolo, aproximadamente um
dos rolos com um medidor intervalo de 1/32 a 1/16 pol. 19. Instale as correias do
de alinhamento e certifique- de distância do rolo ao acionador entre rolos nas
se de que os rolos estejam defletor. polias e tensione-as com o
centrados na estrutura. parafuso de ajuste (para
Aperte os parafusos do 14. Verifique se os rolos estão instruções detalhadas, veja a
suporte dos mancais e retire alinhados em paralelo (veja o Seção "Apêndice").
o ressalto de levantamento. "Procedimento de
paralelização dos rolos", a 20. Instale a tampa das proteções
4. Instale as placas laterais partir da página 3 desta do acionador entre rolos.
(veja a Figura MA-32, seção). Verifique se não há
página 7). interferência entre as
15. Quando os rolos estiverem proteções e quaisquer peças
5. Instalar as tampas das fendas devidamente ajustados, faça móveis.
internas (ver figura MA-33, os ajustes finais da placa
página 7). lateral e prenda a placa 21. Instale as polias do
lateral (veja ajuste da placa acionador principal. Aperte
6. Eleve o rolo dianteiro até a lateral na página 1 desta os parafusos das buchas das
fenda. Instale as tampas das seção). polias de maneira uniforme
fendas dianteiras e o retentor segundo o torque
de vedação em ambos os 16. Para ajustar os especificado para os
lados da trituradora (veja as direcionadores de fluxo (se parafusos de pressão
Figuras MA-28 e MA-31, presentes), desaperte o cônicos. Calibre o
página 7). parafuso de retenção na alinhamento das polias do
extremidade do acionador motor e das polias da
7. Instalar o membro de pressão entre rolos da trituradora e
dianteiro e o suporte do trituradora com uma linha de
gire o eixo até que o prumo ou uma corda.
membro de tensão inferior. direcionador de fluxo esteja
Seção 6 -
8. Instalar os parafusos de voltado para a área de atrito 22. Deslize o motor

travamento e as arruelas de do rolo. Trave o direcionador suficientemente para a frente
tensão. de fluxo ao completar os para que as correias possam
ajustes. ser colocadas sobre as polias
9. Ajuste o alinhamento com o manualmente. Instale as
parafuso de alinhamento de 17. Gire o conjunto de correias no acionador.
maneira a que o medidor de tensionamento das correias
alinhamento deslize do acionador entre rolos para Aviso: Nunca "role"
livremente sob a manga. colocá-lo de volta ao lugar. uma correia em “V”
(Ver ajuste do carro nesta sobre uma polia. Isso
18. Instale as polias do danifica as cordas da
página.) acionador entre rolos. correia e pode resultar
10. Remover o eixo de Reinstale as polias no seu em desempenho
acoplamento (ver figura lugar original para manter as inadequado e redução
MA-25). Apertar os relações de velocidade da vida útil da correia.
parafusos Allen em uma diferencial estabelecidas na
extremidade do eixo de fábrica. Alinhe as polias e
aperte os parafusos de 23. Gire os parafusos de ajuste
acoplamento (ver figura na base do motor para
MA-26, página 7). Apertar pressão de maneira
uniforme. apertar as correias.
os parafusos Allen na outra
extremidade e deslizar o X Nota: Consulte a tabela 24. Trave os parafusos de ajuste
acoplador na outra contida na Seção "Padrões" depois de ajustar a tensão
extremidade (ver figura MA- para obter as especificações correta. Instale a tampa das
27, página 7) sobre o torque dos parafusos proteções do acionador
das buchas das polias. principal. Verifique se não
11. Instalar as peças inferiores há interferência entre as
das proteções das correias. proteções e quaisquer peças
móveis.

X Nota: Veja detalhes sobre a nivelando-se a trituradora com conjunto rolos traseiros no
instalação das correias na calços colocados nos quatro trilho de mancais. O
Seção "Apêndice". cantos da estrutura principal. Os medidor de alinhamento
outros ajustes, naturalmente, deve deslizar livremente
25. Instale a porta dianteira. seriam as chumaceiras sob o eixo do rolo.
horizontais dos mancais.
Ajuste do alinhamento 3. Se o medidor não se
Um método comum para a movimentar livremente,
O ajuste mais difícil de fazer na inspeção do alinhamento dos faça ajustes girando o
trituradora é o ajuste do rolos é colocar uma placa de parafuso de alinhamento.
alinhamento. Quando os rolos vidro temperado sobre os rolos
estão desalinhados, a trituradora (veja a Figura MA-36). Os 4. Em seguida, usando uma
não produz um produto uniforme desalinhamentos podem ser placa de vidro temperado,
ao longo de todo o comprimento detectados com papel ou calços verifique o rolo traseiro e
dos rolos, os rolos desgastam-se no ponto inferior dos rolos, em dianteiro.
excessivamente e de maneira não qualquer dos quatro pontos
uniforme, podendo provocar um indicados à esquerda. Outro 5. Ajuste o rolo dianteiro se
empuxo das extremidades, que método é utilizar um bom nível. necessário (o rolo traseiro
pode resultar em danos aos já deve estar alinhado).
mancais e às chapas laterais (veja Ao ajustar o trilho, o rolo traseiro
detalhes sobre rolos alinhados e deve ser ajustado primeiro, com Além de ajustar o alinhamento,
desalinhados na Figura MA-35). um calibrador de trilhos. O os rolos devem ser centrados
medidor de alinhamento é entre as chapas laterais; ou seja, o
A trituradora é ajustada e fornecido com a trituradora. espaço livre entre as chapas
alinhada antes de deixar a laterais e os rolos deve ser igual
fábrica; porém, quando os 1. Solte os parafusos dos em ambas as extremidades. Para
moinhos de rolos de grande porte mancais (é impossível centralizar os rolos, aperte ou
são aparafusados a um piso não ajustar o alinhamento com desaperte os parafusos de
uniforme, a sua estrutura pode os parafusos apertados). alinhamento (veja a Figura MA-
defletir-se o suficiente para 37). Os rolos e a trituradora
causar o desalinhamento. Essa 2. Deslize o medidor de devem estar nivelados em uma
situação pode ser resolvida alinhamento embaixo do vista lateral e uma vista da
extremidade.
Para maximizar a vida útil da
trituradora e dos rolos e obter
um produto mais uniforme com
o mínimo de manutenção, o
mais importante é ajustar o
Seção 6 -
alinhamento dos rolos.
Figura MA-35: Alinhamento dos rolos - (diagrama A) rolos desalinhados;

(diagrama B) rolos alinhados; (A) vista da extremidade dos rolos com eixos;
(B) vista lateral dos rolos com eixos; (C) posição do rolo alinhado; (D) rolo e
eixo desalinhados.
Figura MA-37: Parafuso de ajuste
de alinhamento.
Figura MA-36: Placa de vidro temperado - (A) vista da extremidade dos rolos;
(B) vista superior dos rolos; (C) placa de vidro. 1, 2, 3 e 4 indicam os pontos
em que o alinhamento deve ser verificado.

Seção 6 -

Lubrificação
O desempenho satisfatório da um tipo de graxa por outro, limpe excessiva pode alcançar as
trituradora a longo prazo requer a completamente a unidade com correias e causar defeitos
devida manutenção e água a fim de evitar a prematuros.
lubrificação. A fábrica abasteceu contaminação entre essas graxas.
todas as caixas de engrenagens Vários dos mancais da trituradora
com os lubrificantes apropriados Para evitar a contaminação dos dispõem de graxeiras remotas e
e colocou graxa em todos os mancais, limpe os encaixes tubos de graxa de poliéster para
mancais antes de enviar a cuidadosamente antes de aplicar facilitar a lubrificação com a
trituradora. a pistola de graxa. Para reduzir a máquina em funcionamento.
possibilidade de danos aos tubos Verifique os tubos
Siga as recomendações de de graxa e vedações, utilize uma periodicamente para se certificar
lubrificação apresentadas a seguir pistola de graxa de aplicação da sua integridade e ter certeza de
para assegurar a manutenção manual em vez de acionamento que a graxa está sendo distribuída
apropriada dos componentes pneumático. pelos mancais.
funcionais da trituradora.
A configuração da trituradora Siga as especificações do
Use graxa de alta qualidade do permite a lubrificação de todos os fabricante do motor para a
tipo Moly EP, como por exemplo mancais enquanto a trituradora lubrificação de todos os motores.
a Sunoco Prestige. Como alguns está em funcionamento. Siga o Os motores requerem uma
aditivos podem não ser cronograma de lubrificação, mas lubrificação menos frequente do
Seção 7 -
compatíveis, não misture tipos não aplique graxa em demasia, que os outros componentes da
diferentes de graxa. Ao substituir visto que a lubrificação trituradora.
Peça a lubrificar: Mancais Peça a lubrificar: Mancais da comporta

intermediários do de alimentação
acionador entre rolos (fechamento da
Tipo de lubrificante: Graxa de várias comporta de
finalidades alimentação)
Intervalo: 1 aplicação a cada 40 Tipo de lubrificante: Graxa de várias
horas finalidades
Intervalo: 1 aplicação mensal*
Peça a lubrificar: Mancais dos eixos dos
rolos Peça a lubrificar: Mancais do
Tipo de lubrificante: Graxa de várias alimentador de
finalidades cilindros
Intervalo: 1 aplicação a cada 40 Tipo de lubrificante: Graxa de várias
horas finalidades
Peça a lubrificar: Macaco de rosca da
máquina (Ajuste do Peça a lubrificar: Atuador da porta de
cilindro) alimentação
Tipo de lubrificante: Graxa de várias Tipo de lubrificante: Graxa de várias
finalidades finalidades
Intervalo: 1 aplicação mensal* Intervalo: 1 aplicação mensal*
Peça a lubrificar: Macaco de rosca da

máquina (Redutor de
ângulo reto)
Tipo de lubrificante: Graxa de várias
finalidades
* Remova o tampão do cano e bombeie graxa até transbordar.

* Drene, descarregue e reabasteça. - um quarto EUA para os modelos 1000
- dois quartos EUA para os modelos 1200
** Drene e reabasteça até o nível do tampão de inspeção inferior.

Lubrificação
Seção 7 -

Normas
Especificações de torque dos parafusos
Utilize o guia abaixo para as especificações de

torque para parafusos de bucha de polia.
Torque
Tamanho
do parafuso (pol-lb) (pés-lb) (NM)
5/16"-18 120-180 10-15 14-20
Seção 8 -
3/8"-16 240-360 20-30 27-40
1/2"-20 480 40 54
1/2"-13 720 60 81
9/16"-12 600-900 50-75 67-101
5/8"-11 1080-1620 90-135 122-183
3/4"-12 1800 150 203
3/4"-10 2700 225 305
7/8"-9 2400-3600 200-300 271-406
1"-8 3600-5400 300-450 406-610
Padrões CPM
Elementos de fixação métricos
Parafuso de tampa
Parafuso de tampa sextavada Parafuso de tampa sextavada com encaixe na cabeça
Classificado 8.8 Classificado 10.9 Classificado 12.9
Rosca Torque Tamanho do Torque Tamanho do Torque Tamanho do
Tamanho mm Por. de aperto encaixe da chave de aperto encaixe da chave de aperto encaixe da chave
métrico Passo (Pés-lb) M-KG (mm) (Pés-lb) M-KG (mm) (Pés-lb) M-KG (mm)
M6x1.0 1.0 7 1 10 10 1.4 10 11 1.6 5

M8x1.25 1.55 18 2.5 13 25 3.5 13 29 4 6
M10x1.5 1.5 32 5 17 47 6 17 58 8 8
M12x1.75 1.75 58 8 19 83 12 19 100 14 10
M16x2.0 2.0 144 20 24 196 27 24 235 33 14
M20x2.5 2.5 260 36 30 366 51 30 440 61 17
M22x2.5 2.5 368 51 32 520 72 32 628 87 17
M24x3.0 3.0 470 65 36 664 92 36 794 110 19
Parafuso de tampa Prendedores

com encaixe na cabeça totalmente
Classificado 8.8 de aço inoxidável
Rosca Tamanho do Torque Comparação

Tamanho mm Por. Retenção encaixe da chave de aperto de tamanhos
métrico Passo (Pés-lb) M-KG (mm) (Pés-lb) M-KG em polegadas
M6x1.0 1.0 6 .8 3 4 .5 1/4"

M8x1.25 1.25 13 1.9 4 10 1.4 5/16"
M10x1.5 1.5 25 3.5 5 19 3 3/8"
M12x1.75 1.75 45 5 6 30 4 1/2"
M16x2.0 2.0 110 15 8 66 10 5/8"
M20x2.5 2.5 220 30 10 119 17 3/4"
M22x2.5 2.5 - - - 165 24 7/8"
M24x3.0 3.0 350 48 12 188 27 1"

Normas
Seção 8 -

Extract from Five Star Products’ Guide on Grouting & Concrete Repair
A P r o f es s i o n a l ’s G u i d e o n G r o u t in g a n d C o n c r e t e R e p a i r
CHAPTER 5
CEMENTITIOUS GROUT PLACEMENT PROCEDURES
INTRODUCTION
Cementitious grout placement involves proper mixing, placing, finishing, and curing, all
of which are critical components of a successful grout installation. Improperly placed
grout will often not perform as designed and can lead to potential problems such as grout
cracking, equipment misalignment, and even grout failure.
Selecting the type of cementitious grout, pumpable, flowable, fluid, or other, is
important and involves a detailed understanding of the application for which the
grout is to be used and of which material will provide the best results.
FLUID GROUTS
The industry definition of a fluid grout is one that will pass a specified volume of
material through a flow cone in accordance with ASTM C 939 in 30 seconds or less.
Fluid grouts are typically easier to place than flowable grouts and can therefore be
expected to flow longer distances at normal clearances or to get into tighter clearances.
Fluid Grouts must be mixed to a specified consistency, which requires having a flow
cone on the jobsite. Without a flow cone available, it is difficult to determine if the grout
is mixed with the appropriate amount of water.
FLOWABLE GROUTS
Flowable grout provides sufficient flow to properly grout a majority of applications.
Flowable grouts are defined as those having a flow of 125 to 145 when tested on a flow
table in accordance with ASTM C 1437- (Standard Test Method for Flow of Hydraulic
Cement Mortar). Flowable grouts are typically very versatile. Properly formulated
flowable grouts will provide long working times (30 to 45 minutes), can often be
extended with coarse aggregate in the field for deep pours, and can be pumped. Some
well formulated flowable grouts, such as FIVE STAR GROUT, can be mixed in ready
mix trucks and pumped long distances. However, it is important to understand that NOT
ALL FLOWABLE GROUTS PERFORM EQUALLY. Some flowable grouts, such as
those based on aluminum powders, have short working times and, therefore, cannot be
mixed in ready mix trucks or pumped.
Flowable grouts are typically packaged in 50 lb or 100 lb bags, and have minimum
and maximum water requirements listed on the bag. NEVER EXCEED THE
MAXIMUM WATER REQUIREMENTS AS STATED ON THE PRODUCT
PACKAGING. OVERWATERING CAN LEAD TO SEGREGATION,
STRENGTH REDUCTION, AND INCREASED GROUT SHRINKAGE,
JEOPARDIZING LONG TERM SUCCESS.
(800) 243-2206 • www.fivestarproducts.com 25
Source: "A Professional’s Guide to Grouting and Concrete Repair," © 2007 Five Star® Products Inc., downloaded from www.fivestarproducts.com January
13, 2009. Make sure to acquire and follow the manufacturer’s Material Safety Data Sheet for the grout you use.
EF2243.1en 1
2 Extract from Five Star Products’ Guide on Grouting & Concrete Repair
Tight clearance applications (less than 1 inch clearance) or baseplates with shear keys
are two applications where
fluid grouts have advantages
over flowable grouts. When
placed properly, fluid grouts
will tend to entrap less air in
shear key applications, though
vent holes should be present
in the baseplate to allow the
venting of any entrapped air.
Sometimes, mixing to a fluid
consistency has been used as
a way to speed the placement of grouts with very short working times, which occa-
sionally has led to shrinkage, air entrapment, and segregation. FIVE STAR FLUID
GROUT 100 is a fluid grout whose unique formulation produces a grout with excellent
workability and without these problems. It can be used where clearances are very tight,
as well as for normal clearances.
CAUTION: Take special note that making a normally flowable grout fluid by
adding more water than the maximum amount specified can result in aggregate
segregating and lower strength from the increased water-cement ratio. There is
also a considerable risk that certain flow agents will cause bubbling at the surface,
significantly reducing EBA. NEVER add more water than the maximum amount
specified on the package.
PUMPABLE GROUTS
Pumpable grouts are either well
formulated flowable grouts that
provide good pumpability or very
specialized grouts that contain
pumping aids. Pumpable grouts should
be able to be pumped with typical grout
pumps or larger pumps, such as
concrete pumps. Pumping grouts may
involve the addition of coarse
aggregate at the jobsite, particularly on
large volume placements. Aggregates
used for extending cementitious grouts
should be clean, washed aggregates of
specified size and conform to ASTM C
33. Dirty aggregates or aggregates with
a large amount of fines will affect pumpability and strength development.
26 (800) 243-2206 • www.fivestarproducts.com
EF2243.1en
Extract from Five Star Products’ Guide on Grouting & Concrete Repair 3
SAFETY
CAUTION: Cement based grout contains cementitious material and crystalline
free silica. The International Agency for Research on Cancer has determined that
there is sufficient evidence for the carcinogenicity of inhaled crystalline silica to
humans. Take appropriate measures to avoid breathing dust. Avoid contact with
eyes and contact with skin. In case of contact with eyes, immediately flush with
plenty of water for at least 15 minutes. Call a physician immediately. Wash skin
thoroughly after handling. Keep this product out of the reach of children.
BEFORE USING, REFER TO THE MATERIAL SAFETY DATA SHEETS, which
are available for all Five Star Products at www.fivestarproducts.com
Take these simple precautions to avoid skin contact with cement powder or freshly
mixed grout or mortar:
• Wear rubber boots high enough to keep out cement products. Top of boots should
be tight to protect feet.
• Wear rubber gloves to protect hands.
• Wear long pants tucked into boots to protect legs.
• Wear kneepads when finishing concrete to protect knees.
• Wear long-sleeved shirts buttoned at the wrists and neck to protect upper body and
arms.
• Wear tight-fitting goggles when handling cement products to protect eyes.
• Do not breathe in the fine dust. Wear a NIOSH approved respirator when opening
or dumping bags.
INSTALLATION
A. GENERAL
The general application procedures that follow are appropriate for use under normal
conditions:
1. Many grouts are not recommended for placement under a wide range of
temperatures. Consult the grout manufacturer’s written instructions for
placement temperature limitations. At temperatures below 70°F, grout tends to
set more slowly than reported on typical product data sheets. At temperatures
above 70°F, grout tends to set faster than reported. When grouting is to be done
when ambient and mix temperatures are not between the manufacturer’s
specified temperature range for the grout, usually 40°F to 90°F, follow the
additional recommendations in the Hot Weather Grouting and Cold Weather
Grouting parts of this section to help maintain the set times and strength gains
at or near the 70°F rate.
2. If there are other unusual or difficult conditions (chemical attack, high working
temperatures, low clearances, shear keys, etc.), the contractor should consult
the owner’s engineer and the grout manufacturer’s Technical Service
Department.
3. All necessary tools and materials should be as close as possible to the area
being grouted. Mortar mixer (with rotating blades), wheelbarrow, shovel, water
measuring container, and grout should be within easy reach.
EF2243.1en
B. PLACEMENT
1. Placing NONSHRINK grout is not a difficult process if the engineer and the
contractor are aware of the variety of methods available to them. The grout
manufacturer can recommend the best grade of grout to use and how to place
it. The specifier can make the contractor’s job easier by specifying a grout that
provides flexibility in placement. Selecting a cement-based grout that can be
placed by only one method can increase the cost of grouting.
2. The placement procedures used for grouts are just as critical as selecting the
proper grout. The leading grout manufacturers maintain extensive technical
service staffs to assist in selecting the proper grout and the applicable placement
procedures.
3. This section describes the three most common methods, most other placement
techniques being simply variations of the basics. The advantages and
disadvantages of each are described to assist the engineer and contractor in
choosing the method best suited to their application.
a. Dry Packing
Dry packing requires a grout with a thick consistency. There should be only
enough water mixed into the grout so that when a ball of grout is squeezed
in a gloved hand, the glove is slightly dampened. Although only a well
braced backboard, a tamping rod, and a mallet are required for placement
by the dry pack method, and carpentry expense for building and stripping
forms is saved, dry packing is not recommended except for very small,
accessible placements. Dry packing is labor-intensive and requires a highly
skilled worker to ensure that the grout is uniformly compacted under the
entire baseplate without cold joints.
b. Pouring
Pouring requires a grout with a
flowable or fluid consistency. To
place a flowable grout, use forms
and a headbox. This method is
appropriate for most grouting
applications. During the mixing
process, a flowable grout, being
stiffer than a fluid grout, is less
likely to incorporate excess air
that later gets trapped under the
baseplate. Watertight forms are required for flowable and fluid grout.
To increase the rate of flow from a headbox, manually apply pressure in
addition to the hydraulic head by using a plunger. A plunger is a tool,
usually fabricated on the job site, made from two pieces of wood nailed
together to form a T. The stem is the plunger handle and the crossbar, just
slightly smaller than the width of the headbox, applies the pressure.
EF2243.1en
c. Pumping
Grout should be placed by pumping for large or multiple grout
installations, particularly when there are obstructions, or when grout must
be transported over great distances, or when venting air is not possible.
Pumping cement-based grout into place is fast, and can achieve good
results. Although it may take somewhat longer to set up the pump and its
associated equipment, once done, the pumping method usually produces
successful installations. A pumpable grout, needing less water than a fluid
grout, contributes to higher strength. Pumping results in fewer air bubbles,
and considerably more grout can be placed in a day by the same size crew.
As grout installers become more experienced with pumping, it will
continue to increase in popularity because of its superior performance
characteristics.
PREPARATION
1. CONCRETE
a. The base concrete should have attained its design strength before grouting.
b. Concrete should be sound and all surfaces that will be in contact with the
grout should be entirely free of oil, grease, laitance, curing compounds, and
other deleterious substances that can prevent cementitious grout from
bonding to concrete.
c. Prepare the surfaces by chipping, sandblasting or other mechanical means
to ensure a roughened profile. Particular care should be given to the quality
of the concrete foundation.
d. Efflorescence may occur on the surface of foundations containing
limestone aggregate.
2. BASEPLATES
a. All metal surfaces of equipment bases which are to be in direct contact with
the grout should be thoroughly cleaned to bare metal immediately before
grouting. NONSHRINK cement-based grout will not bond to grease, oil,
paint, primers, or epoxy coatings that are sometimes found on the underside
– the contact surface – of the baseplate. These foreign materials should be
removed immediately before, or as close as possible to, grouting time.
b. Level and align baseplates according to the project specifications or to the
recommendations of the equipment manufacturer. Provide approximately
two inches of clearance under leveled baseplates for grouting. For large-
volume placements with clearances greater than three inches, grout should be
extended with clean, washed coarse aggregate that meets ASTM C 33.
Contact the grout manufacturer for the size and amount of coarse aggregate
to use for deep pours. The added coarse aggregate helps to manage the heat
generated by the hydrating cement and provides dimensional stability. It acts
as a heat sink and reduces the temperature rise, helping to reduce the potential
for cracking. Special grouts are available to meet the special application
requirements of shallow pours, deep pours, or certain problem environments.
For long and large volume pours, expansion joints may be considered.
EF2243.1en
c. Shims, wedges, blocks, and leveling nuts (see the sketch above) are used to
support the equipment during alignment and grouting. They can be
removed after grouting if the engineer specifies, but they are often left
in place. If they are required to be removed, apply two generous coats of
paste wax to them, wrap them with polyethylene film, or use some other
bond breaker. Shims and wedges that are to remain in place should have
generously rounded corners to ensure that they do not act as points of stress
concentration. They should be set back from the edge of the baseplate by
two inches or more.
d. Before grouting, tighten anchor bolt nuts finger tight only or follow OEM
instructions.
3. ANCHOR BOLTS
a. Grout anchor bolts with cementitious grout when the design engineer or the
equipment manufacturer so specifies. Anchor bolt holes can be precored
when the foundation is poured, or carefully and accurately located and core
drilled before the equipment is installed. Anchor bolt holes should be at
least 2 inches in diameter for bolts up to 1 inch, and at least 2 inches greater
than the bolt for larger sizes. Very deep holes may need to be bigger than
this to allow grout to flow all the way to the bottom. Roughen the sides of
anchor bolt holes and thoroughly clean all hole and bolt surfaces of oil,
greases, loose cement, dust, and other bond-breaking substances. Soak the
hole to saturation (8 to 24 hours) with potable water, and remove all free
surface water from the holes with oil-free compressed air, sponges, or with
a wet/dry vacuum. Refer to Appendix A for more detail.
b. If part of the anchor bolt length is to remain unbonded, protect it with duct
tape or a plastic sleeve. Locate and support the anchor bolt in the hole. Mix
and pour grout into the hole. Rod the grout well to release any trapped air.
When the grout has set, finish the grout surface, and cure the exposed
surface as the manufacturer directs.
4. FORMING
a. Forms are required for all placement methods except dry packing, which
requires a well-braced backboard to pack the grout against.
b. Build all forms of sufficiently strong materials, securely anchored and shored
EF2243.1en
to withstand the considerable pressure forces developed in placing grout.
c. Coat forms with two generous coats of paste wax, form oil, or other
approved release agents for easy form removal. Seal forms tightly against
existing concrete and vertical wood surfaces. To retain grout within the
formwork, seal joints with tape or sealant. Flowable grout can generally be
retained by taping, but fluid grout will usually require a water-tight seal.
d. Air vent holes are mandatory for some baseplate designs. Provide vent
holes (1/4 to 1/2 inch minimum diameter) in each corner of a baseplate with
a perimeter skirt. Baseplates
or skids divided into two or
more compartments by
stiffening cross members,
require a vent hole in each
corner of every compartment,
as shown in the sketch.
5. MIXING
a. FOLLOW DIRECTIONS
Always follow the grout manufacturer’s directions when mixing grout.
Carefully read all mixing information on the package and in the latest
literature. Whenever possible, cement-based grout, as with all mortars,
should be mixed in a mortar mixer (a stationary drum with rotating blades)
rather than in a concrete mixer (a rotating drum with attached fins) or by
hand. If you are in doubt about mixing procedures, consult the grout
manufacturer.
b. MIXER TYPE
All leading grout manufacturers recommend using a mortar mixer with
moving blades to mix grout. A mortar mixer produces a more thorough and
uniform blend of the mixing water into the dry grout mix. For thorough
mixing, the mortar mixer should be large enough that a batch of grout
occupies less than half the mixer’s capacity. Mixing by hand, including the
use of an electric drill
with a propeller blade,
also produces a less
thorough blend, takes
much more time, and
often results in lower
strengths, lumps,
segregation, and less
flowability. Hand mixing
should be used only when
a very small amount of
grout is needed.
EF2243.1en
c. PREPARATION
Have available an adequate number of mortar mixers to support continuous
grouting operations, as well as the buckets, buggies, wheelbarrows, pumps,
trowels and other hand tools that will be needed for the job. Locate the
equipment and tools as close as possible to the grouting site to take
maximum advantage of the available working time.
d. MIXING AND CONSISTENCY
Clean the mortar mixer’s drum and blades thoroughly. Rinse the drum and
blades with potable water, run the mixer briefly, and empty all excess
water. Only then add the measured amount of potable mixing water into the
drum. Start with the minimum amount of mixing water specified on the
package and in the manufacturer’s literature. The consistency of cement-
based grout will vary with the amount of water added. Use this flexibility.
Always start with the minimum amount of potable water printed on the
manufacturer’s bag or label. Run the mixer until the surface water has
disappeared and a uniform consistency is reached. Mixing should not be for
less than three minutes nor for more than five. Only then, add the least
amount of additional potable water needed to obtain the desired
consistency, and remix. REMEMBER that as the amount of water in the
mix goes up, the strength of the grout goes down. NEVER exceed the
maximum amount of water specified by the grout manufacturer and printed
on the bag or label, and NEVER add an amount of water that will cause
segregation of the aggregate. Rarely, a “false set” may occur. Correct this
by remixing — without adding more water! NEVER retemper a mix (that
is, NEVER add more water after the initial stiffening).
e. CLEAN UP
Clean all equipment and tools with water. An abrasive material such as
sand added to the water is helpful in cleaning a mortar mixer.
6. PLACING GROUT
a. GENERAL
1. Check Temperature Conditions
With a thermometer, determine whether the temperatures of the
ambient air, the grout, the potable water for mixing, the concrete
foundation, and the steel baseplate
will be within the manufacture’s
specified temperature range,
commonly between 40°F and
90°F. If not, special hot weather or
cold weather procedures will be
required.
Checking Temperatures
With a Thermometer
EF2243.1en
2. Working Time
For a given grade of cement-based grout, the working time varies with
the temperature. Working time grows shorter as the temperature rises,
and grows longer as the temperature falls. Measure the placement
temperature to estimate the time available to place grout. A simple way
to determine the working time available under job site conditions is to
mix a small sample of grout to the desired consistency, fill a styrofoam
drinking cup, and time the interval between mixing and loss of
workability.
A liquid additive, SUMMERSET, that provides additional working
time for Five Star grouts is available from Five Star Products.
3. Transporting Grout
Use a pump, wheelbarrows, buggies, or buckets to transport grout to
the placement site.
4. Eliminating Voids
Place grout in a way that assures that all spaces are completely filled
and that the grout is in intimate contact with boundary surfaces. Be
sure to check whether air vent holes are needed.
5. Continuous Grouting
To avoid cold joints under the baseplate, grout placement should be
rapid and continuous. If at all possible, cement-based grouts should not
be placed in lifts or layers. All grouting should take place from one side
to the other to avoid trapping air. If grout must be placed through grout
holes in the baseplate, cut off the tip of a traffic cone, invert it, and use
it as a funnel and headbox. It is important, to avoid trapping air, to
place the grout continuously from one hole until full-depth grout has
passed the next hole. Only then may grouting continue through a
second funnel/headbox through the next grout hole. Leave the first
cone full of grout in place as a standpipe at the previous grout hole to
maintain contact between the grout and the bottom of the baseplate.
Pumping is the preferred placement procedure in this case.
EF2243.1en
b. DRY PACKING GROUT
Dry packing grout is the placing of zero-slump or near zero-slump grout by
ramming into a confined space. It is not recommended except for very small
jobs with easy accessibility. Although dry packing avoids the need for
formwork, it requires considerable skill on the part of the worker to obtain a
uniform degree of grout
compression, and therefore,
uniform strength in the grout
bed. To verify the strength of dry
packed grout, test specimens
must be packed to the same
extent, neither more nor less, as
the grout placed in the job.
DRY PACKING
c. POURING GROUT
When a headbox is used and hydraulic head pressure is the means of flowing
grout into place, the minimum height of the headbox should be from 1/3 to 1/2 the
distance that the grout must flow. Fill the head box to the maximum height and
allow the grout to flow down under the baseplate, but refill the headbox before
the level reaches the top of the baseplate. The level of grout in the head box
must never fall below the top of the baseplate to prevent trapping air under the
baseplate. This procedure is repeated until the grout moves completely under
the baseplate, pushing air out in front of it, and rising above the bottom of the
baseplate on the far side. When the baseplate is long and the headbox is less
than the full length of the baseplate, begin grouting at one end of the long side.
When the grout front reaches the far side, begin sliding the headbox down the
length of the baseplate — keeping pace with the advancing grout front — until
the baseplate is completely grouted. To increase the rate of flow from a
headbox, manually apply pressure in addition to the hydraulic head by using a
plunger. A plunger is a tool, usually
fabricated on the job site, made
from two pieces of wood nailed
together to form a T. The stem is
the plunger handle and the
crossbar, just slightly smaller than
the width of the headbox, applies
the pressure.
PLUNGING TO ASSIST
GROUT FLOW
EF2243.1en
d. PUMPING GROUT
Pumping is the preferred method for placing grout on all large or multiple
grouting installations, particularly when there are shear keys, fixators, or other
obstructions under the baseplate, or when grout must be placed over great
distances, or when it is not possible to vent trapped air. Selecting the
appropriate pump to move the grout properly into place is critical. Choose a
positive displacement pump, such as a
diaphragm or piston pump, rather than
a screw pump. The size of the job will
dictate the size of the pump required.
Pumps vary in size from small ones,
delivering 10 to 14 cubic feet per
hour, to large ones, compressor-
driven, delivering several hundred
cubic feet per hour. Rinse the pump,
the hose, and the nozzle with potable
water. Before grouting, wash a
cleansing plug (called a “pig”)
through the line to ensure that it is
open and clear, and follow the pig
with a slurry of grout. This will ensure
that neither water nor cement are
removed from the grout during
pumping, and that neither pump nor
PUMPING CEMENTITIOUS GROUT hose will clog. For large pumping
placements, use the grout
manufacturer’s pumpable grout formulation. Consult the pump manufacturer
and the grout manufacturer for specific recommendations. Do not begin placing
grout until material of uniform consistency begins flowing from the nozzle.
When pumping grout into place, start at the far end of the space to be grouted.
As the grout is pumped in, back the nozzle out slowly so that it always remains
submerged within the grout. This will prevent air entrapment. Notice that
pumping grout into place is the reverse of flowing it into place. When flowing
grout through a headbox, grouting begins at the grouter’s position and flows
away pushing air ahead of it; when pumping, grouting begins at the most distant
point and flows toward the grouter, pushing air ahead of it.
7. FINISHING SHOULDERS
When the grout has stiffened to the point that it will hold its shape when scored with
the point of a trowel, remove the forms and cut the shoulders back at a 45° angle
from the bottom edge of the baseplate to the foundation. Finish the grout shoulder
with a trowel, float, or brush finish, as desired. Do not allow grout to remain above
the bottom edge of the baseplate or in an unchamfered shoulder. In those locations,
grout is prone to cracking because of differential expansion when the temperature
changes. Sometimes, when anchor bolts are close to the edge of the baseplate, a
vertical crack may occur in the grout shoulder. Shoulder cracks rarely propagate
EF2243.1en
under the baseplate, and do not affect the vertical load-carrying capacity of the
grout. For a cosmetic repair, coat the crack with a paste made from the grout and a
little water.
GROUT SHOULDER CONFIGURATIONS

8. CURING
a. FOLLOW MANUFACTURER’S DIRECTIONS
Cure cement-based grout as directed by the grout manufacturer in its latest
product literature, specifications, and package instructions. For any unusual
conditions, consult the grout manufacturer for guidance.
b. WET CURING
In general, and in the absence of manufacturer’s directions, begin wet curing
immediately after hardening. To prevent rapid surface drying, protect the grout
from extreme drying conditions. Cover all exposed grout surfaces with
continuously wetted burlap or flannel rags or seal the surface with polyethylene
film for a minimum of three days. Special grouts may require more or less
wet curing.
c. CURING TEMPERATURE
Maintain the temperature of the baseplate, the concrete foundation, and the
grout between 40°F and 90°F during grouting, and for a minimum of 24 hours
afterward. Machinery and baseplates will cool faster than the grout at low
temperatures and heat up more rapidly than the grout at high temperatures or in
direct sunlight. Protect the grout from these conditions during the curing period.
d. CURING COMPOUNDS
As an alternate to the wet curing procedure in b., wet cure for only one day, then
immediately coat the exposed surfaces of the grout with curing compound.
Apply two coats of white pigmented, resin-based curing compound that meets
the requirements of ASTM C 309, Type 2, Class B.
EF2243.1en
e. ANCHOR BOLT TORQUE
After the grout has cured to its design strength, use a torque wrench to tighten
anchor bolt nuts only to the specified torque. NEVER exceed the specified
torque. Overtorquing can cause the bolts to stretch beyond their yield point and
result in bolt failure.
9. HOT WEATHER GROUTING

High temperatures accelerate the set, decrease working time, and accelerate the
strength gain of cement-based products. The procedures below may compensate for
these conditions. Refer also to ACI 305R-91 “Hot Weather Concreting”.
a. Materials shall be conditioned as necessary so that the mixed grout is between

60°F and 95°F (16°C and 35°C). Due to the mass of palletized material, up to
72 hours of conditioning may be required. [For fast setting grouts, condition to
between 60°F and 80°F (16°C and 27°C)].
b. When temperature of mixed grout exceeds 80°F (27°C), normal setting grouts
shall be placed within 30 minutes of mixing.
c. All surfaces in contact with grout must be preconditioned and maintained below
95°F (35°C) for a minimum of 24 hours. [90°F (32°C) for fast setting grouts].
d. Cooling of surfaces, materials and equipment can be accomplished by using
chilled water for mixing and presoaking concrete and metal surfaces. Shade
area from direct sunlight or pour grout when temperatures are decreasing.
e. Wind breaks shall be provided when necessary to prevent rapid evaporation.
f. Grout shall remain shaded, protected with damp rags prior to set, and a wet cure
continuously maintained for at least three days. Wet cure must be followed
immediately by an approved curing compound that meets the requirements of
ASTM C 309.
10. COLD WEATHER GROUTING

Low temperatures delay the set, increase working time and delay the strength
development of cement-based products. The procedures below may compensate for
these conditions. Refer also to ACI 306R-88, Cold Weather Concreting.
a. Materials shall be conditioned as necessary so that the mixed grout is between
40°F and 80°F (4°C and 27°C). Due to the mass of palletized material, up to 72
hours of conditioning may be required.
b. All surfaces in contact with grout must be preconditioned and maintained at a
temperature between 40°F and 90°F (4°C and 32°C) for at least 24 hours.
EF2243.1en
c. Heating shall be accomplished by indirect exposure. Heated enclosures must be

windproof and weatherproof. Combustion heaters must be vented and shall not
be permitted to heat and dry the concrete locally. Caution: Exhaust gases may
contaminate or cause carbonation within the enclosed environment.
d. The grout temperature shall be maintained above 40°F (4°C) until the grout
reaches 1000 psi (6.9 MPa), typically 24 hours, or until it reaches the required
strength.
e. Gradually reduce the grout temperature to ambient temperature to avoid
thermal shock. [For low temperature conditions to 35°F (2°C), consider the use
of FIVE STAR INSTANT GROUT, which must be kept above 35°F until it
reaches 1000 psi (6.9 MPa), typically 6 hours, or until it reaches the required
strength.]
EPOXY GROUT PLACEMENT PROCEDURES

A. INTRODUCTION
1. The general application procedures outlined below are for use at ambient
temperature of 70°F. Temperatures below 70°F tend to slow the set and stiffen
the consistency of epoxy grout, and temperatures above 70°F tend to accelerate
the set and loosen the consistency of epoxy grout. If grouting is to be done when
ambient temperatures are not between 60°F and 90°F, follow the additional
recommendations given for Hot Weather Grouting and Cold Weather Grouting
for Epoxy Grouts. If other unusual or difficult conditions exist (low clearances,
shear keys, etc.), the contractor should consult the owner’s engineer and the
grout manufacturer’s Technical Service Department.
2. All necessary tools and materials should be as close as possible to the area
being grouted. Mortar box, mortar mixer (with moving blades), wheelbarrow,
hoe, shovels, trowels, and grout components should be within easy reach.
3. If it is desirable that the set times and strength gains are to be maintained at the
70°F rate, the applicable hot weather or cold weather instructions should be
reviewed for guidance.
4. It is advised for health and safety reasons that all personnel handling epoxy
EF2243.1en
material be properly protected. Wearing protective clothing, eye protection
(goggles), a respirator, and chemically resistant gloves and boots is necessary.
Refer to the manufacturer’s Material Safety Data Sheet (MSDS).
B. SURFACE PREPARATION
1. CONCRETE
a. The base concrete should be dry and have attained its design strength
before grouting
b. DO NOT WET CONCRETE. All surfaces to be in contact with grout
should be dry and entirely free of oil, grease, laitance, curing compounds,
frost, and other potential bond-preventing substances.
c. Roughen the surfaces by chipping, sandblasting, or other mechanical
means to remove any laitance or weak surface layer.
2. BASEPLATES
a. All metal surfaces of equipment bases which are to be in contact with the
grout should be thoroughly cleaned. Sandblasting to an SSPC-SP6
commercial finish will ensure an optimal bond.
b. Level and align the baseplates according to the recommendation of the
equipment manufacturer and/or project specifications. For most
conventional epoxy grouts, a minimum 2 inch clearance should be
provided to facilitate placement. For baseplates wider than three feet, it is
imperative to provide an additional one-inch of clearance for each three
feet of width. Aggregate is the least costly of all the components of epoxy
grout. Grout pours deeper than four inches present the potential for
cracking due to excessive internal heat development and subsequent
cooling. Deeper pours can be accomplished by using a low exotherm epoxy
grout, or pouring in lifts. Embedded rebar acts as a heat sink for curing
epoxy. Both methods reduce temperature rise. For placements deeper than
four inches, the grout manufacturer should be contacted for detailed
procedures.
c. Round shims, wedges, and blocks that are to be removed should be covered
with putty, grease, or similar non-bonding material to prevent the grout
from adhering. If shims, wedges, or blocks are to remain in place, they
should have generously rounded corners (to avoid potential crack
development) and be set back at least 2 inches from any plate edge.
3. ANCHOR BOLTS
a. Equipment manufacturers or design engineers often require anchor bolts to
be grouted. All surfaces should be thoroughly cleaned of oil, grease, and
other deleterious substances and must be dry. Holes must be dried by
evaporation, compressed air, or wicking with absorbent rags. Any
compressor used to blow out water or other substances from surfaces in
contact with the grout must be equipped with an oil trap in the air line to
prevent oil from being blown onto the contact surface and preventing the
grout from bonding. Refer to Appendix A for more information.
b. If equipment manufacturers or design engineers require anchor bolts to
remain isolated, sleeves should be used and filled with a pliable material
EF2243.1en
such as duct seal, putty, silicone rubber molding compound, or other
material specified by the equipment manufacturer. Wrapping bolts in duct
tape or foam insulation also works well.
4. SURFACE DRYNESS
All surfaces should be kept completely dry before grouting. Surface must NOT
be wet.
5. GROUT REMOVAL
Surfaces from which grout is to be removed after placing should be treated with
a paste wax or other release agent before placement.
C. FORMING
1. GENERAL
a. Forming or other leak proof containment is always required with epoxy
grout. The forms require careful attention to prevent any leakage. If forms
are not liquid tight, the grout will leak out and leave voids.
b. Forms must be designed to provide a hydraulic head. If additional
hydraulic head is required at the point of placement, headboxes may be
used as shown below. Typically, the headbox height should be 1/3 to 1/2 the
distance the poured grout must flow. If additional hydraulic head is
required at the point of placement, a plunger may be used as shown below.
c. All chamfer edges required in the grouts should be incorporated into the
forms because, after hardening, epoxy grout can only be cut or trimmed
by grinding.
2. FORM STRENGTH
All forms should be built of materials of adequate strength, securely anchored
and shored to withstand liquid head and the forces developed by plunging the
grout into place.
3. SEALING AND WAXING FORMS
Caulking, such as glazier’s putty, butyl rubber caulking, or duct seal should be
used to make all joints liquid tight. This particularly applies to the joint between
the form and the concrete. All forms may be lined with polyethylene film for
easy grout release. Carefully waxing forms with two coats of heavy floor or
paste wax, preferably colored, to ensure 100% waxed area is also acceptable.
EF2243.1en
4. CONTROL OR ISOLATION JOINTS AND REINFORCEMENT
a. Depending upon the application, and as a general rule, control joints may
be placed on 4 to 6 foot centers. However, this spacing may (at the
discretion of the design engineer only) be increased as described in ACI
223-98 (Section 3.4.5). This section of the ACI Manual of Concrete
Practice contains control joint information for shrinkage compensating
concrete that can be used as a general guide to compensate for thermal
expansion differences using epoxy grouts. (There is no shrinkage
compensating standard for epoxy grouts as of this writing.) Control joints
should extend the full depth and full length from form to form.
b. Joint material can be closed cell styrofoam, thick rubber, thick sheet metal
covered with polyethylene, 1/4 inch thick steel or wood strips covered with
polyethylene tape. Any of these will make removal of the joints relatively
easy by preventing the epoxy grout from bonding to them.
c. For pours that are deep (more than 6 inches) or long (more than 6 feet) and
under extreme temperature conditions, reinforcing bars should be placed in
the grout. To distribute the stresses under these conditions, #6 reinforcing
bars should be placed parallel to the equipment frame between the control
joints (see diagram below). If wide shoulders or extreme depths are
required, consult the grout manufacturer for direction.
Air relief holes
A A
TOP VIEW
5. AIR RELIEF HOLES
With some base plate designs, air relief holes are mandatory. Baseplates with a
skirt around the perimeter should have relief holes (minimum 1/4” diameter) in
each dead corner. If the plate is sectioned with stiffening members, then relief
holes should be provided at the intersections with the skirt (see diagram above
for minimum required air relief holes).
6. SHOULDERS
The difference in coefficient of thermal expansion between epoxy grout and
concrete induces stresses in shoulders. It is recommended that shoulders not
exceed a maximum of 2 to 3 inches. If wide shoulders are mandatory, special
anchoring must be provided as shown below and the manufacturer must be
contacted for specific instructions.
EF2243.1en
D. MIXING
1. FOLLOW DIRECTIONS
Grout should be mixed according to the procedures recommended by the
manufacturer. Carefully read all mixing information on the packages and the
latest literature. If in doubt about the mixing procedures, call the manufacturer.
2. MIXER TYPE
a. Mix in a mechanical mixer at a slow speed (15-20 rpm), using a portable
mortar mixer with moving blades (as shown in part three of this section)
inside the drum as opposed to a concrete mixer with fixed-in-place fins on
a rotating drum. A concrete mixer is not recommended as it will cause air
to be entrapped in the mix.
3. MIXING
a. Pour the hardener (Component B) into the epoxy resin (Component A)
container and stir by hand or with a variable speed (250 rpm max.) drill and
a paddle mixer for two to three minutes until all streaks are eliminated and
the mixture is clear. Mixing speed in excess of 250 rpm may entrain air
bubbles that reduce EBA.
b. Transfer the mixed liquids to a clean, dry mortar mixer and start it up. Add
the aggregate slowly and mix only until the aggregate is completely wetted
out. Overmixing results in excess entrapped air and may reduce working
time.
c. To maintain proper proportions of resin, hardener and aggregate, always
mix full units only. Under no circumstances should partial units be used.
For materials prepackaged in one container, such as FIVE STAR RAPID
EPOXY GROUT, follow the instructions on manufacturer’s label.
EF2243.1en
4. CONSISTENCY
a. Many years of experience have shown that epoxy grouts and aggregates
must be supplied in premeasured quantities to ensure a precision product.
Do not vary the ratio of components and never add solvent to change the
consistency. High temperatures will increase flowability and reduce
working time, while cold weather will decrease flowability and extend
working time. An ideal balance is developed at 75°F.
b. The only exception to this rule is for the first unit mixed. Because some of
the liquids will go to wetting the mixer, about half a 50 lb. bag of aggregate
should be withheld from the first batch only. All the following batches
should be mixed in accordance with the manufacturer’s recommendations
with no modifications.
5. CLEANING EQUIPMENT
Equipment and tools must be cleaned before epoxy grout hardens. Hardened
epoxy grout can be removed by soaking in appropriate solvent or by grinding.
After grouting is completed, or if delays occur, clean mixer, tub, wheelbarrows,
tools, etc. with a strong detergent (such as a laundry detergent or trisodium
phosphate) and water. Adding some ordinary sand will assist in cleaning a
mortar mixer. Organic solvents such as Solvesso, xylol, lacquer thinner,
ketones, or similar solvents, as specified by the manufacturer, can also be used
for cleaning, but FOR SAFETY REASONS, USE CAUTION WHEN
CLEANING POWERED EQUIPMENT WITH HIGHLY VOLATILE
SOLVENTS, SUCH AS LACQUER THINNER OR KETONES. KEEP
SPARKS AWAY FROM SOLVENTS AND WEAR APPROPRIATE
RESPIRATORY PROTECTION.
E. PLACING
1. GENERAL
a. Check Temperature Conditions
Determine if ambient temperature will be between 60°F and 90°F at time
of grouting. If not, follow the compensating procedures found in Hot and
Cold Weather Epoxy Grouting in parts H and I of this section.
EF2243.1en
b. Working Time
Temperature affects the consistency of epoxy grout and therefore can affect
placement time. Check placement temperature of materials to estimate the
time available for placing grout.
c. Transporting Grout
Use power buggies, wheelbarrows, or buckets to transport grout to point of
placement.
d. Eliminating Voids
Grout placement should proceed in a manner that will assure that all spaces
are filled and that there is intimate contact between the grout and the
surfaces to be grouted. The placement should be rapid and continuous to
avoid cold joints and to keep voids from forming under the baseplate. All
grouting should take place from one side to avoid trapping air. When
grouting through grout holes or stand pipes, start placing grout into the next
grout hole or stand pipe only when grout from the first hole has reached
that next hole.
e. Check for Leaks
Forms must be checked constantly for leaks. All leaks must be sealed
immediately or voids will develop.
2. USING A HEADBOX
When hydraulic head pressure is used to flow grout in place, the level of grout
in the headbox must never fall below the top of the baseplate, because then air
will be trapped. The headbox
should be filled to the
maximum height (usually 1/3
to 1/2 the pour width) and
worked (plunged) down to the
top of the baseplate. This
procedure is repeated until the
grout moves completely under
the baseplate, pushing air out
in front of it, and rising to the
top of the chamfer strip on the
far side of the pour.
EF2243.1en
F. FINISHING
Epoxy grout cannot be trimmed after set. It must be left at final placement level,
with all chamfer strips built into forms. To provide a smooth surface, puddle the
grout so all aggregate is covered. After initial stiffening, finish with a trowel
moistened with low volatility solvent such as diesel oil. All further finishing will
require grinding after the grout is completely cured.
G. CURING
1. FOLLOW INSTRUCTIONS
Grout should be cured in accordance with the manufacturer’s specifications and
recommendations. Read and follow the directions printed on the packaging or
on the manufacturer’s associated printed material.
2. FORMS
All forms should remain in place until the minimum required strengths are
attained.
3. TEMPERATURE
The temperature of the baseplate, supporting concrete foundation and grout
should be maintained between a minimum of 60°F and a maximum of 90°F
during grouting and for at least 24 hours afterward. See grout manufacturer’s
literature for curing schedules.
4. MOIST CURING
Water interferes with proper curing of epoxy grouts. DO NOT MOIST CURE
EPOXY GROUT!
H. HOT WEATHER GROUTING INSTRUCTIONS FOR EPOXY GROUT
1. PRECONDITIONING TEMPERATURE
All epoxy grout components should be stored in a dry, weatherproof area until
all epoxy grout components reach a temperature between 65°F and 80°F. Since
aggregate is the major portion of the mix, its temperature will be the most
critical in determining final mix temperature.
2. COOLING AND SHADING
Shading or other methods should be used to
cool baseplates to below 90°F, Extreme
caution should be used because all
surfaces in contact with epoxy grout
must be completely dry before grouting.
Concrete, steel, and forms should be
shaded from direct sunlight beginning
24 hours prior to placing grout and kept
shaded until at least one day after
placement.
3. MIXING PRECAUTIONS
Do not allow mixed resin and hardener to remain
without aggregate for more than 3 minutes.
EF2243.1en
4. TIME OF PLACEMENT
Place the grout in the evening or later when the temperature is dropping. This
allows the heat developed during the curing phase to take place during the
coolest part of the day.
I. COLD WEATHER GROUTING INSTRUCTIONS FOR EPOXY GROUT
1. PRECONDITIONING TEMPERATURE
All epoxy grout components should be stored in a dry, weatherproof area until
all epoxy grout components reach a temperature between 70°F and 80°F. Since
aggregate is the major portion of the mix, its temperature will be the most
critical in determining final mix temperature.
2. SURFACE CONDITIONS
All surfaces in contact with grout must be maintained at a temperature of at
least 60°F for at least 24 hours prior to and at least 48 hours subsequent to
grouting. It is economically advantageous to pour and cure the epoxy at
temperatures between 65°F and 75°F. Doing so quickens the pace of placement
and subsequent curing, thus enabling the equipment to start up sooner. It is
important to prevent frost formation on these surfaces.
TENTED, HEATED ENCLOSURE FOR COLD WEATHER GROUTING
3. METHODS
There are many methods of maintaining proper preconditioning, preparation,
and curing temperatures. Consult the grout manufacturer for advice on
techniques best suited to each application.
EF2243.1en
SKF Split Housing Pillow Block Assembly for SAF and SAFS Housings
Outside Source Information for Multiple CPM Parts
Source SKF (www.skf.com) document ’640-810 October 2012_tcm_12-1275SKF 48’. © 2003 SKF USA Inc.
EF3318EN.2 1
2 SKF Split Housing Pillow Block Assembly for SAF and SAFS Housings
EF3318EN.2
SKF Split Housing Pillow Block Assembly for SAF and SAFS Housings 3
EF3318EN.2
4 SKF Split Housing Pillow Block Assembly for SAF and SAFS Housings
EF3318EN.2
Mobilgrease XHP 222 Informações
Informações de fonte externa
1 Informações gerais
Linha Mobilgrease XHP™ 220 Page 1 of 3
Linha Mobilgrease XHP™ 220

Descrição do Produto
A linha Mobilgrease XHP™ 220 é formada por graxas de complexo de lítio de vida útil prolongada, criadas para uma ampla
gama de aplicações e condições severas. Estas graxas foram desenvolvidas para superar o desempenho dos produtos
convencionais, a partir de uma tecnologia de fabricação exclusiva e de última geração de sabões de complexo de lítio. São
formuladas para proporcionar excelente desempenho em alta temperatura, com excepcional adesividade, estabilidade
estrutural e resistência à contaminação por água. Essas graxas possuem um grau elevado de estabilidade química e
oferecem proteção excelente contra oxidação e corrosão. Estas graxas têm pontos de gota altos e uma temperatura
máxima operacional recomendada de 140 °C. As graxas Mobilgrease XHP 220 estão disponíveis nos graus NLGI 00, 0, 1,
2 e 3 com viscosidade do óleo básico ISO VG 220.
As graxas Mobilgrease XHP 220 foram criadas para uma ampla gama de aplicações, incluindo o setor industrial,
automotivo, de construção civil e marítimo. As suas características de desempenho as tornam ideais para diversas
condições de operação, entre elas, operações em alta temperatura, com contaminação por água, com carga de choque e
intervalos de relubrificação prolongados. A Mobilgrease XHP 222 Special é uma graxa de extrema pressão, reforçada com
0,75% de bissulfeto de molibdênio, que proporciona proteção contra o desgaste em condições de pivotamento e outras
condições que levam à perda da película de óleo.
Características e Benefícios
As graxas Mobilgrease XHP 220 são as líderes da linha de produtos da marca Mobilgrease e conquistaram sua reputação
por sua excelência em inovação e desempenho. As graxas Mobilgrease XHP 220 são produtos de alto desempenho,
desenvolvidas pelos nossos tecnólogos de formulação e apoiadas pela nossa equipe técnica mundial.
O fator chave das propriedades excelentes de adesão, coesão e do alto ponto de gota das graxas Mobilgrease XHP 220 é
a tecnologia exclusiva de fabricação desenvolvida em nossos laboratórios de pesquisa e adotada em nossas fábricas
modernas. Esses produtos usam aditivos selecionados especificamente para proporcionar excelente proteção antioxidante,
controle de ferrugem e corrosão, resistência à contaminação por água, bem como proteção antidesgaste e extrema
pressão (EP). A linha de produtos Mobilgrease XHP 220 apresenta as seguintes características e benefícios:
Características Vantagens e Benefícios Potenciais

Garante lubrificação e proteção adequada mesmo sob as
Excepcional resistência à lavagem por água
condições mais severas de exposição à água.
Tenacidade excelente da graxa, ajuda a reduzir os
Estrutura altamente adesiva e coesiva vazamentos e aumentar os intervalos de lubrificação,
diminuindo as exigências de manutenção.
Proteção dos componentes lubrificados mesmo em
Excelente resistência à corrosão e ferrugem
ambientes aquosos hostis.
Ajuda a prolongar a vida útil da graxa e melhorar a proteção
Resistência muito boa à degradação térmica, oxidativa e do mancal em aplicações de alta temperatura, resultando em
estrutural em altas temperaturas manutenção reduzida e economia dos custos com peças de
reposição.
Proteção confiável do equipamento lubrificado, mesmo em
condições de alto deslizamento com potencial para aumentar
Oacute;timo desempenho antidesgaste e EP
a vida útil do equipamento e reduzir o tempo de parada não
programada.
http://www.mobil.com/Brazil-Portuguese/Lubes/PDS/GLXXP2GRSMOMobilgrease_XH... 6/23/2014
Source: www.mobil.com document ’GLXXP2GRSMOMobilgrease_XHP_220’ of 2-2014. © 2001-2014 Exxon Mobil Corporation.
EF3619PTBR.0 1
2 Mobilgrease XHP 222 Informações
Características Vantagens e Benefícios Potenciais

Potencial racionalização dos produtos e diminuição dos
Multiuso abrangente
custos de estoques.
Aplicações
As graxas da linha Mobilgrease XHP 220 são utilizadas em uma ampla série de equipamentos industriais, automotivos, de
construção civil e marítimos. A sua cor azul permite verificar facilmente o seu uso:
As graxas Mobilgrease XHP 005 e 220 são graxas de baixa consistência e de alta temperatura recomendadas pela
ExxonMobil para sistemas centralizados de lubrificação, lubrificação de engrenagens e onde o bombeamento em
temperaturas extremamente baixas é importante.
A graxa Mobilgrease XHP 221 é recomendada pela ExxonMobil para aplicações industriais, marítimas, em componentes de
chassi e em equipamentos agrícolas. Proporciona um desempenho excelente em baixa temperatura.
A graxa Mobilgrease XHP 222 é recomendada pela ExxonMobil para aplicações industriais, marítimas, em componentes de
chassi e em equipamentos agrícolas. Sua fórmula adesiva permite a permanência na aplicação por mais tempo.
A graxa Mobilgrease XHP 223 é recomendada pela ExxonMobil para aplicações onde são exigidas boas propriedades de
alta temperatura e antigotejamento. Ela é recomendada particularmente para uso em rolamentos de rodas de caminhões
de serviço pesado, em rolamentos sujeitos à vibração ou onde a alta velocidade exige uma graxa de alta consistência que
resista à expulsão da pista.
A graxa Mobilgrease XHP 222 Special contém 0,75% de bissulfeto de molibdênio, é de cor cinza e é recomendada pela
ExxonMobil para aplicações industriais de carga moderada, componentes de chassi e equipamentos agrícolas. Também
pode ser usada em pinos mestres, articulações em U, quinta roda e pinos de caçambas.
Especificações e Aprovações
Linha Mobilgrease XHP 220 atende ou excede

005 220 221 222 223 222 Special
as exigências de:
DIN 51825: (2004-06) KP1N-20 KP2N-20
Mobilgrease XHP 220 tem as seguintes

005 220 221 222 223 222 Special
aprovações de fabricantes:
MAG IAS, LLC P-79 P-72 P-64
Propriedades Típicas
Mobilgrease XHP 005 220 221 222 223 222 Special

Grau NLGI 00 0 1 2 3 2
Complexo Complexo Complexo Complexo Complexo Complexo
Tipo de Espessante
de Lítio de Lítio de Lítio de Lítio de Lítio de Lítio
Cor, Aspecto Visual Azul Escuro Azul Escuro Azul Escuro Azul Escuro Azul Escuro Cinza-Preto
Bissulfeto de molibdênio, % peso -- -- -- -- -- 0,75%
EF3619PTBR.0
Mobilgrease XHP 222 Informações 3
Mobilgrease XHP 005 220 221 222 223 222 Special

Penetração Trabalhada, 25°C, ASTM D217 415 370 325 280 235 280
Ponto de Gota, °C, ASTM D 2265 ----- 270 280 280 280 280
Viscosidade do Óleo Básico, ASTM D 445
cSt a 40 °C 220 220 220 220 220 220
Teste 4-Ball - Antidesgaste, ASTM D2266,
0,50 0,50 0.5 0.5 0.5 0.5
cicatriz, mm
Teste 4-Ball, Carga de Solda, ASTM D 2596, kg 315 315 315 315 315 315
Carga Timken OK, ASTM D 2509, lb 40 40 40 40 40 40
Estabilidade à Oxidação, ASTM D 942, queda de
35 (5) 35 (5) 35 (5) 35 (5) 35 (5) 35 (5)
pressão em 100 h, kPa (psig)
Resistência à Corrosão, ASTM D 1743 Passa Passa Passa Passa Passa Passa
Proteção Contra Ferrugem, IP 220-mod.,
0,0 0,0 0,0 0,0 0,0 0,0
Lavagem por Água Destilada
Corrosão em Lâmina de Cobre, ASTM D 4048 1B 1B 1B 1B 1B 1B
Alteração da consistência de penetração,
---- -15 -15 0 0 0
estabilidade à rolagem, ASTM D1831, mm/10
Saúde e Segurança
Com base nas informações disponíveis, este produto não deverá produzir efeitos nocivos para a saúde quando utilizado
nas aplicações para as quais foi concebido e se forem observadas as recomendações da Ficha de Informações de
Segurança de Produto Químico (FISPQ). As FISPQs encontram-se disponíveis mediante pedido ao escritório de vendas
ou pela Internet. Este produto não deve ser usado para outros fins senão aqueles para os quais foi criado. Ao descartar o
produto usado, tome cuidado para proteger o meio ambiente.
Todas as marcas comerciais aqui utilizadas são marcas comerciais ou marcas registradas da Exxon Mobil Corporation ou
de uma de suas subsidiárias, salvo indicação em contrário.
2-2014
Esso Brasileira de Petróleo Ltda.

Rua Victor Civita, 77, Bloco 1
22775-044 Rio de Janeiro-RJ-BRASIL
5521 3433-2000
Propriedades típicas são valores médios, obtidos com tolerâncias normais de produção e não se constituem em
especificação. Variações que não afetam o desempenho do produto são esperadas durante processos normais de
fabricação e em diferentes locais de mistura. As informações contidas neste documento estão sujeitas a alteração sem
aviso prévio. Todos os produtos podem não estar disponíveis localmente. Para obter mais informações, contacte o seu
representante local da ExxonMobil ou visite www.exxonmobil.com
A ExxonMobil é composta de diversas afiliadas e subsidiárias, muitas com nomes que incluem Esso, Mobil, ou ExxonMobil.
Nada neste documento visa anular ou substituir a separação corporativa das entidades locais. A responsabilidade pela
ação local permanece com as respectivas afiliadas da ExxonMobil.
Copyright © 2001-2014 Exxon Mobil Corporation. Todos os direitos reservados.
EF3619PTBR.0
2 Ficha de Dados de Segurança do Material do Mobilgrease XHP 222
Nome do produto: MOBILGREASE XHP 222 SPECIAL

FISPQ N°: 2006163XBR
Data de Revisão: 28 Nov 2013
Página 1 de 10
_____________________________________________________________________________________________________________________
FICHA DE INFORMAÇÕES DE SEGURANÇA DE

PRODUTOS QUÍMICOS (FISPQ)
SEÇÃO 1 IDENTIFICAÇÃO DO PRODUTO E DA EMPRESA
De acordo com a data de revisão acima, esta FISPQ se encontra de acordo com a regulamentação brasileira.
Produto
Descrição do produto: Óleo básico e Aditivos
DGN: 2006163XBR
Código do produto: 2015A0202531, 530550-00
Uso intencionado: Graxa
Identificação da Companhia
Fornecedor: Cosan Lubrificantes e Especialidades S. A.
PRAIA DA RIBEIRA, 1
ILHA DO GOVERNADOR - RIO DE JANEIRO - RJ CEP 21930-080 Brasil
Emergência Saúde 24 horas +55 21 3386-2329/ +55 19 3403-2091/ 0800 644 1562
Informações Técnicas sobre o produto +55 21 3386-2329/ +55 19 3403-2091/ 0800 644 1562
E-Mail suporte.tecnico@cosan.com.br
FAX +55 21 3386-2197
SEÇÃO 2 IDENTIFICAÇÃO DE PERIGOS
Este material não é perigoso de acordo com as diretrizes regulamentares (ver Seção 15 desta FISPQ).
Outras informações de risco:
PERIGOS FÍSICOS / QUÍMICOS

Sem riscos sigificativos
Riscos à Saúde
Injeção de alta pressão sob a pele pode causar sérios danos. Exposição excessiva pode resultar em irritação
dos olhos, pele e aparelho respiratório.
RISCOS PARA O MEIO AMBIENTE

Sem riscos sigificativos
IDENTIDADE DO Saúde: 0 Inflamabilidade: 1 Reatividade: 0

RISCO EMITIDA DA
Source: www.msds.exxonmobil.com document ’MSDS_787059’ of 09 April 2014.
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PELA NFPA:
NOTA: Este material não deve ser usado para nenhum outro fim que não seja para o qual o produto tenha sido
fabricado, descrito na Seção 1, sem que se consulte um perito. Estudos de saúde demontraram que a exposição ao
produto químico pode causar riscos à saúde
SEÇÃO 3 COMPOSIÇÃO E INFORMAÇÕES SOBRE OS INGREDIENTES
Este material é definido como uma mistura.
Substância(s) Perigosa(s) ouSubstância(s) Complexa(s) com divulgação requerida
Nome CAS# Concentração* Códigos de Risco GHS

BENZENAMINA, N-FENIL-, PRODUTOS DA REAÇÃO 68411-46-1 1 - 5% H402, H412
COM 2,4,4-TRIMETILPENTENO
ACIDO FOSFORODITOICO, O,O-DI C1-14-ESTER 68649-42-3 1 - 2.5% H315, H319(2A), H401,
ALQUIL, SAIS DE ZINCO(2:1)(ZDDP) H411
* Todas as concentrações estão em porcentagem de peso, a não ser que o ingrediente seja um gás. As concentrações
dos gases estão em porcentagem volumetrica.
SEÇÃO 4 MEDIDAS DE PRIMEIROS-SOCORROS
INALAÇÃO
Não existe a possibilidade deste produto causar danos quando inalado, quando usado dentro das condições
normais de uso para o qual o produto foi fabricado.
CONTATO COM A PELE

Lave as áreas de contato com água e sabão. Se o produto for injetado para dentro ou debaixo da pele, ou
para dentro de qualquer parte do corpo, sem se importar com a aparência da ferida ou com o seu tamanho, o
indivíduo deve ser avaliado imediatamente por um médico como um caso de emergência cirúrgica. Mesmo que
os sintomas iniciais da injeção com alta pressão sejam mínimos ou ausentes, uma cirurgia cedo, dentro das
primeiras horas, pode reduzir muito a extensão do dano.
CONTATO COM OS OLHOS

Lave muito bem com água. Se irritação ocorrer, procure assistência médica.
INGESTÃO
Normalmente, os primeiros socorros não são necessários. Procure assistência médica se ocorrer algum
desconforto.
SEÇÃO 5 MEDIDAS DE COMBATE A INCÊNDIO
MEIO PARA EXTINÇÃO

Meio Apropriado para Extinção: Use neblina de água, espuma, pó químico ou dióxido de carbono(CO2)
para extinguir as chamas.
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Meio impróprio para extinção: Jatos diretos de água
EXTINÇÃO DE INCÊNDIO
Instruções para Extinção de Incêndio: Promova a evacuação da área. Evite que a água utilizada no
controle de incêndio ou provenientes de diluição alcance os riachos, esgotos, ou abastecimentos de água
potável. Os bombeiros devem utilizar os equipamentos padrão de proteção individual quando estiverem em
espaços fechados e utilizar equipamentos de respiração autônoma. Use aspersão de água para esfriar as
superfícies expostas ao fogo e para proteger os trabalhadores.
Produtos de Combustão Arriscada: Fumaça , Fumos, Aldeídos, Óxidos de enxofre, Produtos da

combustão Incompleta, Óxidos de carbono
Propriedades de Inflamabilidade
Ponto de fulgor [Método]: >204ºC (400ºF) [EST. PARA ÓLEOS, ASTM D-92 (COC)]
Limites de Inflamabilidade (% aproximado do volume no ar): LEL: N/D UEL: N/D
Temperatura de auto ignição: N/D
SEÇÃO 6 MEDIDAS DE CONTROLE PARA DERRAMAMENTO OU

VAZAMENTO
PROCEDIMENTOS PARA NOTIFICAÇÃO

No caso de um derrame acidental, favor notificar as autoridades, de acordo com os regulamentos que se
apliquem.
MEDIDAS DE PROTEÇÃO
Evite contato com o material derramado. Veja Seção 5 para Medidas de Combate a Incêndio. Ver Seção 2
para Identificação de Perigos. Ver Seção 4 para Medidas de Primeiros Socorros. Ver Seção 8 para Controle
de Exposição e Proteção Individual. Medidas de proteção adicionais podem ser necessárias, dependendo das
circunstâncias específicas e/ou o parecer dos peritos de resposta a emergências.
Para os responsáveis pelo atendimento de emergências: Proteção respiratória: proteção respiratória será
necessária apenas em casos especiais, por exemplo, a formação de névoas. Máscara semi-facial ou facial
completa com filtro(s) de poeira/vapor orgânico ou aparelho de respiração autônoma podem ser usados,
dependendo do tamanho do derrame e do nível potencial de exposição. Se a exposição não pode ser
completamente caracterizada ou uma atmosfera deficiente em oxigênio é possível ou previsível, o uso
aparelho de respiração autônoma é recomendado.
Luvas de trabalho resistentes a hidrocarbonetos são recomendadas. Luvas feitas de acetato de polivinila (PVA)
não são resistentes à água e não são apropriadas para uso emergencial. Óculos de proteção contra produtos
químicos se respingos ou contato com os olhos forem possíveis. Pequenos derrames: Roupas de trabalho
anti-estáticas comuns são normalmente adequadas. Grandes derrames: macacão de corpo inteiro resistente a
produtos químicos e com material anti-estático é recomendado.
GERENCIAMENTO DE DERRAMES
Derramamento sobre Terra: Recolha o material derramado com equipamento apropriado(pá) e coloque-o
em recipiente apropriado para reciclagem ou descarte.
Derramamento em água: Pare o vazamento, se você puder fazê-lo sem se arriscar. Confine o derrame
imediatamente com barreiras de contenção. Avise a outros transportadores. Remova da superfície.
As recomendações para quando houver derrames na água e na terra são baseadas na maior possibilidade de
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ocorrência para este material. No entanto, as condições geográficas, o vento, a temperatura, (em caso de
derrame aquático) ondas, e a direção e velocidade das correntes marítmas podem influenciar em grande
escala e ações apropriadas devem ser tomadas. Por esta razão, os espercialistas locais devem ser
consultados. Nota: As regulamentações locais devem prescrever as ações a serem tomadas.
PRECAUÇÕES AO MEIO AMBIENTE

Previna a entrada nos recursos hídricos, esgotos, porões ou áreas confinadas.
SEÇÃO 7 MANUSEIO E ARMAZENAMENTO
MANUSEIO
Previna pequenos derrames e vazamentos para evitar superfícies escorregadias.
Acumulador estático: Este material não é um acumulador estático.
ARMAZENAMENTO
Não armazene em recipientes abertos ou sem rótulo.
SEÇÃO 8 CONTROLE DE EXPOSIÇÃO E PROTEÇÃO INDIVIDUAL
Observação: Os limites / padrões são apenas uma diretriz. Siga os regulamentos aplicáveis.
CONTROLES DE ENGENHARIA
O nível de proteção e tipos de controles necessários irá variar, dependendo das condições e do potencial da
exposição. Considerar medidas de controle:
Nenhum requerimento especial, sob condições normais de uso e com ventilação adequada.
PROTEÇÃO PESSOAL
A seleção de equipamentos de proteção pessoal varia em função das condições de exposição como as
praticas de aplicação, manuseio, concentração e ventilação. Informações sobre a seleção dos equipamentos
de proteção para uso deste material são fornecidas abaixo e são baseadas em seu uso normal.
Proteção Respiratória: Se os controles efetuados pela engenharia do local não mantiverem as

concentrações dos contaminantes de ar a um nível que seja adequado para proteger a saúde do trabalhador,
talvez seja apropriado o uso de um respirador aprovado. A seleção do respirador, a ser utilizado, e sua
manutenção devem estar de acordo com as regulamentações requeridas, se aplicado. Tipos de respiradores
devem ser considerados inclusive para este material.
Normalmente, nenhuma proteção se faz necessária sob condições normais de uso e com ventilação
adequada.
Para concentrações elevadas de ar, use um respirador aprovado com suprimento de ar, operado de modo que
a pressão seja positiva. Pode-se usar respiradores com suprimento de ar com cilindro de escape, quando os
níveis de oxigênio forem inadequados, ou houver perigo de formação de gás/vapor., ou se a capacidade de
purificação do filtro for excessiva.
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Proteção para as mãos: Qualquer informação específica sobre luvas é provida baseada na literatura
publicada e nos dados dos fabricantes de luvas. O tipo adequado de luvas e sua durabilidade irão diferir
dependendo das condições de específicas de uso. Entre em contato com o fabricante das luvas para obter
informações específicas sobre a escolha de luvas e durabilidade. Inspecione e substitua luvas gastas ou
danificadas. Os tipos de luvas consideradas para esse produto incluem:
Normalmente, nenhuma proteção se faz necessária sob condições normais de uso.
Proteção dos olhos/faces: Se existe a possibilidade de contato, se recomenda o uso de óculos de

segurança com proteção lateral.
Proteção da pele e do corpo: Qualquer informação específica sobre as vestimentas é baseada em

literatura publicada e em dados fornecidos pelos fabricantes. Os tipos de vestimentas a serem considerados
para este material incluem:
De acordo com as boas práticas de higiene industrial, medidas de precaução devem ser tomadas
para se evitar contato com a pele. Nenhuma proteção se faz, normalmente, necessária para a pele,
dentro das condições normais de uso.
Medidas específicas de higiene: Sempre observe boas medidas de higiene pessoal, tais como se lavar
depois de trabalhar com o material e antes de comer, beber e / ou fumar. Lave, rotineiramente, as roupas de
trabalho e os equipamentos protetores para remover os contaminantes. Descarte a roupa e sapatos
contaminados que não puderem ser limpos. Pratique bons hábitos de higiene e limpeza.
CONTROLES AMBIENTAIS
Cumprir com as regulamentações ambientais aplicáveis limitando descarga para ar, água e solo. Proteger o
meio ambiente através da aplicação de medidas de controle adequadas para evitar ou limitar emissões.
SEÇÃO 9 PROPRIEDADES FÍSICO E QUÍMICAS
Nota: As propriedades físicas e químicas são fornecidas apenas para considerações de segurança, saúde e
meio ambiente, e podem não representar integralmente as especificações do produto. Contacte o fornecedor
para informações adicionais.
INFORMAÇÕES GERAIS
Estado físico: Sólido
Forma: Semi-fluida
Cor: Cinza Escuro
Odor: Característica
Limiar de odor: N/D
INFORMAÇÕES IMPORTANTES SOBRE SAÚDE, SEGURANÇA E O MEIO AMBIENTE

Densidade Relativa (a 15 ºC): 0.914
Inflamabilidade (sólido, gás):
Ponto de fulgor [Método]: >204ºC (400ºF) [EST. PARA ÓLEOS, ASTM D-92 (COC)]
Limites de Inflamabilidade (% aproximado do volume no ar): LEL: N/D UEL: N/D
Temperatura de auto ignição: N/D
Ponto de ebulição / Faixa: > 316ºC (600ºF) [Estimado]
Temperatura de decomposição: N/D
Densidade do vapor (Ar = 1): N/D
Pressão de vapor: < 0.013 kPa (0.1 mm Hg) a 20ºC [Estimado]
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Razão de evaporação (n-butil acetato = 1): N/D
pH: N/A
Log. da Energia Elétrica [Pow] (n-Octanol / Coeficiente de Partição de Água): > 3.5 [Estimado]
Solubilidade na água: Neglígivel
Viscosidade: 220 cSt (220 mm2/sec) a 40ºC | >16 cSt (16 mm2/sec) a 100ºC
Propriedades Oxidantes: Veja Seção de Identificação de Risco.
OUTRAS INFORMAÇÕES
Ponto de congelamento: N/D
Ponto de fusão: >260ºC (500ºF)
DMSO extraído(somente óleo mineral), IP-346: < 3 % peso
NOTA: A maioria das propriedades físicas acima são para o componente de óleo no material.
SEÇÃO 10 ESTABILIDADE E REATIVIDADE
ESTABILIDADE: O material é estável sob condições normais.
CONDIÇÕES A SEREM EVITADAS: Calor excessivo. Altas fontes de energia de ignição.
MATERIAIS E SUBSTÂNCIAS INCOMPATÍVEIS: Oxidantes Fortes
PRODUTOS PERIGOSOS DA DECOMPOSIÇÃO: O material não se decompõe a temperatura ambiente.
POSSIBILIDADE DE REAÇÕES PERIGOSAS: Não ocorrerá polimerização perigosa.
SEÇÃO 11 INFORMAÇÕES TOXICOLÓGICAS
TOXIDADE AGUDA
ROTA DE EXPOSIÇÃO Conclusão / Observações
Inalação
Toxicidade: Não há dados de ponto Minimamente Tóxico. Baseado na avaliação dos componentes.
final para o material.
Irritação: Não há dados de ponto final Risco negligível quando manuseado em temperaturas ambientes
para o material. ou normais.
Ingestão
Pele
Irritação: Não há dados de ponto final Irritação negligível da pele em temperatura ambiente. Baseado na
para o material. avaliação dos componentes.
Olho
Irritação: Não há dados de ponto final Pode causar desconforto ameno nos olhos, de curta duração.
para o material. Baseado na avaliação dos componentes.
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OUTROS EFEITOS DA SAÚDE DE CURTO E LONGO PRAZO DE EXPOSIÇÃO
Esperam-se efeitos sobre a saúde a partir da sensibilização sub-crônica, crônica respiratória ou de pele,
mutagenicidade, toxicidade reprodutiva, carcinogenicidade, toxicidade de órgãos alvo (exposição única ou repetida),
toxicidade por aspiração e outros efeitos com base na experiência humana e / ou dados experimentais.
Contém:
Óleo básico severamente refinado: Não causou câncer em animais testados. A porção que representava o
material passou no teste IP-346, Modificado de Ames, nem em outros testes de seleção. Estudos sobre a pele
e de inalação demonstraram efeitos mínimos. Estudos dérmicos e de inalação mostraram um efeitos mínimos;
infiltração não específica em celulas imunes dos pulmões, depósito de óleo e mínima formação de granuloma.
Não sensitivo em testes de animais. Destilados médios: Carcinogênicos em cobaias animais. Testes de
pincelamento na pele de animais, durante o curso de suas vidas, produziram tumores, mas o mecanismo é
devido aos ciclos repetidos de danos da pele e hiperplasia restaurativa. Este mecanismo é considerado
improvável em humanos aonde esta irritação prolongada da pela não seria tolerada. Não causou mutações In
Vitro. A inalação de vapores não causou efeitos reprodutivos ou de desenvolvimento em cobaias animais. A
inalação de altas concentrações em animais resultou em irritação do trato respiratório, alterações pulmonares
e alguma redução da função pulmonar. Não sensibilizante em cobaias animais.
Os seguintes ingredientes são citados nas listas abaixo: Nenhum.
--LISTAS REGULAMENTARES PESQUISADAS--

1 = NTP CARC 3 = IARC 1 5 = IARC 2B
2 = NTP SUS 4 = IARC 2A 6 = OSHA CARC
SEÇÃO 12 INFORMAÇÕES ECOLÓGICAS
As informações fornecidas são baseadas em dados disponíveis sobre o material, sobre os componentes do material, e
sobre materiais semelhantes.
ECOTOXICIDADE
Material -- Não se espera que seja prejudicial aos organismos aquáticos.
MOBILIDADE
Componentes do óleo básico -- Material possue baixa solubilidade e irá flutuar e é esperado que migre
da água para a terra. Possibilidade de causar divisão em sedimentos e em sólidos do esgoto.
PERSISTÊNCIA E DEGRADABILIDADE
Biodegradação:
Componentes do óleo básico -- Possibilidade de ser inerentemente biodegradável
POTENCIAL PARA ACÚMULO BIOLÓGICO

Componentes do óleo básico -- Tem o potencial de ser bioacumulativo, no entanto o metabolismo ou
propriedades físicas podem reduzir a bioconcentração ou limites de biodisponibilidade.
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SEÇÃO 13 CONSIDERAÇÕES SOBRE TRATAMENTO E DISPOSIÇÃO
As recomendações para despejo são baseadas no tipo e no modo fornecido do material. O despejo deve estar de
acordo com as leis e os regulamentos atuais aplicáveis, e com as características do material na hora do despejo.
RECOMENDAÇÕES PARA O DESCARTE

O produto pode ser queimado em um incinerador fechado e controlado para combustíveis de valor ou pode
ser incinerado sob supervisão, em temperaturas bastante elevadas para prevenir a formação de produtos
indesejáveis na combustão.
Aviso sobre Embalagens TEXTO DO RÓTULO DE PRECAUÇÃO: Os recipientes vazios podem reter resíduos e
podem ser perigosos. NÃO PRESSURIZE, CORTE, DERRETA, COLOQUE NO FOGO, PERFURE, MOA, NEM
EXPONHA TAIS RECIPIENTES AO CALOR, A CHAMAS, A FAÍSCAS, À ELETRICIDADE ESTÁTICA, OU OUTRAS
FONTES DE IGNIÇÃO; ELES PODEM EXPLODIR E CAUSAR SÉRIOS FERIMENTOS OU MORTE. Não promova o
reenvase ou limpeza do recipiente sem que o resíduo tenha sido totalmente retirado. Tambores vazios devem ser
completamente drenados, secos e devidamente retornados a um recondicionador de tambores. Todos os recipientes
devem ser dispostos de acordo com as regulamentações do meio ambiente e governamentais vigentes.
SEÇÃO 14 INFORMAÇÕES SOBRE TRANSPORTE
TERRESTRE: Não é Regulamentado para Transporte Terrestre

ANTT N° 420 e suas atualizações (Agência Nacional de Transporte Terrestre).
MARITIMO (IMDG): Não é Regulamentado para Transporte Marinho de acordo com o código IMDG
Código Marítimo Internacional de Mercadorias Perigosas (Código IMDG);
Norma 5 do DPC (Departamento de Portos e Costas do Ministério da Marinha);

ANTAQ (Agência Nacional de Transporte Aquaviário).
Poluição Marinha: Não
AÉREO (IATA): Não é Regulamentado para Transporte Aéreo

Regulamento de Produtos Perigosos (DGR IATA);
DAC – Departamento de Aviação Civil do Ministério da Aeronáutica.
SEÇÃO 15 REGULAMENTAÇÕES
Este material não é perigoso conforme definido pela NBR 14725-2 / Sistema de Classificação de Risco.
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Atende às exigências dos seguintes inventários nacionais/regionais de produtos químicos: AICS, ENCS,
IECSC, PICCS, TSCA
Casos Especiais.:
Inventário Status
KECI Restrições de aplicabilidade
NDSL Restrições de aplicabilidade
SEÇÃO 16 OUTRAS INFORMAÇÕES

N/D = Não foi Determinado, N/A = Não se Aplica
CHAVE PARA OS CÓDIGOS H CONTIDA NA SEÇÃO 3 DESTE DOCUMENTO (apenas para informação):
H315: Causa irritação da pele; Corrosão/Irritação da Pele, Cat 2

H319 (2A): Provoca irritação ocular grave; Lesões Oculares Graves / Irritação, Cat 2A
H401: Tóxico para organismos aquáticos; Amb Tox Aguda, Cat 2

H402: Nocivo para a vida aquática; Tox Amb Aguda, Cat 3
H411: Tóxico para os organismos aquáticos com efeitos duradouros; Amb Tox Crônica, Cat 2
H412: danoso à vida aquática com efeitos duradouros; Tox Amb Crônica, Cat 3
ESTA FOLHA DE DADOS DE SEGURANÇA CONTÉM AS SEGUINTES REVISÕES::

Atualizações feitas em conformidade com a implementação dos requisitos do GHS
.
-----------------------------------------------------------------------------------------------------------------------------------------------------
As informações e recomendações contidas neste documento, expressam o que a ExxonMobil possui de melhor
conhecimento sobre este assunto nesta data. Você pode contactar a ExxonMobil para se assegurar que este
documento é o mais recente e disponível pela ExxonMobil. As informações e recomendações são oferecidas para a
análise e consideração do usuário, sendo de sua responsabilidade verificar se as mesmas satisfazerem as
necessidades requeridas para o seu uso particular. Se o comprador reenvasar este produto, será de responsabilidade
do usuário se assegurar que o produto se mantenha dentro de suas propriedades de segurança e saúde e outras
informações necessárias incluindo as da embalagem. Os procedimentos apropriados para o manuseio seguro deste
produto, devem ser informadas a todas as pessoas que tenham contato operacional com ele até o usuário final. A
alteração nos dizeres deste documento é expressamente proibida. Excetuando o que é estabelecido por lei, a
republicação ou retransmissão deste documento de forma total ou parcial não é permitida. O termo ExxonMobil é
utilizado de forma genérica por conveniência, e pode incluir uma ou mais empresas da organização da ExxonMobil
Química ou da corporação ExxonMobil ou qualquer afiliada onde exista o interesse direto ou indireto neste assunto
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Apenas para uso interno

MHC: 0B, 0B, 0, 0, 0, 0 PPEC: A
DGN: 2006163XBR (550276)
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Direitos editoriais 2002 Exxon Mobil Corporation, Todos os direitos reservados.
EF3619PTBR.0

Página 10 de 10
_____________________________________________________________________________________________________________________
EF3619PTBR.0
EF3619PTBR.0
Nook ActionJac Machine Screw Jac Instructions
MACHINE SCREW JACKS
INSTALLATION, MAINTENANCE, &

LUBRICATION INSTRUCTIONS
TABLE OF CONTENTS
General instructions .................................... 2

Ordering Spare/Repair Parts ........................ 2
General Specifications ................................. 3
Lubrication ................................................... 3
Installation Instructions................................ 4
Tips for Disassembly & Reassembly ........... 5
Disassembly Instructions ......................... 5-8
Exploded View of Jack Units..................... 6-7
Reassembly .............................................. 8-9
Troubleshooting ...................................... 9-10
Anti-Backlash Adjustment .......................... 11
Source: Nook Industires, Inc. (www.nookind.com) document ’MSJ_Booklet_web’ downloaded April 18, 2014.
EF3335EN.1 1
2 Nook ActionJac Machine Screw Jac Instructions
CAUTION - The customer is responsible as the unit is operated within the rat-
for providing stops at either end of travel. ing and service conditions for which
Machine Screw Jacks are usually self-lock- it was specifically sold. The purchaser
ing. However, self-lowering or creep could must prevent the existence of any
result from vibratory conditions. In these destructive external conditions which
cases, a brake should be considered. might typically include vibratory loads
Overtravel could cause the lifting screw to due to critical speeds, severe shock
become disengaged from the drive sleeve. loading, mechanical or thermal over-
loads, or side loads if the seller was
GENERAL INSTRUCTIONS not fully advised of their existence at
time of order.
Your Machine Screw Jack is a high quality,
sturdy unit designed to give many hours 5. Adequate installation, maintenance
of trouble-free service. However, certain and safety instructions must be given
precautions and procedures must be ob- by the user to personnel directly re-
served in handling, installing and servicing sponsible for the installation and op-
the unit in order to obtain optimum perfor- eration of the equipment.
mance.
6. In the event of malfunction within the
1. Any apparent or suspected dam- warranty period, the manufacturer
age to equipment manufactured or must be informed promptly or, in any
furnished by Nook Industries during event, within thirty days if it is intend-
transport from the factory to the user ed that the warranty is to covert the
should be immediately reported to incident.
both Nook Industries and the carrier.
CAUTION - UNITS ARE NOT MEANT FOR
2. Upon delivery all equipment fur- PERSONNEL SUPPORT. Refer all applica-
nished should be carefully invento- tions for potential personnel support to the
ried against shipping papers to de- factory for approval.
termine whether any shortages exist
in delivered material. Any such short- ORDERING SPARE/REPAIR PARTS
ages must immediately be reported
to Nook Industries and the carrier. This booklet contains general instructions,
operating, maintenance and troubleshoot-
3. The installation of most power trans- ing instructions for your ActionJac™ Worm
mission equipment does not normally Gear Jack. In the event spare or repair
require the services of a factory engi- parts are required, call your local represen-
neer. These services are not included tative or contact Nook Industries at (216)
in the selling price of the equipment 271-7900 or 1(800) 321-7800.
unless specifically agreed upon in
writing between the seller and pur- Please provide the following information
chaser. In applications requiring a when requesting spare/repair parts:
more complex arrangement of com-
ponents, consideration should be så*ACKå3IZEåå4YPEå$ESIGNATIONåIE åå-3*
given to the use of a factory engineer
så3ERIALå.UMBERåå9EARåOFå-ANUFACTUREåLO-
for construction super-vision or check-
cated on housing nameplate)
out of the installation. These services
are available from Nook Industries by så3TROKEå,ENGTH
contacting the Service Department.
så0ARTå$ESCRIPTIONåSEEåPAGESå
4. The Seller’s warranty applies insofar
2
EF3335EN.1
Nook ActionJac Machine Screw Jac Instructions 3
GENERAL SPECIFICATIONS repeated operation over any segment of

total travel, consult factory.
The worm gear driven Machine Screw
Jack incorporates an alloy steel worm LUBRICATION
WHICHå DRIVESå Aå HIGHå TENSILEå BRONZEå WORMå
gear, accurately machined to the high stan- Machine Screw Jacks are shipped with
dards of Nook Industries for maximum grease in the unit. However, before op-
load carrying capacity and uniformity of erating any unit remove the housing plug
motion transmission. All shafts are mount- and check on the condition of the lubricant.
ed on heavy duty, anti-friction bearings to Lubrication inspection is recommended at
increase operating efficiency of the drive regular intervals. Usually one month in-
mechanism. Thrust bearings are provided tervals are satisfactory unlessexperience
to support the rated thrust load of each indicates that regreasing should occur at
unit. Housings are made of high strength shorter or longer intervals.
material, well proportioned to handle the
RATEDåTHRUSTåANDåTORQUEåLOADSåOFåEACHåSIZEå Each jack unit is furnished with a grease
unit. fitting and a pipe plug on opposite sides of
the housing. After removing the pipe plug,
CAUTION - In the absence of internal or fill unit with grease until lubricant seeps
external stops, it is possible to run the lift- from the pipe plug opening. Replace pipe
ing screw out of the unit. Your Machine plug. Severe operating conditions will
Screw Jack is NOT equipped with internal shorten the lubrication inspection interval.
stops unless specifically requested in your The lubricant should not be corrosive to
order. gears, ball or roller bearings and must be
neutral in reaction.
A lifting screw cover is threaded into the
bottom of the unit on the upright model, The lubricant must not contain any grit or
or in the top of the unit on the inverted dirt, abrasives or fillers. It should not pre-
model, in order to keep the lifting screw cipitate sediment, nor separate at tem-
threads free of foreign material. peratures up to 300°F. The lubricant must
also have resistance to oxidation and must
Depending upon which jack model is pur- be non-channeling. We recommend the
chased, the lifting screw is made of 4140 following extreme pressure greases or
heat treated steel, 304 or 316 stainless equivalents. For operating conditions out-
steel, or a special alloy. The threads of side these limits consult factory.
the lifting screw for all models should be
well lubricated and kept free of grit, dirt, or Temp.
other abrasive contaminants. Fabric type Company Trade Name Range
protective boots, or spiral steel protectors, Exxon* Nebulla EP#1 0 to 300°F
can be provided as an accessory to protect
the exposed portion of the lifting screw. In Mobil Mobilux EP#1 -20 to 225°F
the absence of positive stops, overtravel Areo Litholine EP#1 -20 to 200°F
may crush protective boots. Gulf Gulf Crown EP#1 0 to 250°F
CAUTION - Standard units should not be Shell Aeroshell #22 -85 to 400°F
operated at input speeds over 1,800 RPM
* Calcium base. All others Lithium base
without consulting the factory. Machine
Screw Jacks are designed for a maximum
of two hours intermittent operation per
day. For values higher than two hours per
day, for any continuous operation, or for
3
EF3335EN.1
The above recommendations are based on should be S.A.E. Grade 5 or equiva-

intermittent, medium duty service. If the lent.
Jacks are to be operated at the relative
upper limits of their ratings regarding load CAUTION - In the case of rotating units it
or speed, or the application requires con- is essential, for proper alignment and pre-
tinuous operation, consult factory. Lifting vention of screw failure, that the load be
screws should be checked periodically to attached to the traveling nut only when the
insure they are adequately lubricated. This load is in the position of travel closest to
is especially necessary in rotating units the jack housing
where no lubrication is deposited on the
lifting screw, since it does not pass through Torque values for bolting are as follows:
the jack. All Units are suitable for intermit-
tent operation in ambient temperatures up Bolt Size Approx.Torque Value
to 200°F with proper grease. If protective (in) (in-lb)
boots are used, the material must be able 1
⁄4 6
to withstand the environment. 3
⁄8 20
INSTALLATION INSTRUCTIONS 1
⁄2 50
5
⁄8 100
1. Be certain that the rating of the jack
exceeds the maximum load that may
3
⁄4 165
be imposed upon it. 7
⁄8 265
1 400
2. The foundation for the unit must
be rigid enough to maintain correct 11⁄4 830
alignment with connected machinery 11⁄2 1350
and have ample strength to carry the
13⁄4 2500
maximum load.
2 3650
3. The foundation should have a flat
mounting surface to uniformly sup- IMPORTANT - Take up evenly on mounting
port the jack unit. The opening for the bolts to avoid damaging the housing.
lifting screw cover (or lifting screw)
that passes through base must be as 6. After the Jacks, mitre boxes, cou-
small as possible to provide jack sup- plings, etc. are installed and aligned,
port over the largest possible area. there should be no signs of binding or
misalignment.
4. It is extremely important that the jack
be installed so that the lifting screw 7. Shaft coupling guards are the respon-
is exactly plumb and that all connect- sibility of the customer and are not
ing shafting is aligned with the worm provided unless specifically quoted
shaft. to and ordered by the customer.
5. After precise alignment, each mem- 8. Caution must be taken when oper-
ber must be securely bolted and if ating your jack at either extreme of
possible, doweled in place. Doweling travel. If possible, hard external stops
will assure exact repositioning if ever should be provided.
removed. It is essential that a jack
unit be securely bolted down to its 9. If operating at the upper limits of the
foundation using bolts of the proper unit rating, DO NOT STOP the down-
diameter to fit mounting holes. Bolts ward travel of the unit by running the
EF3335EN.1
lifting screw attachments or the load 3. Remove any protective coatings on

against the housing without check- replacement parts before installing.
ing with Nook Industries, as serious
damage to the internal mechanism DISASSEMBLY INSTRUCTIONS
may result. The customer is respon- 1 MSJ through 100 MSJ Models Only
sible for providing mechanical stops
and switches for control of the prime Refer to typical parts, pages 6-7. No MJ
mover. Noneare included unless spe- models are serviceable in the field. These
cifically quoted by and ordered from instructions are necessarily general, and
Nook Industries. as such, cannot provide for minor details
of construction, which may vary from unit
CAUTION - If limit switches are furnished to unit. For specific questions, consult fac-
by Nook Industries, they are NOT factory tory giving order number and serial num-
set. Limit switches should be set by care- ber from unit name plate.
fully moving to the set position by hand or
jogging. Care must be taken to avoid run- Upright or Inverted Units
ning lifting screws out of units or crushing Disassembly
boots.
1. Unscrew lifting screw cover assem-
TIPS FOR DISASSEMBLY bly from unit.
AND REASSEMBLY
2. Remove protective boot and end at-
CAUTION - Never perform any work on the tachment from lifting screw, if appli-
jack or associated transmission equipment cable.
(mitre boxes, couplings, etc.), until abso-
3. Unscrew lifting screw from drive
lutely certain that the prime mover cannot
sleeve.
be remotely or automatically started. Also
make certain that load cannot affect per- 4. Remove socket head set screws in
sonnel or machinery when the Jac, brake, housing.
or other holding devices are removed. Be
sure disassembly area is relatively clean to 5. Unscrew housing cover.
prevent contamination of parts. Store all
machined parts on wooden blocks or skids 6. Remove end caps on worm shaft as-
to prevent damage to machined surfaces. sembly.
Before starting disassembly, carefully re- CAUTION - Handle shims carefully to

view a typical parts list or certified assem- avoid damage.
bly drawing of the unit.
While tapping one end of the worm shaft
When removing end caps, be sure to tape with a wooden mallet, turn the worm
shaft extension keyways and other sharp shaft. This will loosen the bearing cup to
edges to avoid damaging oil seals. facilitate removal. (2 MSJ - 100 MSJ only)
NOTES: 7. Remove the worm shaft bearing

cups. (2 MSJ - 100 MSJ only)
1. Be sure to clean and dry all parts be-
fore rebuilding. 8. Drive sleeve and gear assembly
should now lift easily from housing.
2. It is advisable to replace old seals
when the unit is rebuilt. 9. Worm shaft assembly can be re-
moved if necessary.
EF3335EN.1
ACTIONJAC™ MACHINE SCREW JACK

6
ALL MODELS 1-MSJ THROUGH 100-MSJ*

EXPLODED VIEW OF A TYPICAL ASSEMBLY
Views are illustrative only. See page 2 for ordering spare/repair parts.
* Models MJ-20 through MJ-200 should not be disassembled. These units arer not serviceable in the field.
TRANSLATING SCREW
KEYED SCREW DESIGN ROTATING SCREW
DESIGN (UPRIGHT ASSEMBLY) DESIGN
Key (special)
Top Plate End
Hex Soc. Hex Soc.

Set Screw Travel N
Set Screw
Hex Soc. Cover Cover
Set Screw
Lifting Screw Lifting Screws
Hex Soc.
Set Screw End Cap
Shim
Thrust
Bearing
Roller Bearing
Seal Ring (Rotating Design Only)
Lifting Screw Drive Sleeve & Gear

Cover Worm Shaft
Thrust Bearing
Hex Soc. Set Screw
Grease Fitting
Housing
Roller Bearing
Housing Col. Oil Seal

Bushing
Shim
End C
Lifting Screw
Lifting Screw
Housing Plug
Cover
(Rotating Design Only)
Hex Soc.
Sealed Bearing Screw
(1 MSJ Only)
Hex Soc. Set Screw
Clevis End Cap
(1 MSJ Only)
TRANSLATING SCREW DESIGN
7
(UPRIGHT ASSEMBLY)
EF3335EN.1
NOTES: 1. Remove key retaining bolt.
1. Bearing cones are press-fitted to worm 2. By turning worm shaft, drive lifting
shaft. If removal is required use bearing screw and key from housing and re-
puller. move key.
2. Removal of the bearings from the drive 3. Remove set screws from housing
sleeves of Jacks equipped with Taper and cover.
Roller bearings, may result in their being
damaged. 4. Unscrew housing cover.
Rotating Units Disassembly 5. Remove end caps on worm shaft as-

sembly.
1. Remove set screws from housing.
CAUTION - Handle shims carefully to
2. Unscrew housing cover. avoid damage.
3. Remove end caps on worm shaft as- 6. While tapping one end of the worm
sembly. shaft with a wooden mallet, turn the
worm shaft. This will loosen the bear-
CAUTION - Handle shims carefully to ing cup to facilitate removal.
avoid damage.
7. Remove the worm shaft bearing
4. While tapping one end of the worm cups.
shaft with a wooden mallet, turn the
worm shaft. This will loosen the bear- 8. Drive sleeve and gear assembly
ing cup to facilitate removal. should now lift easily from the hous-
ing.
5. Remove the worm shaft bearing
cups. 9. Thrust bearing assembly can be re-
moved if required. (see note 2)
6. Drive sleeve and gear assembly can
now be lifted easily from the housing. 10. Worm shaft assembly can be re-
moved if necessary.
7. Thrust bearing assembly can be re-
moved if required. (see note 2) NOTES:
8. Worm shaft assembly can be re- 1. Bearing cones are press-fitted to

moved if necessary. worm shaft. If removal is required us-
ing bearing puller.
NOTES:
2. Removal of the bearings from the
1. Bearing cones are press-fitted to drive sleeves of Jacks equipped with
worm shaft. If removal is required Tapered Roller bearings, may result in
use bearing puller. their being damaged.
2. Removal of the bearings from the
drive sleeves of Jacks equipped with
Tapered Roller bearings, may result
in their being damaged.
Keyed Units Disassembly

8
EF3335EN.1
REASSEMBLY
Your jack can be easily reassembled by sembled, fill with grease, see page 3. 1
reversing the procedure as previously MSJ reassembly may required that one
outlined. In reversing disassembly proce- worm shaft ball bearing be pressed onto
dures, be sure to pack wonn, wonn gear, worm shaft after drive sleeve and worm
and all bearings with grease. Also coat all are assembled in the housing.
seal areas with grease. After unit is reas-
TROUBLE SHOOTING TIPS
Your ActionJac™ Machine Screw Jack will perform satisfactorily if suggestions described
in this booklet are carefully followed. It is estimated that approximately 98 percent of
Machine Screw Jack failures can be attributed to improper lubrication, misapplication,
and misalignment.
TROUBLESHOOTING CHART
TROUBLE WHAT TO INSPECT ACTION

Housing Failure 1. Unit Overload Reduce load or replace with
unit of sufficient capacity.
2. Improper Support Unit should be supported over
entire base area, not just at
bolt hole locations.
3. Uneven Bolting Torque Take up evenly on mounting
bolts.
Worm Shaft Failure 1. Type of Coupling Rigid Couplings can cause
shaft failure. Replace with
coupling will provide adequate
flexibility and lateral float.
2. Coupling Alignment Realign as required.
3. Presence of Excessive Check jack for allowable loads.
Overhung Load
4. Unit Overload See Housing Failure No.1.
5. Shock Loading Apply coupling capable of ab-
sorbing shock and, if neces-
sary, replace with unit of suf-
ficient capacity. Shock loads
can significantly increase ap-
parent dead weight loads.
6. "Ganging" Units If several units are "in-line", the
worm shaft of the first unit
can assume 300% of the rat-
ed input torque. If this value is
exceeded, you must replace
with a larger unit.
EF3335EN.1
TROUBLESHOOTING CHART (continued)
TROUBLE WHAT TO INSPECT ACTION

Bearing Failure 1. Unit Overload See Housing Faliure No.1
2. Excessive Overhung See Worm Shaft Faliure No. 3
Load
3. Coupling Alignment See worm shaft failure No. 2
4. Coupling Lateral Adjust spacing between con-
Alignment necting shafts to relieve end
pressure.
5. Bearing Adjustment Bearings must not be pinched.
Adjustable tapered bearings
must be set at proper lateral
clearance. All shafts should turn
freely when disconnected from
the load.
6. Bearing Lubrication Add lubricant if necessary
7. Shock Loading See Worm Shaft failure No. 5
Drive Sleeve & 1. Unit overload See Housing failure No.1
Worm Gear Wear 2. Bearing Adjustment See Bearing Failure No. 6.
3. Lubrication Proper Levels and grade must
be maintained. See lubrication
page.
Drive Sleeve & 1. Unit Overload See Housing Failure No. 1
Worm Gear Nut 2. Alignment Lifting shafts must be perfectly
Wear plumb.
3. Lubriation See Gear Wear No.3
4. Side Load Eliminate Side Load
Lifting Screw Failure 1. Unit Overload See Housing Failure No. 1.
2. Alignment See Lifting Shaft Failure No. 2.
3. Side Load Check with Nook Industries
Engineering Department for al-
LOWABLEåSIZEåLOADå
10
EF3335EN.1
ANTI-BACKLASH ADJUSTMENT
The anti-backlash feature is set at the factory and normally does not require further
adjustment. However, as wear develops with extended use, it may become necessary
to adjust lash.
ADJUSTMENT PROCEDURE
1. Loosen Locknut (Item a)
2. Loosen Set Screw(s) (Item c)
3. To reduce backlash, rotate Adjusting Cap (Item a) clockwise until resistance is felt.
(Do not over tighten)
4. Place a reference mark between thread on Adjusting Cap and Housing.
5. Rotate Adjusting Cap (Item A) counter clockwise an amount equal to the A dimen-
sion on the o.d. of the threads. (See chart)
6. Tighten Set Screws.
7. Holding Adjusting Cap (Item a) stationary, tighten Locknut (Item b).
8. Operate jack through entire stroke, checking for tight spots. Note: If jack has been
used only over a portion of its stroke, backlash should be adjusted in the least
worn portion of the screw.
CAUTION - Care should be taken not to overtighten the anti-backlash system in order
to prevent binding or lockup between the drive nut and lifting screw. Overtightening can
cause a destructive heat buildup or failure.
a b c
Item Description Jack Model A

a Adjusting Cap 1, 2, 2.5-MSJ 7
⁄32
b Locknut 5, 10-MSJ 5
⁄16
c Set Screw 15, 20, 30-MSJ 3
⁄8
35-MSJ 1
⁄2
50-MSJ 11
⁄16
75-MSJ 13
⁄16
100-MSJ 1
11
EF3335EN.1
STATEMENT OF ASSURANCE
Thank you for purchasing another quality product from Nook Industries, Inc.
Every effort has been taken to assure this product was manufactured to the
highest industry standards of quality, precision, and performance.
GUARANTEE
Unless otherwise stated herein, Seller will repair or replace, without charge,
f.o.b. point of shipment, any parts proven to Seller’s satisfaction and upon
Seller’s examination to have been defective in material or workmanship when
furnished to the original purchaser, provided claim is made within five (5)
years after date of shipment of 1⁄4 ton to 20 ton jacks or within one (1) year
after date of shipment for jacks 30 tons and larger. Deterioration or wear oc-
casioned by abuse, severe eccentric loading, overloading, chemical or abra-
sive action, or excessive heat shall not constitute defects. Equipment and
accessories not of the Seller’s manufacture are warranted only to the extent
that they are warranted by the manufacturers, and this warranty is applicable
only if the defect was the result of normal use, application, and service, and is
void if the product or any part hereof was tampered with, repaired, or altered
BYåANYåPERSONåOTHERåTHANåTHEåFACTORYåORåAUTHORIZEDåREPAIRåSTATIONå4(%2%å!2%å
NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THAT OF
MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR USE.
Under no circumstances shall Seller be liable for any loss of profit or for spe-
cial, consequential, or exemplary damages over and apart from the repair or
replacement of Seller’s part.
This warranty and any controversy or claim arising out of this warranty or
its interpretation, or any breach thereof, which cannot be amicably resolved
between Seller and the original purchaser with sixty (60) days of written no-
tice by the aggrieved party to the other, shall be finally settled by binding
arbitration submitted to the three (3) arbitrators selected from the panels of
the arbitrators of the American Arbitrator’s Association in accordance with
the rules and regulations of the American Arbitrator’s Association sitting in
Cleveland, Ohio, with each party to pay its own cost.
!UTHORIZATIONåFORåRETURNåMUSTåBEåRECEIVEDåFROMå.OOKå)NDUSTRIESåBEFOREåRETURN-
ing any equipment for inspection or warranty repair.
WARNING
The equipment shown in this bulletin is intended for industrial use only and
should not be used to lift, support, or otherwise transport human cargo, un-
less you have a written statement from Nook Industries, Inc. that the Jack
unit as used in your application is suitable for human cargo.
4950 East 49th Street / Cleveland, OH 44125

216.271.7900 - 800.321.7800 - fax: 216.271.7020
www.nookindustries.com
Source: Nook Industires, Inc. (www.nookind.com) document ’MSJ_Booklet_web’ downloaded April 18, 2014.\
EF3335EN.1
EF3335EN.1
Electro-Sensors Digital Ring Kit Information
Outside Source Information for CPM Parts
Digital Ring Kit — NEMA C Frame

DRK Single Channel Output & QDRK Quadrature Output
• High speed digital pulse train
• Easy retrofit, impervious to dust, oil, water, etc.
• Kit includes mounting ring, hardware, magnet wheel & sensor
• 60 or 120 pulses per revolution, NPN open collector output
• Line Driver Option available 5 -15 Vdc — contact factory
R
• ETL approved to UL 913-19
C LIS
US
TED
Product Information
Description Mounting Illustration:
Electro-Sensor’s Digital Ring Kit provides digital feedback from
motors with NEMA C face end bells. It can generate pulses down to
zero speed, and transmit without amplification up to 1500 feet. This is
an ideal pulse generator for speed monitoring, motor control, counting,
process control, cut-to-length, and ratio/draw controlling applications.
The DRK Series Ring Kits can be quickly and easily installed on NEMA
C face motors or between a motor and gear box. Each kit features a
non-contacting digital pulse generator system. This system includes a
199SM magnet wheel (120 magnets of alternating polarity) with a
mounting hub bored to the exact motor shaft size, and the option of a Part No. Fits NEMA Frame Shaft Size
Hall effect, quadrature, or magnetoresistive sensor with 10' of shielded (Q)DRK-56C . . . . . . . . . . . . . . . . . . . .56C . . . . . . . . . . . . . . . . . .5/8"
cable. The output of the Hall effect #1101 Sensor is 60 pulses per (Q)DRK-143TC . . . . . . . .143TC, 145TC, 182C, 184C . . . . . . . .7/8"
revolution. The output when using the #1102 magnetoresistive sensor (Q)DRK-182TC . . . . . . . .182TC, 184TC, 213C, 254C . . . . . . .1-1/8"
is 120 pulses per revolution. The DRK Ring Kit System includes a cast (Q)DRK-213TC . . . . . . .213TC, 215TC, 254UC, 256UC . . . . . .1-3/8"
aluminum mounting ring with a removable gasketed junction box, and (Q)DRK-254TC . . . . . . . . . . . . . .254TC, 256TC . . . . . . . . . . . .1-5/8"
all mounting hardware. Motor frame size and the number of pulses per
revolution needed (60 or 120) must be specified when ordering. Quadrature Output (QDRK Series)
The QDRK Quadrature Ring Kit provides a 60-pulse per revolution Provides two square wave output pulses offset from each other by 90°.
quadrature signal, for use with electronic control equipment requiring The pulses lead or lag each other depending on the direction of
rotational-direction information. Two signals, 90° out-of-phase, are shaft rotation.
produced by the sensor. When the leading edge of signal A precedes Output A
the leading edge of signal B, shaft rotation is forward. When the
Output B
opposite is true, the monitored shaft is rotating in reverse. LAGS
Clockwise
Quadrature Sensor Adjustment (QDRK Series) Figure 1

All Ring Kits are factory gapped to 0.020", and aligned for a 90° phase Gap Adjustment Screw
shift. To adjust the gap distance between the magnet ring and the
sensor, use the following steps (see figure 1): Guide Post
1. With the mounting ring and magnet wheel mounted, set the gap
adjustment screw so that it extends approximately 1/8" below the
adjustment block. Set Screws
Set Screw Adjusted when Gap is Set
2. Place the sensor with the guide post fitting into the guide hole Factory Set
and the barrel of the sensor down the neck of the ring. The
sensor face should be resting on the magnet wheel.
3. Apply a slight downward pressure on the sensor and turn the gap
adjustment screw clockwise until it rests on the base of the
junction box.
4. With continued pressure on the sensor, adjust the gap adjustment
screw 3/4 turn clockwise, raising the face of the sensor slightly off
the magnet ring, and tighten the set screws on the neck of the
Ring Kit. This procedure will result in the sensor being gapped to
approximately 0.020". The kit is now ready to run.
6111 Blue Circle Drive Free Catalog and Application Assistance

Minnetonka, MN 55343
Phone: 952-930-0100 1-800-328-6170
Fax: 952-930-0130 Visit Us Online:
ISO9001:2000 Certified www.electro-sensors.com
Source Electro Sensors (www.electro-sensors.com) document "RingKits_ES975_RevF".
EF3596EN.0 1
2 Electro-Sensors Digital Ring Kit Information
Digital Ring Kit — DRK & QDRK Series

Large NEMA C Ring Kit Small NEMA C Ring Kit
1/2 Inch NPT
Conduit Entrance 1/2 Inch NPT
E F Conduit E F
Entrance
D D
L
H * Only one set screw needed L G
H
G
to secure sensor. It is critical C
C that the magnet wheel is 2 Set-Screw
Shaft
Set-Screw Adjustments* Center
centered directly under the Adjustments*
Line K
K
sensing head in the neck of J
J
the aluminum ring. B Bolt Circle A Pilot
I
B Bolt Circle
A Pilot I
Kit A B C D E F G H I J K L M
(Q)DRK-56C . . . . . 4.50" . . . . . 5.875" . . . . . 9.04" . . . . . 1.52" . . . . . 3.85" . . . . . 1.39" . . . . . 4.86" . . . . . 6.38" . . . . . 0.78" . . . . . 0.12". . . . . . 0.16" . . . . . 5.485" . . . . . 5/8"
(Q)DRK-143TC . . . 4.50" . . . . . 5.875" . . . . . 9.04" . . . . . 1.52" . . . . . 3.85" . . . . . 1.39" . . . . . 4.86" . . . . . 6.38" . . . . . 0.78" . . . . . 0.12". . . . . . 0.16" . . . . . 5.485" . . . . . 7/8"
(Q)DRK-182TC . . . 8.50" . . . . . 7.25" . . . . . 12.81" . . . . . 1.52" . . . . . 3.85" . . . . . 1.39" . . . . . 6.47" . . . . . 8.00" . . . . . 0.86" . . . . . 0.19" . . . . . 0.21" . . . . . 7.095" . . . . 1-1/8"
(Q)DRK-213TC . . . 8.50" . . . . . 7.25" . . . . . 12.81" . . . . . 1.52" . . . . . 3.85" . . . . . 1.39" . . . . . 6.47" . . . . . 8.00" . . . . . 0.86" . . . . . 0.19" . . . . . 0.21" . . . . . 7.095" . . . . 1-3/8"
(Q)DRK-254TC . . . 8.50" . . . . . 7.25" . . . . . 12.81" . . . . . 1.52" . . . . . 3.85" . . . . . 1.39" . . . . . 6.47" . . . . . 8.00" . . . . . 0.86" . . . . . 0.19" . . . . . 0.21" . . . . . 7.095" . . . . 1-5/8"
#199SM Magnet Wheel
0.5625" Sensors #1101 & #1102

Spare Parts List Model No. Part No.
3.75"
2.0" Standard sensor . . . . . . . . . . . . . . . . . . . . . .1101 . . . . . . . . . . . . . . . . . .775-110100
0.437" Magnetoresistive sensor . . . . . . . . . . . . . .1102 . . . . . . . . . . . . . . . . . .775-110200
Magnet wheel . . . . . . . . . . . . . . . . . . . . . . .199-SM . . . . . . . . . . . . . . . .Specify bore
Quadrature Sensor (Large Ring #1202) Shielded cable 3-conductor . . . . . . . . . . . .213A . . . . . . . . . . . . . . . . .610-000200
5.50"
M Small Quadrature sensor . . . . . . . . . . . . . . .1201 . . . . . . . . . . . . . . . . . .775-120101
0.437" Large Quadrature sensor . . . . . . . . . . . . . . .1202 . . . . . . . . . . . . . . . . . .775-120201
Quadrature Sensor (Small Ring #1201) Shielded cable 4-conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .610-000500
3.750"
M = Hub bore to shaft size 0.437"
10' of cable standard.
0.3125" Consult factory for longer length.
DRK & QDRK Series Specifications: Model 1201, 1202 Quadrature Sensor, 60 PPR (cont.)
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . -20°C to +60°C*
Model 1101 Sensor, 60 PPR Hall-Effect
Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 4-conductor shielded, 10' supplied
Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24VDC @ 10mA Color code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red = Supply (+)
Model 1102 Sensor, 120 PPR Magnetoresistive White = Signal output channel A
Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24VDC @ 10mA Green = Signal output channel B
Black = Signal ground
Models 1101 and 1102 Sensors Shield = Tie to signal ground
Output Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NPN open collector
Operating Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-20KHz
Mounting Ring and Junction Box
Sensing Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040" maximum Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Casting
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Stainless steel Conduit Entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 inch NPT
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . -20°C to +60°C * 199SM Magnet Wheel
Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3-Conductor shielded, 10' supplied Magnetic Ring Material . . . . . . . . . . . . . . . . . . . . . . . . . . . Ferrous Nylon
Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red = Supply (+) Number of Magnets . . . . . . . . 120 alternating North & South Poles
Clear = Signal Output Hub Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Casting
Black = Ground Attachment Method . . . . . . . . . . . . . . . . . . . . . 2 Set-Screws, 90° Apart
Shield = Tie to signal ground Max. Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 rpm
NEMA Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bore Sizes . . . . . . . . . . . . . . . . . . . . . 5/8", 7/8", 1-1/8", 1-3/8", 1-5/8" (std)
Model 1201, 1202 Quadrature Sensor, 60 PPR Special Bores up to 3" maximum are available.
Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24VDC @ 16mA Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . -20°C to +60°C*
Output Type . . . . . . . . . . . . . . NPN open collector sink 20mA/channel Ring Kit Ratings:
Signal . . . . . . . . . . . . . . . . . . . . Quadrature, ±15° from 90° phase shift Control Number: 69003
Operating Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-20KHz Intrinsically Safe Apparatus and
Associated Apparatus for use in
Sensing Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040" maximum Class I, II and III Div I
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Stainless steel Hazardous Classified Locations UL913 (1997)
CAN/CSA-C22.2 No. 157-92
Specifications subject to change without notice. * Consult factory for higher temperature ranges ES-975 Rev F
6111 Blue Circle Drive Free Catalog and Application Assistance

Minnetonka, MN 55343
Phone: 952-930-0100 1-800-328-6170
Fax: 952-930-0130 Visit Us Online:
ISO9001:2000 Certified www.electro-sensors.com
Source Electro Sensors (www.electro-sensors.com) document "RingKits_ES975_RevF".
EF3596EN.0
Gast 4AM-NRV-70C 8-Vane Lubricated Air Motor
PART NO. 45-200 D170 Rev D-W
AM SERIES LUBRICATED AIR MOTORS

OPERATION & MAINTENANCE MANUAL
Model 2AM Shown Model 4AM Shown Model 6AM Shown Model 16AM Shown
Thank you for purchasing this Gast product. It is manufactured to the highest standards
using quality materials. This manual includes general safety instructions for operation under normal conditions and for
operation in hazardous conditions. Please follow all recommended maintenance, operational and safety instructions
and you will receive years of trouble free service.
WARNING
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS MOTOR. SAVE THIS MANUAL FOR FUTURE REFERENCE AND
KEEP IN THE VICINITY OF THE MOTOR.
General information
Operating Pressure Limits: Model Pressure
1AM 100 PSI / 7 bar
1 UP 80 PSI / 5.6 bar
2 AM 100 PSI / 7 bar
16 AM 100 PSI / 7 bar
Product Use Criteria:

• Normal conditions: Operate at temperatures up to • Motors are to be used in commercial installations only.
250 ºF (121ºC). • This symbol appears on labels of air motors that
• Hazardous conditions: Operate at temperatures up to are designed for use in hazardous atmospheres.
104ºF (40ºC). These air motors comply with the applicable
• Protect unit from dirt and moisture. standards and specifications and meet the
• Use ONLY compressed air to drive motor. requirements of the guidelines of the EC directive
• Air lines connected to motor should be the same size or 94/9EC (ATEX 100a). They are intended to be used in
the next size larger than the inlet port for efficient zones 1 and 2 where explosive atmospheres are likely
output and speed control. to occur.
• Protect all surrounding items from exhaust air. • Air supply, directional control valve and pressure regulator
• Bearings are grease packed. should be selected based upon the air consumption
• Use Gast #AD220 or a detergent SAE#10 automotive of the motor.
engine oil for lubricating.
ISO 9001 & 14001 CERTIFIED www.gastmfg.com
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright © 2003 Gast Manufacturing Inc. All Rights Reserved.
Source: Gast Manufacturing Inc., document ’lubricated_AM_OM.pdf’ (Part No. 45-200 D170 Rev. D-W) from www.gastmfg.com 2013-11-22.
EF3547EN.0 1
2 Gast 4AM-NRV-70C 8-Vane Lubricated Air Motor
Your safety and the safety of others Complete the following checklist prior to
is extremely important. starting installation in a hazardous area. All
actions must be completed in accordance with ATEX
We have provided many important safety messages in 100a.
this manual and on your product. Always read and Checklist for installation in hazardous areas:
obey all safety messages.
Read air motor label to check that
This is the safety alert symbol. This symbol motor has been designed for use
alerts you to hazards that can kill or hurt you and in a hazardous application:
others. The safety alert symbol and the words • Hazardous zone
“DANGER” and “WARNING” will precede all safety • Hazardous category
messages. These words mean: • Equipment group
• Temperature class
• Maximum surface temperatures
DANGER Example:
You will be killed or seriously injured if you donʼt follow Model designation: 1UP-NRV-10
instructions. Year manufactured: 2003
Gast Mfg. Corp.
WARNING II 2GD c +1Cº Ta +40Cº
Benton Harbor, MI USA
You can be killed or seriously injured if you donʼt follow Telephone: 269.926.6171
instructions.
* Legend:
All safety messages will identify the hazard, tell you II Equipment group II
how to reduce the chance of injury, and tell you what 2 Equipment category 2
can happen if the safety instructions are not followed. G Gas atmospheres
D Dust atmospheres
c Constructional safety
+1CTa +40C* Max. surface temp. 275ºF/135ºC
CODE SYMBOLS Ambient range +1Cº to +40ºC (34ºF/104ºF)
Check the site environment for potentially
Hazard. Possible consequences: death or explosive oils, acids, gases, vapors or radiation
severe injuries. Check the ambient temperature of the site and
the ability to maintain proper ambient
temperature.
Hazardous situation. Possible
consequences: slight or mild injuries. Ambient range:
Normal conditions: 34ºF/1ºC to 250ºF/121ºC
Hazardous conditions: 34ºF/1ºC to 104ºF/40ºC
Dangerous situation. Possible
consequences: damage to the drive or the Check the site to make sure that the air motor
environment. will be adequately ventilated and that there is
no external heat input (e.g. couplings). The
cooling air may not exceed 104ºF/40ºC.
Important instructions on protection
against explosion. Check that products to be driven by the air
motor meet ATEX approval.
Application tips and useful Check that the air motor is not damaged.
information.
INSTALLATION
Improper environment, installation and operation can
result in severe personal injury and/or damage to Correct installation is your responsibility. Make sure you
property. have the proper installation conditions.
Qualified personnel must perform all work to assemble,

install, operate, maintain and repair air motor. WARNING
Qualified personnel must follow:
• These instructions and the warning and information
labels on the motor. Injury Hazard
• All other drive configuration documents, startup
instructions and circuit diagrams.
• The system specific legal regulations and Install proper guards around output shaft as needed.
requirements. Air stream from product may contain solid or liquid
• The current applicable national and regional materials that can result in eye or skin damage.
specifications regarding explosion protection,
safety and accident prevention. Wear eye protection when installing this product.
Failure to follow these instructions can result in
serious injury or property damage.
2
EF3547EN.0
Gast 4AM-NRV-70C 8-Vane Lubricated Air Motor 3
Do not use a hammer on the shaft or

Mounting connections.
This product can be installed in any orientation. Mount
the motor to a solid metal base plate that is mounted to Lubricating the drive shaft will make assembly
a stable, rigid operating surface. Use shock mounts to easier. Use a puller for removal of pulleys,
reduce noise and vibration. Install a pressure regulator couplings and pinions on the motor shaft.
or simple shut-off valve to control motor. Check that the tension on the belt pulley matches the
manufacturerʼs specifications. Do not exceed the
Connection maximum radial and axial forces on the shaft. If the
motor shaft is connected to the part to be driven without
a coupling, check that the radial offset and axial force
effect will not cause problems.
Use only belts with < 109 electrical leakage

resistance to prevent static electrical problems.
Ground the motor.
Accessories
A muffler is shipped with the air motor (except 16AM)
but is not installed. Consult your Gast
Distributor/Representative for additional filter
recommendations. Install a moisture trap and 5 micron
filter in the air line ahead of motor.
Air consumption data at various speeds and pressures
are available from your Gast Distributor/Representative
or the factory.
Check the direction of the motor airflow. A single
rotation motor will operate properly only in one direction.
Single rotation motors require a sound absorber to be
OPERATION
connected to the air port. Remove the plastic shipping
plugs from the ports. Save plugs for future use during
shutdown.
WARNING
Install a 5-micron filter in the air line before the
connection to the motor. Next install an air pressure
regulator to control motor speed and torque.
An automatic air line lubricator should be installed in the
air line as close as possible and no more than 18 Injury Hazard
inches (1/2 meter) from the air motor. Install the Air stream from product may contain solid or liquid
lubricator level with or above the air motor so that the oil material that can result in eye or skin damage
mist will blow directly into or fall down into the motor. Do Not use cumbustible gases to drive this motor.
Wear hearing protection. Sound level from motor
Fill the oil reservoir to the proper level with Gast may exceed 85 db(A).
#AD220 or SAE 10W high detergent or non-detergent Failure to follow these instructions can result in eye
injury or other serious injury.
motor oil. For food processing applications, White Rex
425 food grade motor oil is FDA approved. Adjust
lubricator to feed 1 drop of oil for every 50 CFM of air
while the unit is running, or 1 drop of oil per continuous Check all connections before starting motor. It is your
minute of run time. Do Not overfeed oil or exhaust air responsibility to operate this product at recommended
may become contaminated. speeds, loads and room ambient temperatures. Do not
run the motor at high speeds with no load. This will
Clean the compressed air connection with low pressure
result in excessive internal heat that may cause motor
air to remove any dirt from the line before connecting to
damage.
the ports.
The starting torque is less than the running torque. The
Use the proper sized fasteners. For the most efficient
starting torque will vary depending upon the position of
output and control of speed, use air lines that are the
the vanes when stopped in relation to the air intake
same size as the motor inlet port if the connection is
port.
less than 7 feet (2 meters). For longer connections, use
the next pipe size larger than the motor intake port.
Use a pressure regulator and/or simple shut-off valve to
Connect lines to motor in the proper direction.
regulate the motor’s speed and torque. This will provide
A reversible motor will work equally well in both the required power and will conserve air. Open the air
directions. Connect a 4-way valve with piping to both supply valve to the motor. Set the pressure or flow rate
air ports of motor to make reversing possible. Connect to the required speed or torque. Adjust the lubricator to
the sound absorber on the exhaust air port or valve feed one drop of oil for every 50-75 CFM (1.5-2 M3 per
connection. minute) of air moving through motor. Check the oil level
daily. The gear reducer does not need lubrication.
Do not add any thrust to the end or side of the shaft
when making connections.
EF3547EN.0
Operate the motor for approximately 2 hours at Use only Gast recommended Flushing Solvent. DO
the maximum desired load. Measure the NOT use kerosene or ANY other combustible solvents
surface temperature of the motor on the casting to flush this product.
opposite the pipe ports. The maximum surface
1. Disconnect air line and muffler.
temperature listed on the motor is for normal
2. Add flushing solvent directly into motor. If using
environmental and installation conditions. For most air
liquid solvent, pour several tablespoons directly
motors, the maximum surface temperature should not
into the intake port. If using Gast recommended
exceed 266ºF / 130ºC. Do not continue to operate the
spray solvent for 5-10 seconds into intake port.
motor if the measured surface temperature exceeds
3. Rotate the shaft by hand in both directions for a
temperature listed on the motor. If your measured
few minutes.
temperature does exceed listed value, consult with your
4. You must wear eye protection for this step.
Gast Distributor/Representative for a recommendation.
Cover exhaust with a cloth and reconnect the air
line.
5. Restart the motor at a low pressure of
MAINTENANCE
approximately 10 PSI / 0.7 bar until there is no
trace of solvent in the exhaust air.
WARNING 6. Listen for changes in the sound of the motor. If
motor sounds smooth, you are finished. If motor
does not sound like it is running smoothly,
installing a service kit will be required
(See “Service Kit Installation”).
Injury Hazard
Check that all external accessories such as relief valves
Disconnect air supply and vent all air lines. or gauges are attached and are not damaged before
Wear eye protection when flushing this product. operating product.
Air stream from product may contain solid or liquid Cleaning sound absorber
material that can result in eye or skin damage. 1. Remove the sound absorber.
Flush this product in a well ventilated area. 2. Clean the felt filter.
3. You must wear eye protection for this step.
Do Not use kerosene or other combustible solvents Lubricate motor with 3-4 drops of oil.
to flush this product.
4. Check the air compressor.
Failure to follow these instructions can result in eye 5. Listen for changes in the sound of the motor. If
injury or other serious injury.
motor sounds smooth, you are finished. If motor
does not sound like it running smoothly, installing
It is your responsibility to regularly inspect and make
a service kit will be required (See “Service Kit
necessary repairs to this product in order to maintain
Installation”).
proper operation.
Shutdown
Lubrication
It is your responsibility to follow proper shutdown
Use Gast #AD220 or a detergent SAE #10 automotive
procedures to prevent product damage.
engine oil for lubricating. Lubricating is necessary to
1. Turn off air intake supply.
prevent rust on all moving parts. Excessive moisture in
2. Disconnect air supply and vent all air lines.
air line may cause rust or ice to form in the muffler
3. Disconnect air lines.
when air expands as it passes through the motor.
4. Remove air motor from connecting machinery.
Install a moisture separator in the air line and an after
5. Remove the muffler.
cooler between compressor and air receiver to help
6. Wear eye protection. Keep away
prevent moisture problems.
from air stream. Use clean, dry air
Manual Lubrication to remove condensation from the inlet port of the
Shut the air motor down and oil after every 8 hours of motor.
operation. Add 10-20 drops of oil to the air motor intake 7. Lubricate motor with a small amount of oil into the
port. intake port. Rotate shaft by hand several times to
distribute oil.
Automatic Lubrication
8. Plug or cap each port.
Adjust inline oiler to feed 1 drop of oil per minute for
9. Coat output shaft with oil or grease.
high speed or continuous duty usage. Do Not overfeed
10. Store motor in a dry environment.
oil or exhaust air may become contaminated.
Check intake and exhaust filters after first 500 hours of
operation. Clean filters and determine how frequently Disposal (Please note current regulations)
filters should be checked during future operation. This Parts of the air motor or air powered gear motor,
one procedure will help assure the motor’s performance shafts, cast iron or aluminum castings, gear
and service life. wheels as well as rolling contact bearings may be
Flushing recycled as scrap metal.
Flushing this product to remove excessive dirt, foreign
particles, moisture or oil that occurs in the operating
environment will help to maintain proper vane
performance. Flush the motor if it is operating slowly or
inefficiently.
4
EF3547EN.0
Estimated Ball Bearing Life of Lubricated Air Motors

Air Motor Model Shaft speed in RP Ball Bearing Life
hours L10
1AM 10,000 28,000
1UP 6,000 14,000
2AM 3,000 30,000
4AM 3,000 14,000
6AM 3,000 6,500
8AM 2,500 8,000
16AM 2,000 15,000
Based on running pressure of 60 PSI and coupling connection to motor load. The direction,
magnitude and location of applied loads to the motor shaft will change expected bearing life.
Driving the motor with wet dirty compressed air can reduce expected bearing life. The above are
life estimates not warrantied minimum values.
SPUR & WORM GEAR REDUCERS - OPERATING AND MAINTENANCE INSTRUCTIONS
General Information:
The product nameplate specifies all information required
when ordering parts or requests for information. The
type of lubricant required for unit is also specified on the
nameplate.
Product Use Criteria:

• All worm gear reducers require that the air motor be • Check the oil level in spur gear reducers which have
mounted so that the inlet and exhaust ports are at a been stored or not operated for a period of time.
90º angle to the centerline of the reducer output shaft. • Gear motors require proper lubrication. Insufficient oil
• Gear reducers are NOT self-locking. If a brake is level can cause loss of performance, damage or failure
required for safety, as in the case of air pressure failure, of the gear reducer.
etc., contact your Gast Distributor/Representative.
• Some worm gear reducers may be shipped with a plug
in the top pipe plug. The plug must be removed and the
breather plug installed for proper operation.
Spur Gear Reducer Specifications

Model GR11 GR20 GR25
Speed Range 33.3 to 400 RPM 30 to 300 RPM 20 to 200 RPM

(Reducer Output Shaft)
Gear Reduction 15:1 10:1 15:1
Maximum Allowable 100 lbs/45,4 kg 200 lbs/90,8 kg @300 250 lbs/113,5 kg at 200
End Thrust With RPM to 800 lbs/363,2 kg RPM to 800 lbs/363,2 kg
Zero Overhung Load. at 30 RPM at 20 RPM
Maximum Allowable 100 lbs/45,4 kg at 333 200 lbs/90,8 kg at 300 200 lbs/90,8 kg at 200
Overhung Load With RPM to 200 lbs/90,8 kg RPM to 600 lbs/272,4 kg RPM to 600 lbs/272,4 kg
Zero End Thrust. at 33.3 RPM at 30 RPM at 20 RPM
Lubrication Use a 300 ssu at 100˚F/38˚C turbine quality lubricant – Gast #AG292A, Gulf
Harmony 53, Shell Tellus 33, Socony DTE heavy medium or Humble Nuto 53.
For horizontal operation, remove both plugs and add oil to top hole until
other hole overflows.
For vertical operation, fill to overflow point of upper most hole.
EF3547EN.0
Worm Gear Reducer Series A-F Change output shaft direction of worm gear
Gear Reducer Specifications reducers
All output shafts are in the standard location. 1. Remove drain plug and drain oil from unit.
2. Remove end cover and seal cage cap screws.
Model Air Motor Ratio While supporting output shaft, remove end cover
and shims from unit. Keep shims with cover.
AG803 4AM 20:1
3. Remove output shaft and seal cage together from
AG805 4AM 40:1 extension side. Keep shims with seal cage.
4. Insert seal cage, shims and sub-assembly into
AG807 4AM 60:1 housing from the side opposite from which they
were removed.
AG809 6AM 10:1 5. Insert seal cage cap screws and tighten with light
pressure.
AG811 6AM 20:1 6. Assemble end cover with shims. Insert end cover
AG816 8AM 20:1 cap screws and tighten with light pressure.
7. Turn high speed shaft in both directions to check
that gear train is running freely.
Service, Parts or Repair 8. Cross-tighten seal cage and end cover cap
For service, parts or repair of the worm gear reducer, screws.
contact the manufacturer listed on the nameplate.
TROUBLESHOOTING CHART
Problem
Low Low Wonʼt Run Runs Hot Runs Well Reason & Remedy
Torque Speed Then Slows For Problem.
Down
• • • Dirt or foreign material present.

Inspect and flush.
• • • Internal rust. Inspect and flush.
• • Low air pressure. Increase pressure.
• Air line too small. Install larger line(s).
• • Restricted exhaust. Inspect and repair.
• • • • Motor is jammed. Have motor serviced.
• • Air source inadequate. Inspect and repair.
• • Air source too far from motor.

Reconfigure setup.
EF3547EN.0
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION 1AM/1UP SERIES
1AM SERIES
REF# DESCRIPTION QTY 1AM-NCC-12 1AM-NCW-14 1AM-NRV-39A 1AM-NRV-56 1AM-NRV-60 1AM-NRV-63A
1Δ SEAL 1 AC190A AC190A AC190A AC190A AC190A AC190A

2Δ BEARING 2 AG549 AG549 AG549 AG549 AG549 AG549
3 DOWEL PIN 1 D324A D324A D324A D324A D324A D324A
4 DRIVE END PLATE 1 AC537 AC539 AC520 AC520D AC520D AC520
5 ΔΔ SHIMS 2 AC527B AC527B AC527B AC527B AC527B AC527B
6 BODY 1 AC521 AC521 AC191 AC191 AC191 AC191
7 CAM RING 2 AC195 AC195 AC195 AC195
8 ROTOR ASSEMBLY 1 AC524 AC536 AC193 AC187 AC607 AC193B
9Δ VANE 4 AC205A AC205A AC259A AC259A
8 AC259A AC259A
10 DEAD END PLATE 1 AC538 AC540 AC192 AC192 AC192 AC192
11 Δ END CAP GASKET 1 AC229 AC229 AC229 AC229 AC229 AC229
12 DEAD END CAP 1 AC228A AC228A AC228A AC228A AC228A AC228A
*** Δ MUFFLER 1 AF350 AF350 AF350 AF350 AF350 AF350
*** FOAM 1 AG896 AG896 AG896 AG896 AG896 AG896
*** SERVICE KIT 1 K200 K200 K201 K201 K278 K278
1UP SERIES
REF# DESCRIPTION QTY 1UP-NCC-1A 1UP-NCW-2A 1UP-NRV-3A 1UP-NRV-4 1UP-NRV-10 1UP-NRV-11
1Δ SEAL 1 AC190A AC190A AC190A AC190A AC190A AC190A

2Δ BEARING 2 AG549 AG549 AG549 AG549 AG549 AG549
3 DOWEL PIN 1 D324A D324A D324A D324A D324A D324A
4 DRIVE END PLATE 1 AC616 AC520B AC520 AC520D AC520 AC520D
5 ΔΔ SHIMS 2 AC527B AC527B AC527B AC527B AC527B AC527B
6 BODY 1 AE899 AE899 AE898 AE898 AE898 AE898
7 CAM RING 2 AC195 AC195 AC195 AC195
8 ROTOR ASSEMBLY 1 AE896 AE895 AE897 AF746 AE319 AE333
9Δ VANE 4 AE893 AE893 AE894 AE894
8 AE894 AE894
10 DEAD END PLATE 1 AC617 AC192A AC192 AC192 AC192 AC192
11 Δ END CAP GASKET 1 AC229 AC229 AC229 AC229 AC229 AC229
12 DEAD END CAP 1 AC228A AC228A AC228A AC228A AC228A AC228A
*** Δ MUFFLER 1 AF350 AF350 AF350 AF350 AF350 AF350
*** FOAM 1 AG896 AG896 AG896 AG896 AG896 AG896
*** SERVICE KIT 1 K285 K285 K286 K286 K298 K298
*** Item not shown.

Δ Denotes parts included in the Service Kit.
ΔΔ Parts listed are for stock models manufactured prior to 1998. For specific OEM models, please consult the factory.
When corresponding about or ordering parts, please give complete model and serial numbers.
7 Exploded views are shown for reference only. Units may vary depending upon specific model.
EF3547EN.0
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION 2AM SERIES
2AM SERIES
REF# DESCRIPTION QTY 2AM-FCC-1 2AM-NCW-7A 2AM-FCW-13 2AM-NCC-16 2AM-NCC-43A 2AM-NRV-90 2AM-ACC-88 2AM-ARV-92
METRIC METRIC
1Δ SHAFT SEAL 1 AA466B AA466B AA466B AA466B B2328 B2328
2Δ DRIVE END BEARING 1 AA299J AA299J AA299J AA299J AB519 AB519
2A Δ DEAD END BEARING 1 AA299J AA299J AA299J AA299J AA299J AA299J
3 DOWEL PIN 4 AB162 AB162 AB162 AB162 AB162C AB162C
4 DRIVE END PLATE 1 AC720 AC726 AC722 AC724 AG708 AK425A
5 Δ ** SHIMS 2 B330 B330 B330 B330 B330 B330
6 ROTOR ASSEMBLY 1 AA470A AA489A AA489A AA470A AM449A AM449B
7Δ VANE 4 AA13B AA13B AA13B AA13B AA13B AA13B
8 BODY 1 AA477 AA467 AA477 AA467 AA467 AA467F
9 DEAD END PLATE 1 AC721 AC723 AC723 AC721 AC721 AB622N
10 Δ END CAP GASKET 1 AA46 AA46 AA46 AA46 AA46 AA46
11 END CAP 1 AM307D AM307D AM307D AM307D AM307D AM307D
12 MUFFLER ASSEMBLY 1 AL445 AL445 AL445 AL445 AL445 AL445
13 MUFFLER FELT 1 AC983 AC983 AC983 AC983 AC983 AC983
*** SERVICE KIT 1 K202 K202 K202 K202 K203A K203A
*** Item not shown.

** #AL484 (5A) O-ring replaces shim on some models.
For specific OEM models, please consult the factory.
Exploded views are shown for reference only. Units may vary depending upon specific model.
8
EF3547EN.0
EXPLODED PRODUCT VIEWS, PARTS & ORDERING INFORMATION 4AM SERIES
4AM SERIES
REF# DESCRIPTION QTY 4AM-FRV-13C 4AM-NRV-22B 4AM-FRV-24 4AM-NRV-50C 4AM-NRV-54A 4AM-FRV-63A 4AM-NRV-70C 4AM-ARV-119 4AM-ARV-120
METRIC METRIC
1Δ SHAFT SEAL 1 AC466B AC466B NAS2 B2328 AA466B B2328 B2328 B2328
2Δ DRIVE END BEARING 1 AA299J AA299J AA299J AB519 AA299J AB519 AB519 AB519
2A Δ DEAD END BEARING 1 AA299J AA299J AA299J AA299J AA299J AA299J AA299J AA299J
3 DRIVE END PLATE 1 AC727 AC665 AC727 AG707 AC665` AG707 AK425A AK425A
4 ROTOR ASSEMBLY 1 AB617 AB617 AM426 AM455A AM411 AM319A AM455C AM455B
5Δ VANE 4 AB876 AB876 AB876 AB876 AB876
8 AB876 AB876 AB876
6Δ PUSH PINS 4 AM467 AM467 AM467 AM467 AM467
8 AM467 AM467 AM467
7Δ VANE SPRING 2 AM466 AM466 AM466 AM466 AM466
4 AM466 AM466 AM466
8 BODY 1 AM425 AM410 AM425 AM410 AM410 AM410 AM410M AM410M
9 Δ ** SHIMS 2 B330 B330 B330 B330 B330 B330 B330 B330
10 DEAD END PLATE 1 AC728 AC728 AC727 AC728 AC728 AC728 AB622M AB622M
11 Δ END CAP GASKET 1 AA46 AA46 AA46 AA46 AA46 AA46 AA46
12 DEAD END CAP 1 AM307D AM307D AM307D AM307D AM307D AM307D AM307D
13 MUFFLER ASSEMBLY 1 AL445 AL445 AL445 AL445 AL445 AL445 AL445 AL445
14 Δ MUFFLER CARTRIDGE 1 AL458 AL458 AL458 AL458 AL458 AL458 AL458 AL458
15 Δ MUFFLER FELT 1 AC983 AC983 AC983 AC983 AC983 AC983 AC983 AC983
*** SERVICE KIT 1 K205 K205 K205G K206A K279 K280A K206C K206B
4AM SERIES
REF# DESCRIPTION QTY 4AM-RV-75
1 GEAR STD. 1 AA294

2Δ BEARING 2 AA299J
3 PIN 1 AA297
4 ROTOR 1 AA293
5Δ VANE 4 AB876
6Δ SPRING PIN 4 AM467
7Δ SPRINGS 2 AM466
8 BODY 1 AM410
9Δ SHIMS 2 B330
10 DEAD END PLATE 1 AC728
*** Item not shown.
** #AL484 (9A) O-ring replaces shim on some models. 11 Δ END CAP GASKET 1 AA46
Δ Denotes parts included in the Service Kit. 12 END CAP 1 AM307D
For specific OEM models, please consult the factory. 13 DRIVE END PLATE 1 AA424
When corresponding about or ordering parts, 14 SEAL 1 AA466B
please give complete model and serial numbers. 15 DOWEL PINS 4 AB162
Exploded views are shown for reference only. 16 1/4-28 x .50 PFHMS 6 BB631
Units may vary depending upon specific model. 17 1/4-28 x .625 SHCS 6 BB634
*** SERVICE KIT 1 K205
EF3547EN.0
6AM SERIES
REF# DESCRIPTION QTY 6AM-FRV-5A 6AM-NRV-7A 6AM-NRV-22A 6AM-FRV-23A 6AM-ARV-54 6AM-ARV-55 6AM-NRV-11A
NEMA
1 DRIVE END CAP 1 AD642A AD642A AD642A AD642A AC988 AC988 AD642A
2Δ SHAFT SEAL 1 AC849 AC849 AC849 AC849 AK423 AK423 AC849
3Δ O-RING 1 AD649 AD649 AD649 AD649 AC989 AC989 AD649
4Δ DRIVE END BEARING 1 AD638A AD638A AD638A AD638A AC894B AC894B AD638A
5 DOWEL PIN 4 AB162 AB162 AB162C AB162 AB162C AB162C AB162C
6 DRIVE END PLATE 1 AD651 AD666 AD667 AD651 AK424 AK424 AD667
7Δ BODY GASKET 2 AD641 AD641 AD641 AD641 AD641 AD641 AD641
8 BODY 1 AD650A AD665 AD665 AD650A AD665D AD665D AD665
9 KEY 1 AB136 AB136 AB136 AB136 AK422 AK422 AB136
10 ROTOR ASSEMBLY 1 AD652 AD652 AC398 AC779 AD648E AD648D AD648
11 Δ PUSH PIN 2 AD655A AD655A AD655A AD655A
4 AD655A AD655A AD655A
12 Δ VANE SPRING 4 AD692 AD692 AD692 AD692
8 AD692 AD692 AD692
13 Δ VANE 4 AD691 AD691 AD691 AD691
8 AD691 AD691 AD691
14 DEAD END PLATE 1 AD651 AD651 AD651 AD651 AD651 AD651 AD651
15 Δ DEAD END BEARING 1 AB519 AB519 AB519 AB519 AB519 AB519 AB519
16 Δ END CAP GASKET 1 AD644 AD644 AD644 AD644 AD644 AD644 AD644
17 DEAD END CAP 1 AD643 AD643 AD643 AD643 AD643 AD643 AD643
*** MUFFLER ASSEMBLY 1 AC990 AC990 AC990 AC990 AC990 AC990 AC990
*** MUFFLER FELT 1 AC993 AC993 AC993 AC993 AC993 AC993 AC993
*** SERVICE KIT 1 K208 K208 K281 K281 K281A K281B K208
*** Item not shown.

10
EF3547EN.0
8AM SERIES
REF# DESCRIPTION QTY 8AM-FRV-2B 8AN-NRV-5B 8AM-NRV-28A 8AM-FRV-30A 8AM-NRV-32A 8AM-NRV-42A 8AM-ARV-70 8AM-ARV-71
METRIC METRIC
1 DRIVE END CAP 1 AC835A AC835A AC988 AC835A AC988 AC835A AC988 AC988
2Δ SHAFT SEAL 1 AC839 AC839 AB936 AC839 AB936 AC839 AK420 AK420
3Δ O-RING 1 AC808 AC808 AC989 AC808 AC989 AC808 AC989 AC989
4Δ DRIVE END BEARING 1 AA735B AA735B AB927 AA735B AB927 AA735B AB927 AB927
5 DOWEL PIN 4 AB162 AB162 AB162 AB162 AB162 AB162 AB162 AB162
6 DRIVE END PLATE 2 AC964 AC963 AC965 AC964 AC965 AC963 AK421 AK421
7Δ BODY GASKET 2 AC888 AC888 AC888 AC888 AC888 AC888 AC888 AC888
8 BODY 1 AC877A AC878C AC878C AC877A AC878C AC878C AC878G AC878G
9 KEY 1 AB136D AB136D AB136D AB136D AB136D AB136D AK668 AK668
10 ROTOR ASSEMBLY 1 AC977 AC977 AC986 AC977A AC986A AC977A AC986D AC986C
11 Δ PUSH PIN 2 AC879 AC879 AC879 AC879
4 AC879 AC879 AC879 AC879
12 Δ VANE SPRING 4 AC817 AC817 AC817 AC817
8 AC817 AC817 AC817 AC817
13 Δ VANE 4 AC816 AC816 AC816 AC816
8 AC816 AC816 AC816 AC816
14 DEAD END PLATE 1 AC964 AC964 AC964 AC964 AC964 AC964 AC964 AC964
15 Δ DEAD END BEARING 1 AC894B AC894B AC894B AC894B AC894B AC894B AC894B AC894B
16 Δ END CAP GASKET 1 AC837 AC837 AC837 AC837 AC837 AC837 AC837 AC837
17 DEAD END CAP 1 AC836 AC836 AC836 AC836 AC836 AC836 AC836 AC836
*** MUFFLER ASSEMBLY 1 AC990 AC990 AC990 AC990 AC990 AC990 AC990 AC990
*** MUFFLER FELT 1 AC993 AC993 AC993 AC993 AC993 AC993 AC993 AC993
*** SERVICE KIT 1 K210 K210 K211 K283 K282 K283 K282A K282B
*** Item not shown.

11
EF3547EN.0
16AM SERIES
REF# DESCRIPTION QTY 16AM-FCC-2 16AM-FRV-2 16AM-FRV-13 16AM-FCW-28
1 DRIVE END CAP 1 AD816 AD816 AD816 AD816

2Δ SEAL 1 AC627 AC627 AC627 AC627
3Δ O-RING 1 AD823 AD823 AD823 AD823
4 LOCKNUT 1 AD784 AD784 AD784 AD784
5Δ LOCKWASHER 1 AD712 AD712 AD712 AD712
6Δ DRIVE END BEARING 1 AB777A AB777A AB777A AB777A
7 SPACER AD786 AD786 AD786 AD786
8 DRIVE END PLATE 1 AD771A AD820A AC323
9 DOWEL PIN 4 AB162A AB162A AB162A AB162A
10 Δ SPACER GASKET 2 AD788 AD788 AD788
11 BODY 1 AD770 AD819 AD819 AD770B
12 DRIVE KEY 1 AC628 AC628 AB136D AC628
13 ROTOR ASSEMBLY 1 AD775 AD794 AE807
14 Δ PUSH PIN 3 AD822 AD822
15 Δ VANE SPRING 6 AD796A AD796A
16 Δ VANE 6 AD781 AD795 AD795 AD781
17 DEAD END PLATE 1 AD773A AD821A AD821A
18 Δ DEAD END BEARING 1 AD802 AD802 AD802 AD802
19 END CAP GASKET 1 AG406 AG406 AG406 AG406
20 DEAD END CAP 1 AG405 AG405 AD405 AG405
*** SERVICE KIT 1 K212 K213 K213 K212
*** Item not shown.

12
EF3547EN.0
EXPLODED PRODUCT VIEWS, PARTS & ORDERING INFORMATION
GR11 SERIES
REF# DESCRIPTION QTY PART NO.
1 GEAR HOUSING 1 AC737

2 GEAR HOUSING COVER 1 AC736
3 GEAR SHAFT 1 AC739
4 CLUSTER GEAR 1 AC738
5 SNAP-RING 1 AE189
6 BEARING 1 AE196A
7 SEAL 1 AA517A
8 BEARING 1 AA498
9 BEARING 1 AE195
10 O-RING 1 AD823
11 BEARING 1 AE197
12 SEAL 1 AA623D
13 SCREWS 4 BB542
14 PIPE PLUG 2 BA500
15 SET SCREW 2 BB626
*** DOWEL PIN 2 AE882
*** Item not shown.
GR20 SERIES
1 GEAR SHAFT - OUTPUT 1 AE848

2 RETAINING RING 1 AE853
3 BEARING 1 AE858
4 OIL SEAL 1 AE852
5 BEARING 1 AE857
6 SCREW 6 BB652
*** DOWEL PIN 2 AF482
8 MAGNETIC DRAIN PLUG 2 AH471
9 GEAR - INPUT 1 AA294
10 OIL SEAL 1 AE851
11 HOUSING COVER 1 AE849
12 O-RING 1 AE854
13 GEAR HOUSING 1 AE850
14 GEAR SHAFT 1 AE845
15 GEAR - INTERMEDIATE 1 AE846
16 KEY 1 AE855
17 BEARING 2 AG549
18 KEY 1 AC628
*** Item not shown.

GR25 SERIES
1 BEARING 2 AG549
2 GEAR SHAFT 1 AE845
3 GEAR INTERMEDIATE 1 AE846
4 GEAR HOUSING 1 AE850
5 SEAL 1 AE851
6 SEAL 1 AE852
7 RETAINING RING 1 AE853
8 O-RING 1 AE854
9 KEY 1 AE855
10 BEARING 1 AE857
11 BEARING 1 AE858
*** DOWEL PIN 2 AF482
13 HOUSING COVER 1 AH278
14 GEAR SHAFT - OUTPUT 1 AH279
15 MAGNETIC DRAIN PLUG 2 AH471
16 SCREWS 6 BB652
17 KEY 1 AC628
13
EF3547EN.0
WARRANTY
Gast finished products, when properly installed and operated under normal conditions of use, are warranted by Gast to
be free from defects in material and workmanship for a period of twelve (12) months from the date of purchase from
Gast or an authorized Gast Representative or Distributor. In order to obtain performance under this warranty, the buyer
must promptly (in no event later than thirty (30) days after discovery of the defect) give written notice of the defect to
Gast Manufacturing Incorporated, PO Box 97, Benton Harbor Michigan USA 49023-0097 or an authorized Service
Center (unless specifically agreed upon in writing signed by both parties or specified in writing as part of a Gast OEM
Quotation). Buyer is responsible for freight charges both to and from Gast in all cases.
This warranty does not apply to electric motors, electrical controls, and gasoline engines not supplied by Gast. Gast’s
warranties also do not extend to any goods or parts which have been subjected to misuse, lack of maintenance,
neglect, damage by accident or transit damage.
THIS EXPRESS WARRANTY EXCLUDES ALL OTHER WARRANTIES OR REPRESENTATIONS EXPRESSED OR

IMPLIED BY ANY LITERATURE, DATA, OR PERSON. GAST’S MAXIMUM LIABILITY UNDER THIS EXCLUSIVE
REMEDY SHALL NEVER EXCEED THE COST OF THE SUBJECT PRODUCT AND GAST RESERVES THE RIGHT,
AT ITS SOLE DISCRETION, TO REFUND THE PURCHASE PRICE IN LIEU OF REPAIR OR REPLACEMENT.
GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND,
however arising, including but not limited to those for use of any products, loss of time, inconvenience, lost profit, labor
charges, or other incidental or consequential damages with respect to persons, business, or property, whether as a
result of breach of warranty, negligence or otherwise. Notwithstanding any other provision of this warranty, BUYER’S
REMEDY AGAINST GAST FOR GOODS SUPPLIED OR FOR NON-DELIVERED GOODS OR FAILURE TO FURNISH
GOODS, WHETHER OR NOT BASED ON NEGLIGENCE, STRICT LIABILITY OR BREACH OF EXPRESS OR
IMPLIED WARRANTY IS LIMITED SOLELY, AT GAST’S OPTION, TO REPLACEMENT OF OR CURE OF SUCH
NONCONFORMING OR NON-DELIVERED GOODS OR RETURN OF THE PURCHASE PRICE FOR SUCH GOODS
AND IN NO EVENT SHALL EXCEED THE PRICE OR CHARGE FOR SUCH GOODS. GAST EXPRESSLY DISCLAIMS
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE WITH RESPECT
TO THE GOODS SOLD. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTIONS SET
FORTH IN THIS WARRANTY, notwithstanding any knowledge of Gast regarding the use or uses intended to be made
of goods, proposed changes or additions to goods, or any assistance or suggestions that may have been made by Gast
personnel.
Unauthorized extensions of warranties by the customer shall remain the customer’s responsibility.
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMER’S
USE OR RESALE, OR FOR INCORPORATING THEM INTO OBJECTS OR APPLICATIONS WHICH CUSTOMER
DESIGNS, ASSEMBLES, CONSTRUCTS OR MANUFACTURES.
This warranty can be modified only by authorized Gast personnel by signing a specific, written description of any
modifications.
MAINTENANCE RECORD
DATE PROCEDURE PERFORMED
14
EF3547EN.0
MAINTENANCE RECORD
DATE PROCEDURE PERFORMED
For repair parts ordering information and exploded product view, visit our
website or call us at the number listed below.
We have Gast Authorized Repair Facilities throughout the world. For the most
up-to-date listing, contact one of our sales offices below:
European Sales & Service
Gast Manufacturing, Inc. Gast Hong Kong Headquarters
P.O. Box 97 Gast Group Limited
2300 Highway M139 Unit 12, 21/F, Block B
New Trade Plaza A Unit of IDEX Corporation
Benton Harbor, MI 49022 Unit 11, The I O Centre
Ph: 269/926-6171 6, On Ping Street, Shatin
N. T. Hong Kong Nash Road
FAX: 269/925-8288 Redditch B98 7AS
www.gastmfg.com Ph: (852) 2690 1066
Fax: (852) 2690 1012 United Kingdom
www.gasthk.com Tel: +44 (0) 1527 504040
Fax: +44 (0) 1527 525262
www.gastmfg.com
www.jun-air.com
ISO 9001 & 14001 CERTIFIED www.gastmfg.com
EF3547EN.0
Air Motors
up to 11/2 HP, speeds from 300 to 3,000 rpm, max. pressure 100 psi (7 bar)
MODEL
Product Dimensions (inches, mm)
4AM-FRV-24 (4 Vanes, Dual Shaft)
4AM-FRV-13C (4 Vanes, Reversible) 1.25 1.25 5.81
147,6
31,8 31,8 3.25
4AM-FRV-63A (8 Vanes, Reversible) 1/4 PIPE 1/4 PIPE
1.12
82,6
28,4
Net wt. 9 lbs (4,1 kg)
5.32
FEATURES 135,1
s &OOT MOUNTING 5.04 3.50 0.50 DIA.

12,7
s !NY PLANE OPERATION 128,0 88,9
s 3INGLE OR DUAL SHAFT
s -ETAL MUFmER !# ADDS HEIGHT WHEN
installed 1.50 1.50 2.78 0.94
0.28 HOLE (4) 38,1 38,1 0.38 70,6
7,1 1.50 23,9
3.75 9,7
95,3 38,1
s II 2 GD c T4
RECOMMENDED
s &ILTER !(&
s 2EGULATOR !(2
s 'AUGE !!
s ,UBRICATOR !(,
s /IL !$ n QUART LITRES
s 2EPAIR KIT + 6ANE 2EVERSIBLE
4AM-NRV-22B (4 Vanes, Reversible) Product Dimensions (inches, mm)
4AM-NRV-54A (8 Vanes, Reversible) 5.81

147,6
3.25
Net wt. 9 lbs (4,1 kg) 82,6
1/4 PIPE 2.50 1.12
FEATURES 63,5 28,4
1.25 0.63
31,8 0.50
s &ACE MOUNTING 12,7 16,0
s !NY PLANE OPERATION 1.72
#3 WKW
s -ETAL MUFmER !# ADDS HEIGHT WHEN 43,7

installed 15b 1.750 DIA.
44,45
3.94
100,1 0.16
s II 2 GD c T4 4,1
0.500 DIA.
RECOMMENDED 1.25 0.25 0.31 12,7
31,8 R 6,35 -20 THD. 7,9 DP HOLE (3) 0.555
s &ILTER !(&
14,1
s 2EGULATOR !(2
s 'AUGE !!
s ,UBRICATOR !(,
4AM-NRV-50C (4 Vanes, Reversible) Product Dimensions (inches, mm)

4AM-NRV-70C (8 Vanes, Reversible)
6.69
Net wt. 12 lbs (5,4 kg) 1/4 PIPE INLET 169,9
1/4 PIPE EXHAUST 2.06 2.06
52,3 52,3
FEATURES 1.25 0.38 -16 THD. 0.13
31,8 9,65 (4HLS.) 1.41 3,3
s .%-! # MOUNTING 0.19 SQ. KEY 35,8
s !NY PLANE OPERATION 4,83
s -ETAL MUFmER !# ADDS HEIGHT WHEN 4.50
114,3 DIA.
installed
s II, 2 GD c T4
5.88
149,4
RECOMMENDED 0.625 DIA.
s &ILTER !(& 45q
15,88
s 2EGULATOR !(2 6.50
0.704
165,1 17,88
s 'AUGE !!
s ,UBRICATOR !(,
s 2EPAIR KIT +! 6ANE
s 2EPAIR KIT +! 6ANE
www.gastmfg.com Gast Air Motors / Gear Motors 13
Source: Gast Manufacturing Inc., document ’Airmotor_D-10_Catalog_Final_Feb09-2012_lo-res.pdf’ page 13 from www.gastmfg.com 2013-11-22.
EF3547EN.0
Gates Belt Drive Preventive Maintenance & Safety Manual
BELT DRIVE
PREVENTIVE MAINTENANCE
AND SAFETY MANUAL
www.gates.com/drivedesign
Source: The Gates Corporation (www.gates.com) ’Preventive Maintenance’, copyright 2013.
EF3328EN.2 1
2 Gates Belt Drive Preventive Maintenance & Safety Manual
TABLE OF CONTENTS
Safety Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Sources of Drive Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Drive Shutdown & Thorough Inspection
Simple Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Preventive Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Measuring Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Belt Storage & Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Belt Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Belt Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Belt Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Static Conductive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Belt Drive Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Sprocket Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Problem/Solution Summary Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
NEMA Minimum Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Minimum Recommended Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Installation & Tensioning Allowances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Idler Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Drive Survey Worksheet
High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Low Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Design IQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Trademarks & Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Copyright 2013
Gates Corporation
Denver, Colorado 80217-5887
EF3328EN.2
Gates Belt Drive Preventive Maintenance & Safety Manual 3
SAFETY POLICY
Warning! Be Safe! Gates belt drive systems are very reliable when used safely and within
Gates application recommendations. However, there are specific USES THAT MUST BE
AVOIDED due to the risk of serious injury or death. These prohibited misuses include:
Primary In-Flight Aircraft Systems

Do not use Gates belts, pulleys or sprockets on aircraft, propeller or rotor drive systems
or in-flight accessory drives. Gates belt drive systems are not intended for aircraft use.
Lift Systems
Do not use Gates belts, pulleys or sprockets in applications that depend solely upon the
belt to raise/lower, support or sustain a mass without an independent safety backup
system For applications requiring special “Lift” or “Proof” type chains with minimum
tensile strength or certified/test tensile strength requirements, be advised that because
Gates belts have different drive design procedures from metal chains, the tensile strength
of a belt when compared to the tensile strength of a chain should only be a part of the
design process. Diligent analysis with the customer’s participation should be sued when
considering any such application.
Braking Systems
Do not use Gates belts, pulleys or sprockets in applications that depend solely upon the
belt to slow or stop a mass, or to act as a brake without an independent safety backup
system. Gates belt drive systems are not intended to function as a braking device in
“emergency stop” systems.
DRIVE DESIGN SOFTWARE

Drive design software can be found at
www.gates.com/drivedesign.
This software assists designers in quickly
selecting optimum drive solutions
EF3328EN.2
SOURCES OF DRIVE PROBLEMS
Poor Drive Design

Improper Belt or Improper Belt
Pulley Installation Storage or Handling
Environmental
Factors
Defective Drive
Components
Improper Drive
Maintenance
EF3328EN.2
PREVENTIVE MAINTENANCE
Why have a preventive maintenance program?

When compared to the constant lubrication problems
associated with chain drives, or the mechanical problems
and high costs associated with gear drives, belts are the
most cost-effective, reliable means of power transmission.
However, optimum belt drive performance requires
proper maintenance. The potential for long service life is
built into every Gates belt. When coupled with a regularly
scheduled maintenance program, belt drives will run rela-
tively trouble-free for a long time.
Belt drive should have adequate guard
Carefully inspect all belts

Power should be shut off and controls locked * Note - If belt looks bad, it probably is
before inspecting
Important to your business
An effective preventive maintenance program saves time
and money. Inspecting and replacing belts and faulty drive
components before they fail will reduce costly downtime
and production delays.
What is a good belt maintenance program?
A comprehensive, effective program of preventive mainte-
nance consists of several elements:
• Maintaining a safe working
environment.
• Regularly scheduled belt drive inspections.
• Proper belt installation
procedures.
• Belt drive performance
evaluations.
• Belt product knowledge.
• Belt storage and handling.
• Troubleshooting.
EF3328EN.2
SAFETY
Maintaining A Safe Working Environment Maintain Safe Access to Drives

It is common sense to establish a safe working environment Always maintain safe access to the belt drives. Keep area
in and around belt drives. The following precautions will around drives free of clutter, debris and other obstructions.
make belt drive inspection and maintenance easier Floors should be clean and free of oil and debris to insure
and safer. good footing and balance while working on machinery.
Power should be shut off and controls locked

before inspecting
Don’t clutter area around belt drive
Wear Proper Clothing Drive Guards

Never wear loose or bulky clothes, such as neckties, exposed Always keep drives properly guarded. Every belt drive must
shirttails, loose sleeves or loose lab coats around belt drives. be guarded when in operation. Guard must be designed
Remove jewelry and tie up or restrain long hair. Wear gloves and installed according to OSHA standards.
while inspecting sheaves or sprockets to avoid being cut
by nicks, burrs or sharply worn pulley edges. Wear safety
glasses to avoid eye injuries. Don’t be foolish! Wear proper
clothing. Always wear proper personal protective equipment,
including gloves, eye & ear protection, steel toe shoes, and
a hard hat.
A properly guarded belt drive
A Properly Guarded Belt Drive

A properly designed guard has the following features:
• Completely encloses drive.
• Grills or vents for good ventilation.
• Accessible inspection door or panels.
• Can easily be removed and replaced if damaged.
• Where necessary, should protect the drive from
weather, debris and damage.
No loose or bulky clothing. This technician’s bulky
lab coat is a hazard near moving components
Follow these precautions to make your preventive
maintenance easier.
EF3328EN.2
DRIVE SHUTDOWN & THOROUGH INSPECTION
Simple Drive Inspection How Often To Inspect

Begin preventive maintenance with a periodic drive inspec- The following factors influence how often to inspect a drive.
tion as a normal part of your maintenance rounds. Look and
listen for any unusual vibration or sound while observing the • Critical nature of equipment
guarded drive in operation. A well designed and maintained • Drive operating cycle
drive will operate smoothly and quietly. • Accessibility of equipment
Inspect guard for looseness or damage. Keep it free of • Drive operating speed
debris or dust and grime buildup on either the inside or the • Environmental factors
outside of the guard. Any accumulation of material on the • Temperature extremes in environment
guard acts as insulation, and could cause drives to run hot-
ter. Experience with specific equipment is the best guide to how
often to inspect belt drives. Drives operating at high speeds,
The effect of temperature on belt life is important. For heavy loads, frequent stop/start conditions and at tempera-
example, an internal temperature increase of 18°F (or ture extremes or operating on critical equipment require
approximately 36°F rise in ambient drive temperature) may frequent inspection.
cut belt life in half. Beware of hot surfaces and the potential
for injury. When To Perform Preventive Maintenance
Also look for oil or grease dripping from guard. This may To help establish a preventive maintenance schedule, keep
indicate over-lubricated bearings. If this material gets on the following in mind.
rubber belts, they may swell and become distorted, leading
to early belt failure. Critical Drives
It’s a good idea to check motor mounts for proper tightness. A quick visual and noise inspection may be needed every
Check take-up slots or rails to see that they are clean and one to two weeks.
lightly lubricated.
Normal Drives
With most drives, a quick visual and noise inspection can be
performed once a month.
Complete Inspection
A drive shutdown for a thorough inspection of belts,
sheaves or sprockets and other drive components may be
required every three to six months.
Remember, a well-designed industrial belt drive is capable
of operating for several years when properly maintained and
used under normal conditions.
Follow the Preventive Maintenance Procedure on the fol-
lowing page when performing detailed maintenance during
equipment shutdowns.
EF3328EN.2
Preventive Maintenance Check List

By following these steps, belt drives can be maintained
efficiently and safely.
1. Always turn off the power to the drive. Lock the con-
trol box and tag it with a warning sign “Down For
Maintenance. Do Not Turn Power On.”
Make sure the power is turned off for the
correct drive. Never have contact with a belt
drive unless the system is tagged and locked
out.
2. Test to make sure correct circuit has been turned off.
3. Place all machine components in a safe (neutral) Turn off power, lock controls and tag
position. Make sure that moving components are
locked down or are in a safe position. Make sure
that fans cannot unexpectedly freewheel.
8. Inspect other drive components such as bearings,
4. Beware of pinch points. Keep hands and fingers shafts, motor mounts and take-up rails.
clear, especially where belts enter sheaves and
9. Inspect static conductive grounding system (if used)
sprockets.
and replace components as needed.
5. Remove guard and inspect for damage. Check for
10. Check belt tension and adjust as needed.
signs of wear or rubbing against drive components.
Clean and realign guard to prevent rubbing if neces- 11. Recheck sheave or sprocket alignment.
sary.
12. Reinstall belt guard.
6. Inspect belt for wear or damage. Replace as needed.
13. Turn power back on and restart drive. Look and lis-
7. Inspect sheaves or sprockets for wear and misalign- ten for anything unusual.
ment. Replace if worn.
EF3328EN.2
Preventive Maintenance Procedure

Once the power is off, locked and tagged, and the machine
components are in safe positions, remove the guard and
Using a straight edge to
begin the inspection. check alignment
How to Inspect a Belt

Observing signs of unusual belt wear or damage will help
troubleshoot possible drive problems.
Mark or note a point on the belt, or on one of the belts in
a multiple V-belt drive. Wearing gloves, work around the
belt(s), checking for cracks, frayed spots, cuts, or unusual Using a string to check
wear patterns. Beware of pinch points. Keep hands and alignment
fingers clear, especially where belts enter sheaves and
sprockets.
Using EZ Align® laser

alignment tool on both
ends
Using EZ Align® laser

Begin by inspecting the belt alignment tool, showing
reflected laser on emitter
Check the belt for exposure to excessive heat. Excessive heat
can come from a hot environment or from belt slip that
generates heat. A typical maximum environmental tempera-
ture for a properly maintained V-belt is 160˚F to 180˚F. The
maximum environmental temperature for a properly main-
tained synchronous belt is 185˚F. Using EZ Align® laser
alignment tool showing
Rubber belts that are running hot, or running in a hot envi-
laser line on target
ronment will harden and develop cracks from the bottom of
the belt upwards.
Refer to the PROBLEM/SOLUTION SUMMARY TABLE for
other symptoms.
If using a straight edge (or string), line the straight edge
Belts should be replaced if there are obvious signs of crack- along the outside face of both sheaves or sprockets as
ing, fraying, unusual wear or loss of teeth. shown in the photo. If the drive is properly aligned, the
straight edge or string will contact each sheave or sprocket
How to Check Alignment evenly. The straight edge or string (pulled tight) should
While the drive is shut down, it is a good idea to check the touch the two outer edges of each sheave or pulley for a
sheaves or sprockets for proper alignment. total of four points of contact. Misalignment of sprockets
and shafts will show up as a gap between the outside face
To check alignment, use a straight edge, string, or Gates EZ of the sheave or sprocket and the straight edge. Check for
Align™ laser alignment tool. tilting or shaft misalignment by using a bubble level. For
proper alignment, the bubble should be in the same position
as measured on each shaft.
EF3328EN.2
If using the Gates EZ Align® laser alignment tool, follow the Misalignment on V-belt drives should be less than 1/2˚ or
detailed instructions included with the tool. The EZ Align 1/10” per foot of center distance. Misalignment for synchro-
laser alignment tool makes it very quick and easy to check nous, Polyflex®, or Micro-V® belts should be less than 1/4˚ or
alignment of shafts, sheaves and sprockets. EZ Align is avail- 1/16” per foot of center distance.
able with a red laser, or a green laser for outdoor or brighter
When a synchronous belt drive has been aligned (follow-
environment use.
ing the procedure discussed above in the “How to Check
Alignment” section), do not continue to adjust alignment
in an attempt to make the synchronous belt ride in the cen-
ter of the sprocket’s face width. Synchronous belts, while
neutral tracking, will tend to ride in contact with a flange
on one side of the sprockets. Synchronous belts on drives
that are properly aligned will lightly contact the flanges.
Synchronous belts on misaligned drives will ride hard against
the flanges and generate additional noise. Attempting to
adjust a synchronous belt drive’s alignment to force the belt
to ride in the center of the sprocket’s face width will typi-
cally result in misalignment.
Guard Inspection
Check the guard for wear or possible damage. Don’t over-
look wear on the inside of the guard. Check for any areas
that may be contacting the belt. Clean the guard to prevent
it from becoming blocked and closed to ventilation. Clean
off any grease or oil that may have spilled onto the guard
from over-lubricated bearings.
Check Other Drive Components

It is always a good idea to examine bearings for proper lubri-
cation. Check the motor base bolts and adjustment screws
to make sure they are not loose. If loose, tighten to the rec-
ommended torque value. Make sure that adjustment screws
There are three possible causes and solutions of sheave or are free of debris, dirt, or rust.
sprocket misalignment:
1. Angular Misalignment: The motor shafts and driven Check Belt Tension
machine shafts are not parallel. Following the drive component inspection, the final step is
to check belt tension. Rotate the drive two or three revolu-
a. Correct alignment by adjusting the motor
tions by hand and check the belt tension. If necessary, reten-
shaft into alignment with the driveN shaft.
sion the belt and make a final alignment check.
2. Parallel Misalignment: Sheaves or sprockets are not
If V-belts are undertensioned, they can slip. Slippage gener-
properly located on the shafts.
ates heat and will result in cracking and belt failure.
a. Loosen and reposition one or both sheaves or
If synchronous belts are undertensioned, they can jump
sprockets until properly aligned.
teeth or ratchet. Ratcheting will damage the belt and result
3. Sheaves or sprockets are tilted on the shaft due to in premature belt failure.
incorrect bushing installation.
If belts are overtensioned, belt and bearing life can be
a. Rotate drive by hand and look for excessive reduced.
wobble. Beware of pinch points. Keep hands
The proper way to check belt tension is to use a tension
and fingers clear, especially where belts enter
tester. Gates has a variety of tension testers, ranging from
sheaves and sprockets. If wobble is observed,
the simple spring scale type tester to the sophisticated Sonic
remove and reinstall sheave or sprocket. Follow
Tension Meter.
the bushing installation procedures explained in
the INSTALLATION section. Further check
alignment by using one of the previously
mentioned methods.
EF3328EN.2
Measuring Belt Tension 1. Measure span length (t). Span length is the distance from
The spring scale type tester measures how much force is where the belt exits one pulley to where it enters the
required to deflect the belt a specified distance at the center next pulley.
of its span. This is the force deflection method of tensioning Deflection
belts. 1/64” per inch
Span L of span
ength, t
The Sonic Tension Meter measures the vibration of the belt
span and instantly converts the vibration frequency into belt
static tension. This is the span vibration method of tension-
ing belts.
Force
2. Position the lower of the two O-Rings using either of

these methods:
a. On the scale reading “Deflection Inches”, set the
O-Ring to show a deflection equal to 1/64” per inch
of span length (t).
b. On the scale reading “Inches of Span Length”, set
O-Ring to show a deflection equal to the inches of
measured span length (t).
3. At the center of the span (t), apply force using the appro-
priately sized Gates tension testers. Apply the force per-
pendicular to the span. If the belt is a wide synchronous
belt or a PowerBand belt, place a piece of steel or angle
iron across the belt width and deflect the entire width
of the belt evenly. Deflect the belt until the bottom edge
of the lower O-Ring is at the correct deflection distance.
If multiple individual V-belts are used on the drive, the
deflection distance can be measured against an adjacent
belt. For drives with only one belt, use a straightedge or
string pulled tight across the sheaves, sprockets, or top
of the belt to establish a reference line. When the belt is
deflected to measure tension, measure the deflection dis-
For more information, refer to the Troubleshooting Tools tance by measuring from the belt to the straight edge or
section. string reference line.
Force Deflection Tension Method

The force deflection tension method does not directly
measure belt span tension or static tension. The deflection
force is a calculated value that is based on the amount of
static tension required in the belt. Static tension is the ten-
sion force that is actually in the belt, while deflection force
is simply a measurement to check how much static tension
is in the belt. The tension testers used for the force deflec-
tion tension method are available in one, two, or five barrel
configurations. The one barrel tension tester can measure up
to 30 lb. of force; the two barrel tension tester can measure
up to 66 lb. of force; and the five barrel tension tester can
measure up to 165 lb. of force. Add the force readings from
each barrel to determine the total force being measured.
EF3328EN.2
4. Find the amount of deflection force on the upper scale of

the tension tester. The sliding rubber O-Ring slides up the
scale as the tool compresses and stays up for a reading of
the deflection force. Read at the bottom edge of the ring.
Remember to slide the O-Ring down before using again.
5. Installation tension forces should ideally be calculated for
each specific drive. The tension calculations are included
in all Gates drive design manuals. Additionally, the Gates
drive design and selection computer program, Design
Flex® Pro™ can be used to quickly calculate the proper
installation tensions. Design Flex® Pro™ and Design Flex
Web® are available at www.gates.com/drivedesign.
If installation tension values for a specific V-belt
drive are not available, the tables shown can be used to
determine generic tension values based on the V-belt
cross section. As synchronous belt drives are more sensi-
tive to proper belt tensioning, there are no similar quick
reference tension tables for them.
Compare the deflection force with the range of forces rec-
ommended. If less than the minimum recommended deflec-
tion force, the belts are too loose and should be tightened.
If more than the maximum recommended deflection force,
the belts are too tight and should be loosened.
10
EF3328EN.2
Recommended Deflection Force Per Belt For Metric-Power V-Belts Span Vibration Method
Small Recommended The Gates Sonic Tension Meter can be used with all Gates
V-Belt Small Sheave Sheave Speed Deflection Force (Lbs.)
Cross Diameter RPM Ratio Minimum Maximum belts. The Sonic Tension Meter measures the vibration
Section (In.) Range Range in the belt span, and converts that measurement into a
2.20 2.64 1200-3600 3.2 4.5 reading of the actual static tension in the belt. To use the
2.80 1200-3600 3.6 5.0 Sonic Tension Meter, you will need to enter the belt unit
2.00
SPZ
2.95 3.15 1200-3600
to
4.1 5.9 weight, belt width for synchronous belts or number of ribs
3.35 3.74 1200-3600 4.00 4.5 6.8 or strands for V-belts, and the span length. To measure the
3.94 4.92 900-3600 5.4 7.7 span vibration, press the “Measure” key on the meter, tap
5.20 7.09 900-3600 5.9 8.6
the belt span to vibrate the belt, and hold the microphone
3.15 3.74 1200-3600 5.4 7.3
2.00
approximately 3/8” to 1/2” away from the back of the belt.
3.94 4.92 900-3600 6.4 9.5
SPA to The Sonic Tension Meter will display the static tension, and
5.20 7.87 600-1800 4.00 8.6 12.7
can also display the vibration frequency.
8.35 9.84 600-1800 9.1 13.6
4.41 5.91 1200-3600 10.4 16.3 Since the span vibration method is intended to be a very
2.00
SPB
6.30 7.87 600-1800
to
13.2 20.0 accurate method of measuring actual tension in a belt, it is
8.35 11.02 600-1800 4.00 16.3 22.7 important that the proper recommended tension is calcu-
11.81 15.75 400-1200 17.2 26.3
lated for the specific belt drive. Procedures for calculating
7.09 9.29 600-1800 18.1 27.2
2.00 belt tension are included in each of the appropriate Gates
SPC 9.84 13.98 400-1200 to 23.1 34.0
4.00 drive design manuals. To determine the belt tension recom-
14.76 20.87 400-900 27.2 40.8
mended for specific drive applications, refer to the appropri-
2.20 1200-3600 3.2 5.0
2.36 2.48 1200-3600 3.6 5.9
ate belt drive design manual or download the Gates belt
2.64 2.80 1200-3600 4.1 6.4
drive selection program, DesignFlex® Pro™, at
2.00
XPZ 2.95 3.15 1200-3600 to 4.5 6.8 www.gates.com/drivedesign. Alternatively, Gates Power
3.35 3.74 1200-3600 4.00 5.0 7.3 Transmission Product Application engineers can be
3.94 4.92 900-3600 5.9 8.6 contacted at ptpasupport@gates.com or (303) 744-5800.
5.20 7.09 900-3600 7.3 10.9
3.15 4.92 900-3600 2.00 8.2 12.2
XPA to
5.20 7.87 900-3600 4.00 10.0 14.1
4.41 4.65 1200-3600 10.9 16.3
4.92 5.51 1200-3600 12.2 18.6
5.91 6.69 1200-3600 2.00 13.6 21.3
XPB to
7.09 7.87 600-1800 4.00 16.3 24.0
8.35 11.02 600-1800 17.2 24.9
11.81 15.75 400-1200 18.6 29.0
7.09 9.29 600-1800 2.00 22.7 34.0
XPC 9.84 13.98 400-1200 to 29.5 43.1
14.76 20.87 400-900 4.00 36.3 49.9
2.20 1200-3600 2.8 4.1
2.35 2.50 1200-3600 3.2 4.7
2.65 2.80 1200-3600 2.00 3.5 5.1
10X 3.00 3.15 1200-3600 to 3.8 5.5
3.35 3.65 1200-3600 4.00 4.1 6.0
4.12 5.00 900-3600 4.8 7.1
5.30 6.90 900-3600 5.8 8.6
3.00 3.8 5.4
3.20 1750 2.00 3.9 5.6
13X 3.40 3.60 to to 4.1 5.9
3.80 4.20 3600 4.00 4.3 6.3
4.60 7.00 4.9 7.1
4.60 7.1 10.0
5.00 5.20 1160 2.00 7.3 11.0
17X 5.40 5.60 to to 7.4 11.0
6.00 6.80 1800 4.00 7.7 11.0
7.40 9.40 7.9 12.0
11
EF3328EN.2
The adjusted belt weights for use with the Gates Sonic Tension Meter are shown in the following table.
Belt Belt Belt Adjusted Belt Weight

Product Family Cross Section Type (grams/meter)
3VX Single 61
5VX Single 158
8VX Single 383
3V Single 72
5V Single 200
Super HC® V-Belts 8V Single 510
3VX PowerBand® 70
5VX PowerBand® 185
3V PowerBand® 96
5V PowerBand® 241
8V PowerBand® 579
5VP Single 198
8VP Single 513
AP Single 114
BP Single 174
CP Single 324
SPBP Single 208
Predator® V-Belts
SBCP Single 377
3VP PowerBand® 89
5VP PowerBand® 217
8VP PowerBand® 528
BP PowerBand® 212
CP PowerBand® 332
AX Single 85
Tri-Power® V-Belts BX Single 144
CX Single 232
A Single 96
B Single 168
C Single 276
D Single 554
Hi Power® II V-Belts E Single 799
A PowerBand® 151
B PowerBand® 200
C PowerBand® 342
D PowerBand® 663
AA Single 125
BB Single 194
Hi Power® II Dubl-V Belts
CC Single 354
DD Single 750
H Single 5
J Single 7
Micro-V® Belts K Single 18
L Single 29
M Single 109
Metric Power™ V-Belts 10X-Notched Single 44
13X-Notched Single 86
17X-Notched Single 139
For belt lengths over 3000mm 13X Single 100
For belt lengths over 3000mm 17X Single 171
XPZ Single 51
XPA Single 87
XPB Single 156
XPC Single 249
For belt lengths over 3000mm SPZ Single 72
For belt lengths over 3000mm SPA Single 115
For belt lengths over 3000mm SPB Single 186
For belt lengths over 3000mm SPC Single 337
12
EF3328EN.2
Belt Belt Belt Adjusted Belt Weight

Product Family Cross Section Type (grams/meter)
2L Single 22
3L Single 44
Truflex® V-Belts
4L Single 77
5L Single 125
3L Single 52
PoweRated® V-Belts 4L Single 83
5L Single 138
3M Single 4
5M Single 10
7M Single 24
11M Single 49
Polyflex® V-Belts
3M JB® 5
5M JB® 11
7M JB® 30
11M JB® 64
MXL Synchronous 1.3
XL Synchronous 2.4
L Synchronous 3.2
PowerGrip Timing Belts
®
H Synchronous 3.9
XH Synchronous 11.3
XXH Synchronous 14.9
XL Synchronous 1.9
PowerGrip® Timing Twin Power® Belts L Synchronous 3.2
H Synchronous 4.6
3M Synchronous 2.4
5M Synchronous 3.9
PowerGrip® HTD® Belts 8M Synchronous 6.2
14M Synchronous 9.9
20M Synchronous 12.8
3M Synchronous 2.7
5M Synchronous 4.6
PowerGrip® HTD® Twin Power® Belts
8M Synchronous 7.2
8M Synchronous 5.8
PowerGrip® GT® Belts
14M Synchronous 9.7
2M Synchronous 1.4
3M Synchronous 2.8
PowerGrip® GT®2 Belts 5M Synchronous 4.1
8M Synchronous 5.5
14M Synchronous 9.6
8M Synchronous 6.93
PowerGrip GT 2 Twin Power Belts
® ® ®

Poly Chain® GT®2 Belts 5M Synchronous 3
Poly Chain® GT®2 and 8M Synchronous 4.7
Poly Chain® GT® Carbon™ Belts 14M Synchronous 7.9
13
EF3328EN.2
INSTALLATION
How to Install Belts 5. Remove old belt

When a belt is being installed, the same basic steps must be
followed, regardless of whether the belt is a Inspection
V-belt or a synchronous belt. 6. Inspect the old belt for any unusual wear. Excessive
or unusual wear may indicate problems with the
Preparation drive design or past maintenance procedures. Refer
1. Confirm that the power is off, locked, and tagged. to the Problem/Solution Summary Table in the Belt
Never work on a belt drive until this important step is Performance and Troubleshooting section for guide-
completed. Wear proper safety equipment (hardhat, lines in matching belt appearance to possible problem
gloves, safety glasses, steel toe shoes). causes.
2. Remove belt guard and place away from drive so that it 7. Inspect the sheaves or sprockets for unusual or exces-
does not interfere with working on the drive. sive wear. Belt life will be reduced if the sheaves or
sprockets are worn. Wear gloves for protection from
Removal nicks or sharp surfaces.
3. Loosen motor mounting bolts or adjusting screws. For V-belt sheaves: Inspect grooves for wear and
nicks. Use Gates sheave gauges to determine if the
grooves are worn. Place the proper sheave gauge into
the sheave groove and check for wear. If more than
1/32” of wear can be seen between the gauge and
groove side wall, the sheaves are worn and should be
replaced. A light source such as a flashlight may be
used to backlight the gauge.
4. Move the motor in until the belt is slack and can be

removed easily without prying. Never pry off a belt,
as the sheave or sprocket can be damaged. Prying off
belts also adds the risk of injury.
Do not be misled by “shiny” grooves. Grooves that are

“shiny” are often polished because of heavy wear.
Inspect the sheave grooves for rust or pitting. If rusted
or pitted surfaces are found, the sheave should be
replaced.
For Synchronous sprockets: Inspect sprocket grooves
for unusual or excessive wear. Check for excessive wear
by both visually inspecting the grooves and by running
your finger along the sprocket grooves. If you can feel
or see noticeable wear, the sprockets are worn and
should be replaced.
14
EF3328EN.2
INSTALLATION
Do not be misled by “shiny” grooves. Grooves that are Catenary effect is a curve made by a cord of uniform
“shiny” are often polished because of heavy wear. weight suspended between two points.
Inspect the sprocket grooves for rust or pitting. If rust-
Follow the recommended run-in and retensioning pro-
ed or pitted surfaces are found, the sprocket should be
cedure to minimize the visible difference in belt sag.
replaced.
14. Rotate the belt drive by hand for a few revolutions.
Check the sprocket flanges and make sure that they
Re-check the belt tension and adjust as necessary.
are not loose or bent. Bent flanges can interfere with
the belt and cause premature belt wear and failure. 15. Re-check the drive alignment and adjust as necessary.
8. If necessary, clean sheave and sprocket grooves by
Completion
wiping the surface with a rag slightly dampened with
a light, non-volatile solvent. Do not sand or scrape the 16. Secure motor mounting bolts to the correct torque.
grooves to remove debris. 17. Re-check the belt tension and adjust as necessary.
Tightening the motor mounting bolts may have
Installation changed the belt tension.
9. If necessary, install new sheaves or sprockets. Refer to
18. Replace the belt guard.
page 14 for detailed instructions for installing QD or
Taper-Lock® bushings. 19. Start the drive, looking and listening for any unusual
noise or vibration. If possible, shut down the drive and
10. Check the sheave or sprocket alignment. In order
check the bearings and motor for unusual heat. If the
to achieve optimum belt life, it is important that the
motor or bearings are hot, the belt tension may be
drive’s sheaves or sprockets be aligned properly. Use a
too high, or bearings may not be properly lubricated.
straightedge or Gates EZ Align® laser alignment tool.
Temperatures can be checked with an infrared pyrom-
Adjust the sheave or sprocket position as necessary.
eter.
11. Install the new belt or set of belts.
V-Belt Run-In Procedure
Replace all belts on multiple V-belt drives. Never replace
a single belt or a portion of a multiple belt drive. 20. A run-in procedure is recommended for all V-belt
Always use belts from the same manufacturer on a drives so that the optimum belt life can be achieved.
multiple belt drive. If a new belt is used with old belts, A run-in consists of starting the drive and letting it run
the load will not be shared evenly between the belts under full load for up to 24 hours. If a 24 hour run-in
on a multiple V-belt drive. Mixing new and old belts is not possible, let the belt drive run overnight, to the
very possibly could lead to premature belt failure and next shift, or at least a few hours. After the belts have
uneven sheave wear. run-in, stop the belt drive and check the belt tension.
Running the belts under full load for an extended peri-
When installing the belt, make sure that there is clear- od of time will seat the V-belts into the sheave grooves.
ance to slip the belt over the sheave or sprocket. Do V-belt tension will drop after the initial run-in and seat-
not pry or use force to install the belt. Do not roll the ing process. This is normal. Adjust the belt tension as
belt onto the drive. necessary.
12. Adjust the motor base adjustment screws to take up Since tension in V-belts will drop after the initial run-in
the center distance on the belt drive until the belts are and seating process, failure to check and retension the
tight. belt will result in low belt tension and belt slippage.
13. Check belt tension, using a tension gauge or Sonic This slippage will result in premature belt failure.
Tension Meter. Adjust the belt drive’s center distance
until the correct tension is measured.
On multiple belt drives, some belts may appear to hang
unevenly when installed. It is normal for belts within
RMA length and matching tolerances to have notice-
able differences in the distance the belt span sags. This
is called the “catenary effect”.
15
EF3328EN.2
INSTALLATION
How to Install Taper-Lock® and QD® Bushed Sheaves Taper-Lock® Bolt Torque
and Sprockets Bushing Bolts Torque Wrench
Style Qty. Size lb-ft lb-in
It is important that new or replacement sheaves or sprockets
1008 2 1/4-20 x 1/2 4.6 55
be properly installed. Most sheaves or sprockets are attached 1108 2 1/4-20 x 1/2 4.6 55
to a shaft with a tapered bushing that fits a mating tapered 1210 2 3/8-16 x 5/8 14.6 175
bore in the sheave or sprocket. Bushings come in several dif- 1610 2 3/8-16 x 5/8 14.6 175
2012 2 7/16-14 x 7/8 23.3 280
ferent bore size diameters. This allows for a reduction in the 2517 2 1/2-13 x 1 35.8 430
parts inventory required in your plant because one bushing 3020 2 5/8-11 x 1 1/4 66.7 800
size with multiple bore sizes can be used with a number of 3525 3 1/2-13 x 1 1/2 83.3 1000
4030 3 5/8-11 x 1 3/4 141.7 1700
different sizes of sheaves or sprockets. 4535 3 3/4-10 x 2 204.2 2450
5040 3 7/8-9 x 2 1/4 258.3 3100
There are two styles of bushings: Taper-Lock® and QD®. 6050 3 1 1/4-7 x 3 1/2 651.7 7820
7060 4 1 1/4-7 x 3 1/2 651.7 7820
Installation and removal instructions for each style are noted
below.
5. To increase and ensure bushing gripping force, firmly
Taper-Lock® Type Sprocket Installation and Removal tap the bushing face using a drift or punch (do not hit
bushing face directly with hammer), then re-torque
screws to the recommended torque level.
Note: Do not continue tightening screws further
after target torque has been reached as bushing over
insertion and hub fracture may occur.
To Remove TL Type Hardware

1. Release belt tension and lift belt off of sprockets
(Note: Do not pry or roll belts off).
2. Loosen and remove screws securing sprockets to bush-
To Install Taper-Lock® Type Hardware
ings.
1. Clean the shaft, bushing bore, tapered bushing bar-
rel and the sprocket hub bore of all oil, paint and dirt 3. Insert screws into removal holes (“ “).
(Note: Lubricants are not to be applied to bushings 4. Alternately tighten screw or screws in small but equal
or sprockets). Remove any burrs with a file or emery increments until sprockets disengage from bushings.
cloth.
5. Remove sprockets and bushings from shafts as neces-
2. Insert bushing into sprocket hub matching hole pat- sary.
terns, not threaded holes. Tightening holes (“ ” in
diagram above) will be threaded on the sprocket hub
side only. Removal holes (“ “ in diagram above) will
be threaded on the bushing side only. Thread screws
into the installation or “ ” holes.
3. With the key in the shaft keyway ” ”, position the
assembly onto the shaft at the desired location. Allow
for small axial sprocket movement on bushing during
tightening. (Note: When mounting sprockets on verti-
cal shafts, precautions must be taken to prevent the
sprocket/bushing from falling during the tightening).
4. Alternately torque screws to the recommended torque
level specified in the table below. Note: Using worn
hex key wrenches may damage screw heads prevent-
ing proper tightening torque and removal.
16
EF3328EN.2
INSTALLATION
QD Type Hardware Installation and Removal 5. When positioned to the desired location, secure the
first sheave/bushing assembly to the shaft by tight-
To Install QD Type Hardware ening the bushing cap screws. Allow for small axial
1. Clean the shaft, bushing bore, tapered bushing bar- sheave movement on bushing during tightening. Using
rel and the sheave hub bore of all oil, paint and dirt a torque wrench, tighten the cap screws evenly in an
(Note: Lubricants are not to be applied to bushings or alternating pattern until the recommended torque level
sheaves). Remove any burrs with a file or emery cloth. in the following table is reached. (Note: When mount-
ing sprockets on vertical shafts, precautions must
2. Determine the type of mounting that will be used: be taken to prevent the sheave/bushing from falling
during the tightening).
Note: Do not continue tightening cap screws further after
target torque has been reached as bushing over insertion
and hub fracture may occur. The gap between the bush-
ing flange and sheave hub is intentional and necessary.
QD Bolt Torque
Conventional Mounting Reverse Mounting
Bushing Bolts Torque Wrench
Style Qty. Size lb-ft lb-in
3. Conventional Mounting:
H 2 1/4 x 3/4 7.9 95
A. Insert key into the shaft keyway (Note: If key is JA 3 10-24 x 1 4.5 54
SH & SDS 3 1/4-20 x 1 3/8 9.0 108
furnished with bushing, it is special and must be
SD 3 1/4-20 x 1 7/8 9.0 108
used). SK 3 5/16-18 x 2 15.0 180
SF 3 3/8-16 x 2 30.0 360
B. Insert a screw driver blade (or similar) into the bush- E 3 1/2-13 x 2 3/4 60.0 720
ing flange saw cut to enlarge bore slightly (Caution: F 3 9/16-12 x 3 5/8 75.0 900
Excessive enlargement can split bushing). J 3 5/8-11 x 4 1/2 135.0 1620
M 4 3/4-10 x 6 3/4 225.0 2700
C. Slide bushing onto shaft with the flange side N 4 7/8-9 x 8 300.0 3600
towards the equipment. Position bushing and tight- W 4 1 1/8-7 x 11 1/2 600.0 7200
S 5 1 1/4-7 x 15 1/2 750.0 9000
en set screw to prevent sliding on shaft.
P 4 1-8 x 9 1/2 450.0 5400
D. Place sheave onto bushing and insert cap screws.
Align drilled holes in sheave hub with tapped holes To Remove QD Type Hardware
in bushing flange. (Note: Install M thru S bushings
so that the two tapped removal holes in sheave 1. Release belt tension and lift belts off of sheaves
hubs are located far away from bushing saw (Note: Do not pry or roll belts off).
cuts). Finger-tighten the screws. 2. Loosen and remove cap screws securing sheaves to
4. Reverse Mounting: bushings. If applicable, loosen keyway set screws.
A. Insert key into the shaft keyway (Note: If key is fur- 3. Insert cap screws into the tapped removal holes adja-
nished with bushing, it is special and must be used). cent the drilled holes.
B. Place sheave onto shaft without bushing. 4. Alternately tighten cap screws in small but equal incre-
ments until sheaves disengage from bushings. (Note:
C. Insert a screw driver blade (or similar) into the bush- Uneven or excessive pressure on cap screws can
ing flange saw cut to enlarge bore slightly (Caution: break bushing flanges making removal extremely dif-
Excessive enlargement can split bushing). ficult)
D. Slide bushing onto shaft with flange facing out- 5. Remove sheaves and bushings from shafts as necessary.
ward, away from equipment. Position bushing and
tighten the set screw enough to prevent sliding on
shaft.
E. Place sheave onto the bushing and insert cap
screws. Align drilled holes in bushing flange with
tapped holes in sheave hub (Note: Install M thru S
bushings so that the two tapped removal holes in
sheave hubs are located far away from bushing
saw cuts). Finger-tighten the screws.
17
EF3328EN.2
BELT STORAGE AND HANDLING
Storage Recommendations Do not crimp belts during handling or while stored.

Proper preventive maintenance should not be limited to Belts are crimped by bending them to a diameter smaller
the actual belt drive operating on equipment, but should than the minimum recommended diameter sheave or
also include following proper storage procedures. In order sprocket for that cross section. Do not use ties or tape to
to retain their serviceability and dimensions, proper stor- pull belt spans tightly together near the “end” of the belt.
age procedures must be followed for all belt types. Quite This will crimp the belt and cause premature belt failure. Do
often premature belt failures can be traced to improper belt not hang on a small diameter pin that suspends all of the
storage procedures that damaged the belt before it was belt weight and bends the belt to a diameter smaller than
installed on the drive. By following a few common sense the minimum recommended sheave or sprocket diameter.
steps, these types of belt failures can be avoided. Improper storage will damage the tensile cord and the belt
will fail prematurely. Handle belts carefully when removing
General Guidelines from storage and going to the application. Do not inadver-
Recommended tently crimp or damage the belts by careless handling.
Belts should be stored in a cool and dry environment with Storage Methods
no direct sunlight. Ideally, less than 85˚ F and 70% relative
humidity. V-Belts
Store on shelves or in boxes or containers. If the belt is pack- V-belts can be coiled in loops for storage purposes. Each coil
aged in a box, like Poly Chain® GT® Carbon™ belts, store results in a number of loops. One coil results in three loops,
the belt in its individual box. two coils results in five loops, etc. The maximum number of
coils that can be used depends on the belt length. If coiling
V-belts may be stored by hanging on a wall rack if they are a belt for storage, consult the table on the next page and
hung on a saddle or diameter at least as large as the mini- follow the limits shown.
mum diameter sheave recommended for the belt cross sec-
tion.
When the belts are stored, they must not be bent to diam-
eters smaller than the minimum recommended sheave or
sprocket diameter for that cross section. (see Technical
Information section) Belts should not be stored with back
bends that are less than 1.3 times the minimum recom-
mended sheave or sprocket diameter for that cross section.
If stored in containers, make sure that the belt is not dis-
torted when in the container. Limit the contents in a con-
tainer so that the belts at the bottom of the container are
not damaged by the weight of the rest of the belts in the
container.
Not Recommended
Belts should not be stored near windows, which may expose
the belts to direct sunlight or moisture.
Belts should not be stored near heaters, radiators, or in the
direct airflow of heating devices.
Belts should not be stored near any devices that generate
ozone. Ozone generating devices include transformers and
electric motors.
Belts should not be stored where they are exposed to sol-
vents or chemicals in the atmosphere.
Do not store belts on the floor unless they are in a protec-
tive container. Floor locations are exposed to traffic that may
damage the belts.
18
EF3328EN.2
BELT STORAGE AND HANDLING
Belt Cross Section Belt Length (in) Belt Length (mm) Number of Coils Number of Loops
3L, 4L, 5L, A, AX, Under 60 Under 1500 0 1

AA, B, BX, 3V, 60 up to 120 1500 up to 3000 1 3
3VX, 9R, 13R, 13C, 120 up to 180 3000 up to 4600 2 5
13CX, 13D, 16R, 180 and over 4600 and over 3 7
16C, 16CX, 9N
BB, C, CX, 5V, Under 75 Under 1900 0 1
5VX, 16D, 22C, 75 up to 144 1900 up to 3700 1 3
22CX, 15N 144 up to 240 3700 up to 6000 2 5
240 and over 6000 and over 3 7
CC, D, 22D, 32C Under 120 Under 3000 0 1
120 up to 240 3000 up to 6100 1 3
240 up to 330 6100 up to 8400 2 5
330 up to 420 8400 up to 10,600 3 7
420 and over 10,600 and over 4 9
8V, 8VX, 25N Under 180 Under 4600 0 1
80 up to 270 4600 up to 6900 1 3
270 up to 390 6900 up to 9900 2 5
390 up to 480 9900 up to 12,200 3 7
Over 480 12,200 and over 4 9
PowerBand® V-Belts, Synchronous Belts, Micro-V® Belts Variable Speed V-Belts

Poly Chain GT Carbon™ belts are shipped in individual
® ®
Variable speed belts have a thicker cross section and are
boxes. Poly Chain® GT® Carbon™ belts should be stored in more sensitive to distortion than other V-belts. Do not hang
the box in which it was shipped. variable speed belts from pins, racks, or saddles. Store vari-
able speed belts on their edge on shelves. Variable speed
These belts may be stored by hanging on a wall rack if they
belts that are in sleeves may be stacked, taking care to avoid
are hung on a saddle or diameter at least as large as the
distorting the belts at the bottom of the stack.
minimum diameter sheave or sprocket recommended for the
belt cross section, and the belts are not distorted.
Storage Effects
PowerBand® V-belts, Synchronous belts, and Micro-V® belts In order to retain their serviceability and dimensions, proper
up to 120 inches (3000 mm) may be stored in a nested con- storage procedures must be followed for all belt types. Quite
figuration. Nests are formed by laying a belt on its side on often premature belt failures can be traced to improper belt
a flat surface and placing as many belts inside the first belt storage procedures that damaged the belt before it was
as possible without undue force. When nests are formed, installed on the drive.
do not bend the belts to a diameter that is smaller than
the minimum recommended sheave or sprocket diameter. Belts may be stored up to six years if properly stored at tem-
Nests may be stacked without damaging the belts if they are peratures less than 85˚F and relative humidity less than 70%.
tight and stacked with each nest rotated 180˚ from the nest If the storage temperature is higher than 85˚ F, the storage
below. limit for normal service performance is reduced by one half
PowerBand® V-belts and Micro-V® belts over 120 inches for each 15˚F increase in temperature. Belts should never be
(3000 mm) may be rolled up and tied for shipment. These stored at temperatures above 115˚F.
individual rolls may be stacked for easy storage. When the At relative humidity levels above 70%, fungus or mildew
belts are rolled, they must not be bent to a diameter that is may form on stored belts. This has minimal affect on belt
smaller than the minimum diameter recommended for the performance, but should be avoided.
cross section.
When equipment is stored for prolonged periods of time
(over six months), the belt tension should be relaxed so that
the belt does not take a set, and the storage environment
should meet the 85˚F and 70% or less relative humidity con-
dition. If this is not possible, belts should be removed and
stored separately in a proper environment.
19
EF3328EN.2
BELT IDENTIFICATION
When preventive maintenance inspections indicate that belts The information on the following pages will help identify the
need replacing, it is important to install the correct belts. belt types used in industry. Gates makes a belt to fit nearly
any application.
Consequently, it is important to identify the various types
and sizes of belts available, and then quickly be able to
specify the correct replacement.
V-Belts
Super HC® V-Belts
1" 1"
3/8" 3/8"
5/8"
5V 35/64"
5/8"
5VX 35/64"
8V 7/8" 8VX 53/64"
3V 21/64" 3VX 21/64"

* * *
Hi-Power® II V-Belts
1-1/2”
1-1/4"
7/8"
1/2"
A 5/16"
21/32"
B 13/32" C 17/32" D 3/4"

E 29/32"
* * *
Tri-Power® V-Belts PowerBand® – Hi-Power® II, Super HC®

and Predator®
7/8"
21/32"
1/2"
AX 5/16" BX 13/32" CX 17/32"
Metric Power™ V-Belts

22mm
16mm 17mm
13mm 13mm
10mm 10mm
13mm 18mm
8mm 10mm 8mm 10mm
6mm
SPZ/XPZ SPA/XPA SPB*/XPB SPC*/XPC 10X 13X 17X

*available in Predator® belt construction
20
EF3328EN.2
BELT IDENTIFICATION
Multi-Speed Belts
Top Width-Sheave Angle
Example: Belt No. 2326V310 designates:

23 26 V 310
Top Width in 16ths of Sheave Angle in Multi-Speed Pitch Circumference to the
an Inch: 23/16” = 1-7/16” Degrees (26) Nearest 10th Inch: 31.0”
Truflex® (Light Duty) V-Belts

21/32”
1/2”
1/4” 3/8”
7/32’ 5/16” 3/8”
1/8”
2L 3L 4L 5L
PoweRated® V-Belts Dubl-V Belts

21/32”
1/2”
3/8”
7/32’ 5/16” 3/8”
3L 4L 5L
AA BB CC DD
Micro-V® Belts
J Section 3/32"
L Section
3/16"
K Section M Section
3/8"
Standard Polyflex® V-Belts Polyflex® JB® V-Belts

7/16"
9/32"
1/8" 3/16"
3M 5M 7M 11M 3M 5M 7M 11M
21
EF3328EN.2
BELT IDENTIFICATION
Synchronous Belts
All synchronous belts are identified in a similar manner, in 2. Pitch Length: Total length (circumference) in inches or
either English or metric units. Belts are measured by: millimeters as measured along the pitch line. It is equal to
the pitch multiplied by the number of teeth in the belt.
1. Pitch: Distance in inches or millimeters between
two adjacent tooth centers as measured on the 3. Width: Denoted in inches or millimeters.
belt pitch line.
Poly Chain® GT® Carbon™ Belts PowerGrip® HTD® Belts
3M
3mm Pitch
5M
5mm Pitch Pitch
14M
14mm Pitch
Pitch
8M
8mm Pitch
14M
14mm Pitch
8M Pitch 20M
20mm Pitch
8mm Pitch
PowerGrip® GT®2 Belts PowerGrip® Timing Belts
2M *
2mm Pitch
MXL *
.080" Pitch
3M * XL *
3mm Pitch
.200" Pitch
5M * L
5mm Pitch .375" Pitch
8M
8mm Pitch
H
.500" Pitch
14M XH
14mm Pitch
.875" Pitch
XXH
1.250" Pitch
Pitch
*also available in TruMotion® belt construction
22
EF3328EN.2
BELT IDENTIFICATION
Twin Power® Timing Belts
XL
.200” Pitch
L
.375” Pitch
H
.500” Pitch
Pitch
Twin Power® PowerGrip® GT®2 Belts
3M
3mm Pitch
5M
5mm Pitch
8M
8mm Pitch
14M
14mm Pitch
Pitch
23
EF3328EN.2
BELT IDENTIFICATION
Synchro-Power® Polyurethane Belts
T5
5mm Pitch
T10
10mm Pitch
T20
20mm Pitch
Pitch
AT5
5mm Pitch
AT10
10mm Pitch
AT20
20mm Pitch
Pitch
5M HTD
5mm Pitch
8M HTD
8mm Pitch
14M
14mm Pitch
HTD
Pitch
24
EF3328EN.2
BELT TYPES
Narrow Section V-Belts

These high capacity belts are used to substantially reduce
drive costs and decrease space requirements. This V-belt
handles the complete range of drive horsepower recom-
mended with three narrow cross sections instead of the
five regular cross sections needed for classical heavy-duty
belts. Specified by 3V, 5V or 8V cross sections. Specify Gates
Super HC® V-belts.
Classical Section V-Belts

These are the original belts used in heavy duty applications.
They are specified by cross section and standard length.
The size is designated as A, B, C, D or E. The easiest way to
select a replacement is by finding the belt number on the
worn belt. If not legible, measure the belts outside circum-
ference with a flexible tape, preferably while it is still on the
drive.
Then, order the Gates Hi-Power® ll V-belt which has the next
shorter standard length. For example: For an “A” section
belt with a 28.0” O.C., order an A26 replacement belt.
Banded and Bandless Belts

Banded belts, also called wrapped or covered belts, have
a fabric cover. Un-notched and generally with concave
sidewalls, banded belts have rounded bottom corners and
arched tops.
Bandless belts have no fabric cover, straight cut-edge side-
walls, and special molded notches. The notches reduce
bending stress which allows belts to run on smaller diameter
sheaves than comparable non-notched banded belts.
Gates offers these two types in both the classical and nar-
row sections. In the classical section, Gates Tri-Power®
molded notch is available in AX, BX and CX cross sections.
Its length is specified by the same standard belt number as Note: The revolutionary Gates belt construction is used in
other classical section belts. the notched belts.
Gates also offers Super HC® Molded Notch V-belts in
3VX, 5VX and 8VX sizes.
In both cases, an “X” is used in the belt number to desig-
nate a molded notch construction. For example: An AX26 is
a bandless, molded notch classical section belt. A 5VX1400
is a narrow section, bandless, molded notch belt with a
140” O.C.
25
EF3328EN.2
BELT TYPES
Light Duty Belts

These are used on light duty fractional horsepower drives
and are designed for use with backside idlers. Gates
Truflex® and PoweRated® V-belts are offered in this cat-
egory and are specified by cross section and outside circum-
ference. Truflex® is recommended for the lower lighter duty
range. PoweRated®, a special belt designed for clutching,
heavier shock-load and backside idler drives, is recognized
by its green color. Reinforced with an aramid fiber tensile
(pound for pound stronger than steel). PoweRated® can
interchange with Truflex®, but Truflex® cannot inter-
change with PoweRated®.
Synchronous Belts
These belts are also known as timing or positive drive belts
and are used where driveN shaft speeds must be synchro-
nized to the rotation of the driveR shafts. They can also be
used to eliminate noise and maintenance problems caused
by chain drives.
Synchronous belts, such as Gates Poly Chain® GT®
Carbon™, can be used in high horsepower drives, drives
where space is severely limited and where there is limited
take up.
Synchronous drives are extremely efficient... as much as
98% with properly maintained Poly Chain® GT® Carbon™
or PowerGrip® GT®2 systems. By contrast, chain drives are Number of Sprocket Grooves
in the 91-98% efficiency range, while V-belts average in the
93-98% range. Width - Face width.
Distinctive tooth profiles (shapes) identify synchronous belts. Note: The sprocket’s pitch diameter is always greater than
Various sizes and constructions are available to meet a wide its outside diameter.
range of applications. The three important dimensions of a Note: PowerGrip® GT®2 belts must be used with PowerGrip®
synchronous belt are pitch, width and pitch length. Tooth GT®2 sprockets for new designs.
profiles must also be identified.
Note: 8 and 14 mm pitch PowerGrip® GT®2 belts can be
Belt Pitch - Distance in inches or millimeters between two used as replacement belts for competitive curvilinear tooth
adjacent tooth centers as measured on the belt’s pitch line. profiles. See page 30.
Belt Pitch Length - Circumference in inches or millimeters Example: 14mm-170mm width – substitute a PowerGrip®
as measured along the pitch line. GT®2-14mm-115 without any performance loss. Refer to
Width - Top width in inches or millimeters. page 30 for crossover information.
Tooth Profile - See the Belt Identification section for the

easiest way to identify tooth profile.
Synchronous belts run on sprockets, which are specified by
the following:
Pitch - Distance between groove centers, measured on the
sprocket pitch circle. The pitch circle coincides with the pitch
line of the mating belt.
26
EF3328EN.2
BELT TYPES
Polyflex® JB® V-Belts

Polyflex® is a unique belt with a distinctive 60° belt angle
and ribbed top specifically designed for long life in small
diameter sheave drives. Polyflex® JB® is ideal for compact
drives, drives with high speed ratios, and drives requiring
especially smooth operation.
The “JB” refers to the belt’s configuration: two, three or five
belts joined together to provide extra stability and improved
performance. This joined belt style should be used instead of
matched single belts whenever possible.
Polyflex® JB® belts are ideal for these applications:
• Milling, grinding or drilling machines

• Lathes
• Machine spindle drives
• Centrifuges
• Blowers
• High speed compressors
Polyflex® JB® belts are specified by Top Width and

Effective Length
Multi-Speed Belts
(Variable Speed Drives)
Multi-Speed belts have a distinct shape. Multi-Speed belt
top widths are usually greater than their thicknesses. This
permits a greater range of speed ratios than standard belts.
Usually cogged or notched on the underside, Multi-Speed
belts are specified for equipment which require changes in
driveN speed during operation.
Multi-Speed belts are specified by Top Width, Outside
Circumference, and the required Groove Angle. The
groove angle can be measured from the drive pulleys.
Micro-V® or V-Ribbed Belts

Gates Micro-V® belts outperform other V-ribbed belts
because the tips of the “V” are truncated (shorter). This
shorter profile gives the new Micro-V belts increased flex-
ibility, reduced heat buildup and allows them to operate at
extra high speeds on smaller diameter sheaves.
Additional advantages of the truncated tips are: (1) the belt
does not bottom in the sheave, therefore providing a higher
degree of wedging and (2) the belt can better tolerate debris
in the sheave groove. They are extremely smooth running and
highly resistant to oil, heat and other adverse conditions.
Three cross sections are available for industrial applications: J,
L and M.
27
EF3328EN.2
BELT STYLES
Spliced and Linked Belting

Used on drives with little or no take-up, or as an emergency Nu-T-Link®, a high performance, linked belt, is also avail-
belt replacement. able for use as emergency belting, and for drives where con-
ditions are detrimental to rubber belts.
Belting is sold on reels in standard V-belt cross sections.
Easy-Splice V-belting ends are spliced with fasteners that
require special assembly tools. Always use the correct
fasteners with the correct belt type and cross section.
PowerBand® Belts
PowerBand belts were developed by Gates for drives sub-
jected to pulsating loads, shock loads or extreme vibrations
where single belts could flip over on the pulleys. A high-
strength tie band permanently joins two or more belts to
provide lateral rigidity. This keeps the belts running in a
straight line in the pulley grooves. PowerBand® construction
is offered with Gates Hi-Power® II, Super HC® and Super
HC® Molded Notch Belts.
Predator® V-Belts
Gates Predator® V-belts are available in single, or multi- Primary features of Predator® V-belts:
layered PowerBand® construction that adds strength, dura-
bility, shear and tear resistance and lateral rigidity to handle • Aramid tensile cords for extraordinary strength, durability
the toughest shock-loaded applications. and virtually zero stretch.
• Chloroprene rubber compounds for superb oil and heat
resistance.
• Specially-treated extra tough cover withstands slip and
shear forces at peak loads without generating excessive
heat. It also fends off penetration by foreign materials.
• Gates curves that compensate for effects that occur
when belts bend around a sheave for uniform loading
and maximum life.
• Matched by request to maximize power absorption and
belt life.
28
EF3328EN.2
BELT STYLES
Round Endless Belts

Recommended for replacing leather belting on serpentine
or quarter-turn drives. They are specified by Diameter and
Inside Length.
If your current drive has leather or round endless belting,
you should consider a new drive design. V-belt drives offer
many advantages in performance, even on serpentine or
quarter-turn drives.
Also available in Heavy-Duty

PowerRound™ constructiom
PowerBack® V-Belts
PowerBack™ belts are “B” section V-belts with a flat back
surface. The flat back surface makes PowerBack™ belts ideal
for driving roll-to-roll conveyor applications.
Power Curve® V-Belts

Power Curve® belts are “B” section V-belts offering
increased flexibility for demanding power turn conveyor
applications. The belts “bend” around corners and drive the
rollers in most conveyor applications.
29
EF3328EN.2
BELT STYLES
Dubl-V Belts
A special version of Gates Hi-Power® II for serpentine drives
where power is transmitted by both the top and bottom of
the belt. Dubl-V belts are specified by A, B, C or D cross sec-
tions, and by Effective Length.
Static Conductive Belts

Static discharge can pose a hazard on belt drives that oper- Gates Hi-Power® II, Tri-Power®, Super HC®, Super HC®
ate in potentially explosive environments. Static discharge Molded Notch, Metric Power™, Micro-V®, Truflex® V-belts
can also interfere with radios, electronic instruments, or and 8mm and 14mm PowerGrip GT2 are all static conduc-
controls used in a facility. While uncommon, static dis- tive when new as defined by RMA Bulletin IP 3-3. Belts that
charge can also cause bearing pitting if the discharge occurs have been in operation can be checked for static conductiv-
through the bearing. Static conductivity is a required belt ity by using an ohmmeter and following the inspection rec-
characteristic in these cases in order to prevent static dis- ommendations given in the RMA IP 3-3 bulletin.
charge.
PowerGrip® GT®2* in 2mm, 3mm, 5mm pitches, PowerGrip®
The Rubber Manufacturer’s Association (RMA) has Timing, Poly Chain® GT®, Poly Chain® GT®2, Poly Chain®
published Bulletin IP 3-3 for static conductivity. Static GT® Carbon™, Polyflex®, Polyflex® JB®, PoweRated®, and
conductivity testing involves using an ohmmeter to pass an Predator® belts do not meet the static conductivity require-
electrical current with a nominal open circuit 500 volt poten- ments specified in RMA Bulletin IP 3-3 and are not consid-
tial through a belt. The test should be performed with the ered to be static conductive.
belt off of the belt drive. The belt’s resistance is measured
by placing electrodes 8.5 inches apart on the clean driving PowerGrip® GT®2* in 2mm, 3mm, 5mm pitches and
surface of the belt. A resistance reading of six (6) meg- PowerGrip® Timing belts can be manufactured in a static
ohms or more constitutes a test failure. Belts that measure conductive construction on a made-to-order basis.
a resistance of 6 megohms or more are considered to be When a belt is used in a hazardous environment, additional
non-conductive. Belts that measure a resistance of less than protection must be employed to assure that there are no
6 megohms are considered to be static conductive. A static accidental static spark discharges. The portion of the belt
conductive belt with a resistance of 6 megohms or less has that contacts the sheave or sprocket must be conductive
sufficient conductivity to prevent measurable static voltage to ensure that static charge is conducted into the drive
buildup, thus preventing a static discharge. hardware. V-belts must have a static conductive sidewall in
V-belts are generally manufactured to be static conductive in contact with a conductive sheave groove. Synchronous belts
accordance with the RMA IP 3-3 bulletin, but it is important must have a static conductive tooth surface in contact with
to confirm with the belt manufacturer that a specific belt conductive sprocket grooves.
product or product line is static conductive.
* NOTE: 8mm pitch PGGT2 belts at 12mm wide are NOT static conductive.
30
EF3328EN.2
BELT STYLES
Unusual or excessive debris or contaminant on the belt con- Any belt drive system, whether it uses a synchronous belt or
tact surface or sheave or sprocket grooves should be cleaned V-belt, that operates in a potentially hazardous environment
and removed. Banded V-belts (V-belts with a fabric bandply must be properly grounded. A continuous conductive path
on the driving surface) should be inspected for bandply to ground is necessary to bleed off the static charge. This
wear. If the fabric bandply on the belt sidewall has worn path includes a static conductive belt, a conductive sheave
away, the belts should be replaced immediately. Bandless or sprocket, a conductive bushing, a conductive shaft, con-
V-belts do not have to be replaced if wear is evident on the ductive bearings, and the ground. As an additional mea-
belt sidewall. If there is any question about the belt’s physical sure of protection, a static-conductive brush or similar
condition and its static conductivity characteristics, replace the device should be employed to bleed off any residual
belt. static buildup that might remain around the belt.
BELT DRIVE PERFORMANCE

To provide proper maintenance, you must understand Gates Corporation is the recognized industry leader in prod-
the nature of the belt drives in your plant. You know the uct innovation and belt drive technology. New products and
expected belt service life on each drive, and you are aware applications are continually made available to Gates custom-
of the capabilities and limitations of this equipment. ers. Here are examples of advanced Gates belt innovations.
On occasion, however, it is necessary to give some thought
Advanced Gates Belt Drive Products & Solutions
to belt service life, especially when belt service life is below
the expected performance level and the situation must be • Poly Chain® GT® Carbon™ positive drive (synchro-
improved. nous) belts
• PowerGrip® GT®2
Upgrade Drive Performance • Polyflex® JB® belts
A belt drive can sometimes be upgraded to improve perfor- • PoweRated® light-duty V-Belts
mance. The first step is to see if simple improvements can • Nu-T-Link® spliced belting
be made at minimal costs. This involves checking the drive
• Super HC® Molded Notch V-Belts
design for adequate capacity using the appropriate drive
design manual or Gates Design Flex® Pro™ drive design soft- • Predator® Single & PowerBand® belts
ware. • Power Curve® V-Belts
• PowerBack® V-Belts
If further improvement is needed, the next step is to
upgrade the drive to a higher performance belt system. • Stainless steel sprockets & bushings (stock)
• Gates Design Flex® Pro™ Software
Here are examples of minor changes that could improve per-
• Gates Design Flex® Web™ Online
formance.
• Gates Design IQ™ Software
• Increase sheave or sprocket diameters
• Increase the number of belts, or use wider belt
Your local Gates distributor or representative can work with
• Add vibration dampening to system
you to upgrade your existing drives and reduce your mainte-
• Improve guard ventilation to reduce operating nance and down time costs.
temperature
• Use at least the correct, minimum recommended pul- Or, you may have a problem or excessive maintenance costs
ley diameters on inside and backside idlers with a non-belt drive, such as gear or chain. Again, your
• Use premium belts rather than general purpose types local Gates distributor or representative can offer you excel-
• Replace sheaves or sprockets when they are worn lent advice as to whether or not a belt drive could solve the
• Keep sheaves or sprockets properly aligned problem and reduce your maintenance costs.
• Place idler on span with lowest tension
• Re-tension newly installed belts after a 4 to 24 hour
run-in period
• Review proper belt installation and maintenance pro-
cedures
31
EF3328EN.2
BELT DRIVE PERFORMANCE
In most cases, synchonous belt drives that are using non-Gates curvilinear belts can be changed to a Gates PowerGrip® GT®2
belt to reduce width. Use the table below to identify product types that can be converted, and what widths are recommend-
ed.
For example, a competitor’s belt in 14mm pitch, 85mm wide, can be replaced with a narrower 55mm Gates PowerGrip®
GT®2 belt.
Reference www.gates.com/interchange for electronic interchange information.
32
EF3328EN.2
NOISE
V-belt, synchronous belt, roller chain, and gear drives will For comparison, some typical noise levels and their sources
all generate noise while transmitting power. Each type of are listed below.
system has its own characteristic sound. V-belt drives tend
to be the quietest belt drives, and synchronous belt drives
are much quieter than roller chain drives. When noise is an Normal Speech 60 dBA
issue, there are several design and maintenance tips that
Busy Office 80 dBA
should be followed to achieve the quietest possible belt
drive. Textile Weaving Plant 90 dBA
Canning Plant 100 dBA
Noise: Decibel and Frequency
Noise is an unwanted or unpleasant sound that can be Heavy City Traffic 100 dBA
described with two criteria – frequency and decibel (dBA) Punch Press 110 dBA
levels. Frequency is measured in Hertz.
The human ear is capable of distinguishing frequencies Air Raid Siren 130 dBA
typically from 20 to 20,000 Hertz. The human ear Jet Engine 160 dBA
generally does not perceive frequencies higher than 20,000
Hertz. Reducing Noise
The noise level or intensity of noise is measured in terms Following proper installation and maintenance procedures,
of decibels (dBA). The decibel has become the basic unit of as well as some simple design alternatives can reduce belt
measure since it is an objective measurement that approxi- drive noise.
mately corresponds to the subjective measurement made by
Belt Drive Tension and Alignment
the human ear. Since sound is composed of several distinct
and measurable parts and the human ear doesn’t differenti- Properly tensioning and aligning a belt drive will allow the
ate between these parts, measuring scales that approximate belt drive to perform at its quietest level.
the human ear’s reaction have been adopted. Three scales
Improperly tensioned V-belt drives can slip and squeal.
– A, B, and C are used to duplicate the ear’s response over
Improper tension in synchronous belt drives can affect how
the scale’s ranges. The A scale is most commonly used in
the belt fits in the sprocket grooves. Proper tension mini-
industry because of its adoption as the standard in OSHA
mizes tooth to groove interference, and thereby reduces belt
regulations.
noise. Check to make sure that the drive is properly ten-
Noise described in decibels (dBA) is generally perceived as sioned by using Gates tension measurement gauges.
the loudness or intensity of the noise.
Misaligned V-belt drives will be noisier than properly aligned
While the human ear can distinguish frequencies from 20 drives since interference is created at the belt’s entry point
to 20,000 Hertz, the ear is most sensitive in the range of into the sheave. Misaligned synchronous belt drives tend to
normal speech – 500 to 2000 Hertz. As a consequence, be much noisier than properly aligned drives due to the even
this range is the most common concern for noise control. greater amount of interference that is created between the
Frequency is most closely related to what the ear hears as belt teeth and the sprocket grooves. Misaligned synchronous
pitch. High frequency sounds are perceived as whining or belt drives may cause belt tracking that forces the edge of
piercing, while low frequency sounds are perceived as rum- the belt to ride hard against a sprocket flange. Misalignment
bling. causing belt contact with a flange will generate noise that
is easily detected. Follow the guidelines discussed in the
The combination of decibel and frequency describes the
installation section of this manual for checking and correcting
overall level of loudness to the human ear. One without the
alignment.
other does not adequately describe the loudness potential
of the noise. For example, an 85 dBA noise at 3000 Hertz is
going to be perceived as much louder than an 85 dBA noise
at 500 Hertz.
33
EF3328EN.2
NOISE
Noise Barriers and Absorbers
Sometimes, even properly aligned and tensioned belt drives
may be too noisy for a work environment. When this occurs,
steps can be taken to modify the drive guard to reduce the
noise level.
Noise barriers are used to block and reflect noise. Noise

barriers do not absorb or deaden the noise; they block the
noise and generally reflect most of the noise back towards
its point of origin. Good noise barriers are dense, and should
not vibrate. A sheet metal belt guard is a noise barrier. The
more complete the enclosure is, the more effective it is as
a noise barrier. Noise barrier belt guards can be as sophisti-
cated as a completely enclosed case, or as simple as sheet
metal covering the front of the guard to prevent direct
sound transmission.
Noise absorbers are used to reduce noise reflections and to

dissipate noise energy. Noise absorbers should be used in
combination with a noise barrier. Noise absorbers are com-
monly referred to as acoustic insulation. Acoustic insulation
(the noise absorber) is used inside of belt guards (the noise
barrier) where necessary. A large variety of acoustic insula-
tion manufacturers are available to provide different prod-
ucts for the appropriate situation.
A combination of noise barrier (solid belt guard) and noise

absorber (acoustic insulation) will provide the largest reduc-
tion in belt drive noise. While the noise reduction cannot be
predicted, field experience has shown that noise levels have
been reduced by 10 to 20 dBA when using complete belt
guards with acoustic insulation.
34
EF3328EN.2
SPROCKET CORROSION PREVENTION

Poly Chain® GT® Carbon™ belt drives are excellent replace-
ments for roller chain drives. Poly Chain® GT® Carbon™
belt drives offer significant maintenance savings and perfor-
mance advantages over roller chain drives on applications
that operate in corrosive environments. Synchronous belt
drives also provide energy savings compared to V-belt drives.
Some of these applications may also operate in corrosive
environments.
Corrosive Environments
Many applications in the food and beverage industry are
located in areas that require periodic wash down. Unless a
drive is completely shielded and protected from wash down,
rust and corrosion will be rapidly apparent in these types of
environments.
Applications that are located in environments that have high
humidity or moisture content will also develop sprocket and
bushing corrosion. Examples of these types of environments
are pulp processing applications and cooling tower applica-
tions that pass moist air over the belt drive.
Effects of Corrosion
Corrosion will attack the sprocket grooves, building up rust
deposits. The corrosion will increase over time, building up
in the sprocket grooves and non-driving surfaces (flanges,
sprocket faces, bushing face).
Sprockets with corrosion in the grooves will rapidly wear

the belt’s teeth. Sprockets with corroded grooves will wear
through the abrasion resistant tooth fabric, resulting in
tooth shear and premature belt failure.
35
EF3328EN.2
SPROCKET CORROSION PREVENTION

Preventing Corrosion
Sprocket corrosion can be prevented by using Gates stainless
steel Poly Chain® GT®2 sprockets and bushings. Sprockets
can also be electroless nickel plated. Both solutions will elim-
inate corrosion as a cause of failure on belt drives located in
these damaging environments.
The sprocket shown below has been electroless nickel
plated. Compare the grooves to the unprotected corroded
sprocket shown on page 35.
The photo below illustrates the difference in wear between

belts running on properly plated sprockets and those run-
ning on corroded sprockets. The wear on the belt running
on corroded sprockets is severe and will result in a greatly
shortened belt life.
Belt ran on properly plated or stainless steel sprockets
Belt ran on corroded sprockets
36
EF3328EN.2
TROUBLESHOOTING GUIDE
When troubleshooting a drive problem, the goal is to iden- Step 1

tify the cause(s), then take appropriate corrective action. The Describe the problem
following steps should be followed to help with this process.
• What is wrong?
1. Describe the drive problem as accurately as possible.
Use Step 1 as a guide. Use this step as a guide in the • When did it happen?
troubleshooting process. • How often does it happen?
2. Go through the list of “Drive Symptoms”. Check • What is the drive application?
those symptoms that are observed and record them,
as well as observations of anything unusual about • Have the machine operations or output changed?
the drive. • What kind of belt(s) are being used?
3. Go through the “Problem/Solution Summary Table”. • What are the expectations for belt performance in this
List the probable cause(s) and corrective action. application?
Also, review the list of observations.
4. After identifying probable causes and corrective
action, review and implement. Step 2
What to Do When All Else Fails Identify symptoms and record
observations of anything unusual.
If the problem still exists after all troubleshooting efforts
have been exhausted, contact the local Gates distributor.
If the local distributor cannot solve the problem, a qualified
Gates representative can be contacted. Save the failed belt(s) V-Belt Drive Symptoms
for further inspection. Check List
(Check those that are observed)
Gates Power Transmission Product Application engineers are
also available at ptpasupport@gates.com or (303) 744-5800
to answer additional drive design and troubleshooting • Premature Belt Failure
questions.
Broken belt(s)
Belt(s) fail to carry load (slip). No visible reason
Edge cord failure
Belt delamination or undercord separation
• Severe or Abnormal Belt Wear

Wear on belt top surface
Wear on top corners of belt
Wear on belt sidewall
Wear on belt bottom corners
Wear on bottom surface of belt
Undercord cracking
Burn or hardening on bottom or sidewall
Belt surface flaking, sticky or swollen
Belt stretch
Extensive hardening of belt exterior
37
EF3328EN.2
TROUBLESHOOTING GUIDE
V-Belt Drive Symptoms Checklist–cont. Synchronous Drive Symptoms Checklist
• Problems with PowerBand® Belts • Belt Problems
Tie-band separation Unusual noise
Top of tie-band frayed, worn or damaged Tension loss
Band comes off drive Excessive belt edge wear
One or more ribs run outside of pulley Tensile break
Cracking
• V-Belt Turns Over or Jumps Premature tooth wear
off Sheave
Tooth shear
Single belt
Belt ratcheting
One or more belts in a set
Land area worn
Joined or banded belts
• Sprocket Problems
• Problems with Belt Take-Up
Flange failure
Single belt
Unusual wear
Multiple belts stretch unequally
Rusted or corroded
All belts stretch equally
Belts do not match
• Performance Problems
Incorrect driveN speeds
• V-Belt Noise
Belt tracking problems
Squeal or “chirp”
Excessive temperature: bearings, housings,
Slapping noise shafts, etc.
Rubbing sound Shafts out of sync
Grinding Vibration
Unusually loud drive
• Unusual Vibration
Belts flopping
Excessive vibration in drive system
• Problem With Sheaves

Broken or damaged
Severe, rapid groove wear
• Problems With Drive

Components
Bent or broken shafts
Hot bearings
38
EF3328EN.2
PROBLEM/SOLUTION SUMMARY TABLE

V-Belt Drive Symptoms
Premature Belt Failure
Symptoms Probable Cause Corrective Action
Broken belt(s) 1. Under-designed drive 1. Redesign, using Gates manual.
2. Belt rolled or pried onto sheave 2. Use drive take-up when installing.
3. Provide adequate guard or drive
3. Object falling into drive protection.
4. Redesign to accommodate shock
4. Severe shock load load.
Belts fail to carry load, no 1. Redesign, using Gates manual.

visible reason 1. Underdesigned drive
2. Damaged tensile member 2. Follow correct installation proce-
dure.
3. Worn sheave grooves 3. Check for groove wear; replace as
needed.
4. Center distance movement 4. Check drive for center distance
movement during operation.
Edge cord failure

1. Pulley misalignment 1. Check alignment and correct.
2. Damaged tensile member 2. Follow correct installation
procedure.
Belt de-lamination or undercord

separation 1. Too small sheaves 1. Check drive design, replace with
larger sheaves.
2. Use of too small backside idler 2. Increase backside idler to accept-
able diameter.
NOTE: Belt Failure Analysis poster #12975 available. Contact your Gates Representative.
39
EF3328EN.2

Severe or Abnormal V-Belt Wear
Wear on top surface of belt 1. Rubbing against guard 1. Replace or repair guard.
2. Idler malfunction 2. Replace idler.
Wear on top corner of belt 1. Belt-to-sheave fit incorrect (belt 1. Use correct belt-to-sheave
too small for groove) combination.
1. Belt slip 1. Retention until slipping stops.

Wear on belt sidewalls
2. Misalignment 2. Realign sheaves.
3. Worn sheaves 3. Replace sheaves.
4. Incorrect belt 4. Replace with correct belt size.
Wear on bottom corner of belt 1. Belt-to-sheave fit incorrect 1. Use correct belt-to-sheave combi-
nation.
Wear on bottom surface of belt 1. Belt bottoming on sheave groove 1. Use correct belt/sheave match.
3. Debris in sheaves 3. Clean sheaves.
1. Sheave diameter too small 1. Use larger diameter sheaves.

Undercord cracking
2. Belt slip 2. Retention.
3. Backside idler too small 3. Use larger diameter backside idler.
4. Improper storage 4. Don’t coil belt too tightly, kink or

bend. Avoid heat and direct sun-
light.
40
EF3328EN.2

Severe or Abnormal V-Belt Wear–cont.
Undercord or sidewall burn or 1. Belt slipping 1. Retension until slipping stops.
hardening 2. Worn sheaves 2. Replace sheaves.
3. Underdesigned drive 3. Refer to Gates drive manual.
4. Shaft movement 4. Check for center distance
changes.
Belt surface hard or stiff 1. Hot drive environment 1. Improve ventilation to drive.
Belt surface flaking, sticky or 1. Oil or chemical contamination 1. Do not use belt dressing. Eliminate
sources of oil, grease or chemical
swollen
contamination.
Problems With PowerBand® Belts

Tie band separation 1. Worn sheaves 1. Replace sheaves.
2. Improper groove spacing 2. Use standard groove sheaves.
Top of tie band frayed or worn 1. Interference with guard 1. Check guard.
2. Backside idler malfunction or dam- 2. Replace or repair backside idler
aged
PowerBand® belt comes off 1. Debris in sheaves 1. Clean grooves. Use single belts to
drive repeatedly prevent debris from being trapped
in grooves.
2. Misalignment 2. Realign drive.
41
EF3328EN.2

Problems With PowerBand® Belts–cont.
One or more “ribs” runs out of 1. Misalignment 1. Realign drive.
pulley 2. Undertensioned 2. Retension.
V-Belts Turn Over or Come Off Drive

Involves single or multiple belts 1. Shock loading or vibration 1. Check drive design. Use Gates
PowerBand® belts or Power Cable®
belts.
2. Foreign material in grooves 2. Shield grooves and drive.
3. Misaligned sheaves 3. Realign the sheaves.
4. Worn sheave grooves 4. Replace sheaves.
5. Damaged tensile member 5. Use correct installation and belt
storage procedure.
6. Incorrectly placed flat idler 6. Carefully align flat idler on slack
side of drive as close as possible to
driveR sheaves.
7. Mismatched belt set 7. Replace with Gates matched belts.
Do not mix old and new belts.
8. Poor drive design 8. Check for center distance stability

and vibration dampening.
Problems with V-Belt Take-Up

Multiple belts stretch unequally 1. Misaligned drive 1. Realign and retension drive.
2. Debris in sheaves 2. Clean sheaves.
3. Broken tensile member or cord 3. Replace all belts, install properly.
damaged
4. Mismatched belt set 4. Install Gates matched belt set.
Single belt, or where all belts 1. Insufficient take-up allowance 1. Check take-up. Use allowance
stretch evenly specified in Gates design manuals.
2. Grossly overloaded or under 2. Redesign drive.
designed drive
3. Broken tensile members 3. Replace belt, install properly.
Belts do not match 1. Not all belts are from the same 1. Use Gates belts
manufacturer
42
EF3328EN.2

V-Belt Noise
Belt squeals or chirps 1. Belt slip 1. Retension.
2. Contamination 2. Clean belts and sheaves.
Slapping Sound 1. Loose belts 1. Retension.
2. Mismatched set 2. Install matched belt set.
3. Misalignment 3. Realign pulleys so all belts share
load equally.
Rubbing sound 1. Guard interference 1. Repair, replace or redesign guard.
Grinding sound 1. Damaged bearings 1. Replace, align & lubricate.
Unusually loud drive 1. Incorrect belt 1. Use correct belt size. Use correct
belt tooth profile for sprockets on
synchronous drive.
2. Incorrect Tension 2. Check tension and adjust
3. Worn sheaves 3. Replace sheaves
4. Debris in sheaves 4. Clean sheaves, improve shielding,
remove rust, paint, or remove dirt
from grooves.
Unusual Vibration
Belts flopping 1. Loose belts (under tensioned) 1. Retension.
2. Mismatched belts 2. Install Gates matched belts.
3. Pulley misalignment 3. Align pulley
Unusual or excessive vibration 1. Incorrect belt 1. Use correct belt cross section in
pulley. Use correct tooth profile
and pitch in sprocket.
2. Poor machine or equipment 2. Check structure and brackets for
design adequate strength.
3. Pulley out of round 3. Replace with non-defective pulley.
4. Loose drive components 4. Check machine components and
guards, motor mounts, motor
pads, bushings, brackets and
framework for stability, adequate
design strength, proper mainte-
nance and proper installation.
Problems With Sheaves

Symptoms Probable Cause
Corrective Action
Broken or damaged sheave 1. Incorrect sheave installation
1. Do not tighten bushing bolts beyond
2. Foreign objects falling into drive recommended torque values.
3. Excessive rim speeds 2. Use adequate drive guard.
3. Keep pulley rim speeds below
4. Incorrect belt installation maximum recommended value.
4. Do not pry belts onto pulleys.
Severe Groove Wear 1. Excessive belt tension
2. Sand, debris or contamination 1. Retension, check drive design.
2. Clean and shield drive as well as
3. Wrong belt possible.
3. Make sure belt and sheave combi-
nation is correct.
43
EF3328EN.2

Problem With Other Drive Components
Bent or broken shaft 1. Extreme belt overtension 1. Retension
2. Overdesigned drive* 2. Check drive design, may need to
use smaller or fewer belts.
3. Accidental damage 3. Redesign drive guard.
4. Machine design error 4. Check machine design.
5. Accidental damage to guard or 5. Repair, redesign for durability.
poor guard design
6. Pulley mounted too far away from 6. Move pulley closer to bearing.
outboard bearing
Hot Bearings 1. Worn grooves - belts bottoming 1. Replace sheaves. Tension drive
and won’t transmit power until properly.
overtensioned*
2. Improper tension 2. Retension.
3. Motor manufacturer’s sheave 3. Redesign using drive design manual.
diameter recommendation not fol-
lowed
4. Bearing underdesigned 4. Check bearing design.
5. Bearing not properly maintained 5. Align and lubricate bearing.
6. Sheaves too far out on shaft 6. Place sheaves as close as possible to
bearings. Remove obstructions
7. Belt Slippage 7. Retension.
* Using too many belts, or belts that are too large, can severely stress motor or driveN shafts. This can happen when load requirements are reduced on a
drive, but the belts are not redesigned accordingly. This can also happen when a drive is greatly overdesigned. Forces created from belt tensioning are too
great for the shafts.
Synchronous Drive Symptoms

Synchronous Belt Problems
Unusual noise 1. Misaligned drive 1. Correct alignment.
2. Too low or high tension 2. Adjust to recommended value
3. Backside idler 3. Use inside idler.
4. Worn sprocket 4. Replace.
5. Bent guide flange 5. Replace.
6. Belt speed too high 6. Redesign drive.
7. Incorrect belt profile for sprocket 7. Use proper belt/sprocket combina-
tion.
8. Subminimal diameter 8. Redesign drive using larger diam-
eters.
9. Excessive load 9. Redesign drive for increased
capacity.
44
EF3328EN.2

Synchronous Belt Problems–cont.
Tension Loss 1. Weak support structure 1. Reinforce structure.
2. Excessive sprocket wear 2. Use alternate sprocket material.
3. Fixed (non-adjustable) centers 3. Use inside idler for belt adjust-
ment.
4. Excessive debris 4. Remove debris, check guard.
capacity.
eters.
7. Belt, sprocket or shafts running 7. Check for conductive heat transfer
too hot from prime mover.
8. Unusual belt degradation 8. Reduce ambient drive temperature
to 185°F maximum.
Excessive Belt Edge Wear 1. Damage due to handling 1. Follow proper handling instructions.
2. Flange damage 2. Repair flange or replace sprocket.
3. Belt too wide 3. Use proper width sprocket.
4. Belt tension too low 4. Adjust tension to recommended
value.
5. Rough flange surface finish 5. Replace or repair flange (to elimi-
nate abrasive surface).
6. Improper tracking 6. Correct alignment.
7. Belt hitting drive guard or 7. Remove obstruction or use inside
bracketry idler.
8. Misalignment 8. Realign drive
Tensile Break 1. Excessive shock load 1. Redesign drive for increased
capacity.
eters.
3. Improper belt handling and storage 3. Follow proper storage and han-
prior to installation (crimping) dling procedures.
4. Debris or foreign object in drive 4. Remove objects and check guard.
5. Replace sprocket.
5. Extreme sprocket run-out
Belt Cracking 1. Subminimal diameter 1. Redesign drive using larger diam-

eter.
2. Backside idler 2. Use inside idler or increase diam-
eter of backside idler.
3. Extreme low temperature at start-up. 3. Pre-heat drive environment.
4. Extended exposure to harsh 4. Protect drive.
chemicals
5. Cocked bushing/sprocket assembly 5. Install bushing per instructions.
Premature Tooth Wear 1. Too low or high belt tension 1. Adjust to recommended value.
2. Belt running partly off unflanged 2. Correct alignment.
sprocket
3. Misaligned drive 3. Correct alignment.
4. Incorrect belt profile for sprocket 4. Use proper belt/sprocket combina-
tion.
5. Worn sprocket 5. Replace.
6. Rough sprocket teeth 6. Replace sprocket.
45
EF3328EN.2

Synchronous Belt Problems–cont.
Premature Tooth Wear–cont. 7. Damaged sprocket 7. Replace.
8. Sprocket not to dimensional 8. Replace.
specification
9. Belt hitting drive bracketry or 9. Remove obstruction or use idler
other structure
capacity
11. Insufficient hardness of sprocket 11. Use a more wear-resistant
material sprocket
13. Cocked bushing/sprocket 13. Install bushing per instructions.
assembly
Tooth Shear 1. Excessive shock loads 1. Redesign drive for increased
capacity.
2. Redesign drive.
2. Less than 6 teeth-in-mesh 3. Replace sprocket.
3. Extreme sprocket run-out 4. Replace.
4. Worn sprocket 5. Use inside idler
5. Backside idler 6. Use proper belt/sprocket combina-
6. Incorrect belt profile for the tion.
sprocket 7. Realign.
7. Misaligned drive 8. Adjust tension to recommended
8. Belt undertensioned value.
Belt Ratcheting 1. Drive is undertensioned 1. Adjust tension to recommended
value.
2. Excessive shock loads 2. Redesign drive for increased
capacity.
3. Drive framework not rigid 3. Reinforce system.
Land Area Worn 1. Excessive tension 1. Adjust tension to recommended

value.
2. Check sprocket condition. Replace
2. Excessive sprocket wear if necessary.
Synchronous Sprocket Problems

Flange Failure 1. Belt forcing flange off 1. Correct alignment or properly
secure flange to sprocket.
Unusual Sprocket Wear 1. Sprocket has too little wear resis- 1. Use alternate sprocket material.
tance (i.e. plastic, aluminum, soft
metals)
2. Misaligned drive 2. Correct alignment.
capacity.
5. Belt tension too low or high 5. Adjust tension to recommended
value.
6. Incorrect belt profile 6. Use proper belt/sprocket combina-
tion.
46
EF3328EN.2

Synchronous Sprocket Problems–cont.
Rust and Corrosion 1. Rust caused by high moisture 1. Replace cast iron sprockets and
conditions in the production area, bushings with stainless steel com-
or by the use of water-based ponents.
cleaning solutions. 2. Replace cast iron sprockets with
nickel plated sprockets.
Performance Problems
Incorrect driveN speed 1. Design error 1. Use correct driveR/driveN sprocket
size for desired speed ratio.
Belt Tracking 1. Belt running partly off unflanged 1. Correct alignment.
sprocket
2. Centers exceed 8 times small 2. Correct parallel alignment to set
sprocket diameter belt to track on both sprockets.
Flange both sprockets.
3. Excessive belt edge wear 3. Correct alignment.
Excessive Temperature (Belt, 1. Misaligned drive 1. Correct alignment.
Bearing, Housing, Shafts, etc.) 2. Too low or high belt tension 2. Adjust tension to recommended
value.
3. Incorrect belt profile 3. Use proper belt/sprocket combina-
tion.
Shafts Out of Sync 1. Design error 1. Use correct sprocket sizes.
2. Incorrect belt 2. Use correct belt with correct tooth
profile for grooves.
Vibration 1. Incorrect belt profile for the 1. Use proper belt/sprocket combina-
sprocket tion.
2. Too low or high belt tension 2. Adjust tension to recommended
value.
3. Bushing or key loose 3. Check and reinstall per instructions.
47
EF3328EN.2
MAINTENANCE TOOLS
The tools available to help troubleshoot drive problems Belt & Sheave Groove Gauges
range from the surprisingly simple to complicated. Following
is a list of tools that can be used to effectively diagnose a If a belt-to-sheave groove mismatch is suspected, English
problem. While Gates does not sell all of the items discussed and metric belt and sheave groove gauges can be used
in this section, the items are readily available from industrial to check dimensions. These also are handy for identify-
instrumentation outlets throughout the United States. ing a belt cross section for replacements and for checking
sheave grooves
Eyes, Ears & Nose for wear.
When troubleshooting a belt drive problem, stand back and
observe the drive while it is in operation and at rest. Is there These gauges
a warm rubber smell? Is there anything unusual about the are available
way the belt travels around the drive? Is the drive frame from the local
flexing under load? Are there chirping, squealing or grinding Gates
noises? Is there an accumulation of dust or debris beneath distributor.
the drive which might interfere with the belts?
English Gauge:
Product No.
Squirt Bottle With Soapy Water
7401-0014
When a belt drive is excessively noisy, the belt is often incor- Metric Gauge:
rectly blamed. It is easy to eliminate the belt as the problem Product No.
by spraying it with soapy water while it is running. If the 7401-0013
noise goes away, or decreases, then the belt is part of the
problem. If the same noise is still present, the problem is
likely due to other drive components.
Long Straight Edge
String
While V-belts can be somewhat forgiving of misalign-
Variation in drive center distance, often caused by weak ment, this condition can still affect V-belt performance.
supporting structure, can cause problems from vibration Even slight misalignment can cause major problems on
to short belt life. To determine if center distance variation a synchronous drive. Use a long straight edge, made of
exists, turn off the drive and tightly tie a piece of string from wood, metal or any rigid material, to quickly check drive
the driveR to the driveN shaft. Start up the drive and note if alignment. Simply lay the straight edge across the pulley
the string stretches almost to the point of breaking, or goes faces and note the points of contact (or lack of contact).
slack. If either is the case, the problem could be center dis-
tance variation. Design Flex® Pro™ and Design IQ™ Software
It is particularly important to observe the string right at drive
start up when the loads are highest. String can also be used Gates design suite of engineering programs include inter-
to check pulley alignment. active support software and a user friendly interface for
rapid data retrieval and smooth design work.
Both programs are available at www.gates.com/drivedesign.
NOTE: In some cases redesign of the drive is

necessary. Gates Design Flex® Pro™ drive design software
provides a quick, accurate and flexible method of correctly
redesigning problem drives.
48
EF3328EN.2
MAINTENANCE TOOLS
A B C D E F
G H
Belt Tension Testers D. Krikit Gauge

(Product No. 7401-0071) I
Improper belt tension, either too
high or too low, can cause belt drive For use with Automotive V-belts up
problems. An “experienced” thumb to and including 7/8" top width.
may be okay for ordinary drives, but Krikit II
for critical drives, Gates recommends (Product No. 7401-0072)
using a tension gauge. Proper tension For use with Automotive V-ribbed
and installation can extend belt life belts up to 8 ribs in width.
and reduce costly downtime. E. Sonic Tension Meter
Several types of tension gauges are Model 507C
available. (Product No. 7420-0507)
For extremely accurate belt tension
A. Tension Tester measuring, the Gates Sonic Tension
(Product No. 7401-0076) Meter is an electronic device that
Maximum deflection force: 30 measures the natural frequency of a
lbs. For use with all small V-belt free stationary belt span and instantly Accessories:
and Synchronous drives, including computes the static belt tension based F. Flexible Sensor
PowerBand® and Poly Chain® GT® upon the belt span length, belt width (Product No. 7420-0204)
Carbon™ belt drives. and belt type.
G. Optional Inductive Sensor
B. Double Barrel Features: (Product No. 7420-0212)
Tension Tester
(Product No. 7401-0075) • Can be used for synchronous and H. Replacement Magnets
Maximum deflection force: 66 lbs. V-belts. for Inductive Sensor
For use with all multiple • Uses sound waves instead of force/ (Prod. No. 7420-1212, set of 10)
V-belt and large Synchronous deflection.
drives, including PowerBand® and I. EZ Align® Laser Alignment Tool
• Results are repeatable with any
Poly Chain® GT® Carbon™ belt (Product No. 7420-1000
operator.
drives. - Red Laser)
• Portable, lightweight and easy to use. (Product No. 7420-3000
C. 5-Barrel Tension Tester • Fast. Calculates tension in seconds. - Green Laser)
(Product No. 7401-0079) • Can be used in almost any environ- • Compact design
Maximum deflection force: 165 lbs. ment. • Laser projects a line
for use with multiple V-belt and • Model 507C runs on two AAA • Mirror reflects laser line, making it
large Synchronous drives. batteries. easy to align shafts
• Laser line is very easy to read on
targets
• Includes a hard foam filled plastic
carrying case
• Green laser is ideal for outdoor or
bright environment use.
49
EF3328EN.2
MAINTENANCE TOOLS
Dial Indicator Infrared Pyrometer Strobe Tachometer

Improperly mounted sheaves or out-of- The pyrometer accurately measures It is not always possible to see what
round pulleys are sometimes the root of external belt temperatures and envi- is happening to a drive while it is in
vibration or more severe problems. This ronmental temperatures. operation. This instrument visually
device can be used to measure side-to- stops the action to get a better idea of
side sheave wobble or diameter varia- the dynamic forces affecting the drive.
tion by holding it up to the sheave side- The strobe tachometer is best used
wall or top of the belt inside the pulley after initial diagnosis of the problem
groove, respectively. IMPORTANT: because it helps pinpoint the cause. It
Always turn off the machine before will help identify such things as single
using the dial indicator. Rotate the drive or dual mode belt span vibration and
by hand to make your measurements. frame flexure.
Noise Meter
Use a noise meter to measure environ-
mental and belt drive noise.
50
EF3328EN.2
TECHNICAL INFORMATION
Table No. 1 Table No. 2

Heavy-Duty V-Belt Section, Sheave Diameters Maximum Allowable Outside Diameters
and Standard Groove Angles For Cast Iron Pulleys
Sheave Datum Standard Maximum Maximum Allowable
Belt Diameter Groove Angle Shaft Pulley
Section (D.D.) (in.) (± 0.20˚) Speed Diameter
(RPM) (in.)
A, AX Up to 5.4 34
600 41.4
A, AX Over 5.4 38
870 28.5
B, BX Up to 7.0 34
1,160 21.4
B, BX Over 7.0 38
1,400 17.7
C, CX Up to 7.99 34
1,600 15.5
C, CX 8.0 to 12.0 36
1,750 14.2
C, CX Over 12.0 38
2,000 12.4
D Up to 12.99 34
2,400 10.3
D 13.0 to 17.0 36
2,800 8.8
D Over 17.0 38
3,000 8.3
E Up to 24.0 36
3,450 7.2
E Over 24.0 38
4,000 6.2
Sheave Outside Standard
Belt Diameter Groove Angle 4,500 5.5
Section (O.D.) (in.) (± 0.20˚) 5,000 5.0
3V, 3VX Up to 3.49 36 7,500 3.31
3V, 3VX 3.50 to 6.00 38 10,000 2.48
3V, 3VX 6.0 to 12.00 40
3V, 3VX Over 12.00 42
5V, 5VX Up to 9.99 38
5V, 5VX 10.00 to 16.0 40
5V, 5VX Over 16.00 42
8V Up to 15.99 38
8V 16.00 to 22.4 40
8V Over 22.4 42
Table No. 3
Depth hk
Shaft Diameter (Inches) Width wk +0.015-0.000
(inches)* (Inches)
Up Through 7/16 (0.44) 3/32 (0.094) 3/64 (0.047)
Over 7/16 (0.44) To and Incl. 9/16 (0.56) 1/8 (0.125) 1/16 (0.062)
Over 9/16 (0.56) To and Incl. 7/8 (0.88) 3/16 (0.188) 3/32 (0.094)
Over 7/8 (0.88) To and Incl. 1 1/4 (1.25) 1/4 (0.250) 1/8 (0.125)
Over 1 1/4 (1.25) To and Incl. 1 3/8 (1.38) 5/16 (0.312) 5/32 (0.156)
Over 1 3/8 (1.38) To and Incl. 1 3/4 (1.75) 3/8 (0.375) 3/16 (0.188)
Over 1 3/4 (1.75) To and Incl. 2 1/4 (2.25) 1/2 (0.500) 1/4 (0.250)
Over 2 1/4 (2.25) To and Incl. 2 3/4 (2.75) 5/8 (0.625) 5/16 (0.312)
Over 2 3/4 (2.75) To and Incl. 3 1/4 (3.25) 3/4 (0.750) 3/8 (0.375)
Over 3 1/4 (3.25) To and Incl. 3 3/4 (3.75) 7/8 (0.875) 7/16 (0.438)
Over 3 3/4 (3.75) To and Incl. 4 1/2 (4.50) 1 (1.000) 1/2 (0.500)
Over 4 1/2 (4.50) To and Incl. 5 1/2 (5.50) 1 1/4 (1.250) 5/8 (0.625)
Over 5 1/2 (5.50) To and Incl. 6 1/2 (6.50) 1 1/2 (1.500) 3/4 (0.750)
Over 6 1/2 (6.50) To and Incl. 7 1/2 (7.50) 1 3/4 (1.750) 3/4 (0.750)
Over 7 1/2 (7.50) To and Incl. 9 (9.00) 2 (2.000) 3/4 (0.750)
Over 9 (9.00) To and Incl. 11 (11.00) 2 1/2 (2.500) 7/8 (0.875)
Over 11 (11.00) To and Incl. 13 (13.00) 3 (3.000) 1 (1.000)
*Tolerance on Width, wk for widths up through 1/2’’ (0.500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.002-0.000

For widths over 1/2’’ (0.500) through 1’’ (1.000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.003-0.000
For widths over 1’’ (1.000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.004-0.000
51
EF3328EN.2
NEMA MINIMUM DIAMETERS
Electric Motor Frames

and Minimum Sheave and Sprocket Diameters
Table No. 4
The National Electric Manufacturers Horsepower at Synchronous Speed (rpm) Synchronous
Belts
Association (NEMA) publishes recom-
Motor Shaft 3600 1800 1200 900 Min.
mendations for the minimum diameter Frame Dia. (3450) (1750) (1160) (870) Pitch
of sheaves to be used on General Code (in) Dia. (in)
Purpose electric motors. Purpose of 143T 0.875 1-1/2 1 3/4 1/2 2.0
the recommendations is to prevent 145T 0.875 2—3 1-1/2 — 2 1 3/4 2.2
the use of too small sheaves, which 182T 1.125 3 3 1-1/2 1 2.2
can result in shaft or bearing damage 182T 1.125 5 — — — 2.4
because belt pull goes up as sheave 184T 1.125 — — 2 1-1/2 2.2
diameter goes down. 184T 1.125 5 — — — 2.2
184T 1.125 7-1/2 5 — — 2.7
The NEMA Standard MG-1-14.42,
213T 1.375 7-1/2—10 7-1/2 3 2 2.7
November 1978 shows minimum
215T 1.375 10 — 5 3 2.7
recommended sheave diameters as a
215T 1.375 15 10 — — 3.4
function of frame number. The table
254T 1.625 15 — 7-1/2 5 3.4
below lists the NEMA frame assign-
254T 1.625 20 15 — — 4.0
ments and minimum diameter recom-
256T 1.625 20-25 — 10 7-1/2 4.0
mendations according to the 1964
256T 1.625 — 20 — — 4.0
rerating program.
284T 1.875 — — 15 10 4.0
284T 1.875 — 25 — — 4.0
286T 1.875 — 30 20 15 4.7
324T 2.125 — 40 25 20 5.4
326T 2.125 — 50 30 25 6.1
364T 2.375 — — 40 30 6.1
364T 2.375 — 60 — — 6.7
365T 2.375 — — 50 40 7.4
365T 2.375 — 75 — — 7.7
404T 2.875 — — 60 — 7.2
404T 2.875 — — — 50 7.6
404T 2.875 — 100 — — 7.7
405T 2.875 — — 75 60 9.0
405T 2.875 — 100 — — 7.7
405T 2.875 — 125 — — 9.5
444T 3.375 — — 100 — 9.0
444T 3.375 — — — 75 8.6
444T 3.375 — 125 — — 9.5
444T 3.375 — 150 — — 9.5
445T 3.375 — — 125 — 10.8
445T 3.375 — — — 100 10.8
445T 3.375 — 150 — — 10.8
445T 3.375 — 200 — — 11.9
For other than the General Purpose AC motors (for example, DC motors, Definite
Purpose motors, motors with special bearings or motors that are larger than those
covered by the NEMA standard), consult the motor manufacturer for minimum
sheave diameter recommendations. It is helpful to the manufacturer to include
details of the application with your inquiry.
52
EF3328EN.2
NEMA MINIMUM DIAMETERS
Minimum Recommended Sprocket Outside Diameters

for General Purpose Electric Motors
Data in the white area are from NEMA Standard MG-1-14-42, NOTE: For a given horsepower and speed, the total belt pull is
June 1972. Figures in black area are from MG-1-43, January 1968. related to the motor sprocket size. As the size decreases, the total
The gray area is a composite of electric motor manufacturer data. belt pull increases. Therefore, to limit the resultant load on motor
They are generally conservative and specific motors and bearings and shaft bearings, NEMA lists minimum sprocket sizes for the vari-
may permit the use of a smaller motor sprocket. Consult the motor ous motors. The sprocket on the motor (DriveR sprocket) should be
manufacturer. at least this large.
NEMA Minimum Sprocket Diameters
Motor RPM (60 Cycle and 50 Cycle Electric Motors)
Motor 575 690 870 1160 1750 3450 Motor
Horsepower 485• 575• 725• 950• 1425• 2850• Horsepower
1/2 - - 2.0 - - - 1/2
3/4 - - 2.2 2.0 - - 3/4
1 2.7 2.3 2.2 2.2 2.0 - 1
1-1/2 2.7 2.7 2.2 2.2 2.2 2.0 1-1/2
2 3.4 2.7 2.7 2.2 2.2 2.2 2
3 4.1 3.4 2.7 2.7 2.2 2.2 3
5 4.1 4.1 3.4 2.7 2.7 2.2 5
7-1/2 4.7 4.1 4.0 3.4 2.7 2.7 7-1/2
10 5.4 4.7 4.0 4.0 3.4 2.7 10
Table No. 5 15
20
6.1
7.4
5.4
6.1
4.7
5.4
4.0
4.7
4.0
4.0
3.4
4.0
15
20
25 8.1 7.4 6.1 5.4 4.0 4.0 25
30 9.0 8.1 6.1 6.1 4.7 - 30
40 9.0 9.0 7.4 6.1 5.4 - 40
50 9.9 9.0 7.6 7.4 6.1 - 50
60 10.8 9.9 9.0 7.2 6.7 - 60
75 12.6 11.7 8.6 9.0 7.7 - 75
100 16.2 13.5 10.8 9.0 7.7 - 100
125 18.0 16.2 13.5 10.8 9.5# - 125
150 19.8 18.0 16.2 11.7 9.5 - 150
200 19.8 19.8 19.8 - 11.9 - 200
250 19.8 19.8 - - - - 250
300 24.3 24.3 - - - - 300
*These RPM are for 50 cycle electric motors. # Use 8.6 for Frame Number 444 T only.
NEMA Minumum V-Belt Sheave Diameters

Minimum Recommended Sheave Outside Diameters for Minimum Recommended Sheave Datum Diameters for General
General Purpose Electric Motors Purpose Electric Motors
Super HC ® V-Belts, Super HC PowerBand ® Belts, Hi-Power ® II V-Belts, Hi-Power II PowerBand Belts
Polyflex ® JB® Belts. or Tri-Power® Molded Notch V-Belts.
Motor Motor RPM (60 cycle and 50 cycle Electric Motors) Motor Motor Motor RPM (60 cycle and 50 cycle Electric Motors) Motor
Horse- 575 690 870 1160 1750 3450 Horse- Horse- 575 690 870 1160 1750 3450 Horse-
power 485* 575* 725* 950* 1425* 2850 power power 485* 575* 725* 950* 1425* 2850 power
1/2 — — 2.2 — — — 1/2 1/2 2.5 2.5 2.2 — — — 1/2
3/4 — — 2.4 2.2 — — 3/4 3/4 3.0 2.5 2.4 2.2 — — 3/4
1 3.0 2.5 2.4 2.4 2.2 — 1 1 3.0 2.5 2.4 2.4 2.2 — 1
1 1/2 3.0 3.0 2.4 2.4 2.4 2.2 1 1/2 1 1/2 3.0 3.0 2.4 2.4 2.4 2.2 1 1/2
2 3.8 3.0 3.0 2.4 2.4 2.4 2 2 3.8 3.0 3.0 2.4 2.4 2.4 2
3 4.5 3.8 3.0 3.0 2.4 2.4 3 3 4.5 3.8 3.0 3.0 2.4 2.4 3
5 4.5 4.5 3.8 3.0 3.0 2.4 5 5 4.5 4.5 3.8 3.0 3.0 2.6 5
7 1/2 5.2 4.5 4.4 3.8 3.0 3.0 7 1/2 7 1/2 5.2 4.5 4.4 3.8 3.0 3.0 7 1/2
10 6.0 5.2 4.4 4.4 3.8 3.0 10 10 6.0 5.2 4.6 4.4 3.8 3.0 10
15 6.8 6.0 5.2 4.4 4.4 3.8 15 15 6.8 6.0 5.4 4.6 4.4 3.8 15
20 8.2 6.8 6.0 5.2 4.4 4.4 20 20 8.2 6.8 6.0 5.4 4.6 4.4 20
25 9.0 8.2 6.8 6.0 4.4 4.4 25 25 9.0 8.2 6.8 6.0 5.0 4.4 25
30 10.0 9.0 6.8 6.8 5.2 — 30 30 10.0 9.0 6.8 6.8 5.2 — 30
40 10.0 10.0 8.2 6.8 6.0 — 40 40 10.0 10.0 8.2 6.8 6.0 — 40
50 11.0 10.0 8.4 8.2 6.8 — 50 50 11.0 10.0 9.0 8.2 6.8 — 50
60 12.0 11.0 10.0 8.0 7.4 — 60 60 12.0 11.0 10.0 9.0 7.4 — 60
75 14.0 13.0 9.5 10.0 8.6 — 75 75 14.0 13.0 10.5 10.0 9.0 — 75
100 18.0 15.0 12.0 10.0 8.6 — 100 100 18.0 15.0 12.5 11.0 10.0 — 100
125 20.0 18.0 15.0 12.0 10.5# — 125 125 20.0 18.0 15.0 12.5 11.5† — 125
150 22.0 20.0 18.0 13.0 10.5 — 150 150 22.0 20.0 18.0 13.0 — — 150
200 22.0 22.0 22.0 — 13.2 — 200 200 22.0 22.0 22.0 — — — 200
250 22.0 22.0 — — — — 250 250 22.0 22.0 — — — — 250
300 27.0 27.0 — — — — 300 300 27.0 27.0 — — — — 300
*These RPM are for 50 cycle electric motors. # 9.5 for Frame Number 444T. *These RPM are for 50 cycle electric motors. † 11.0 for Frame Number 444T.
Data in the white area of Table No. 6 are from NEMA Standard MG-1-14.42, November 1978. Data in the gray area Data in the white area of Table No. 7 are from NEMA Standard MG-1-14.42, November 1978. Data in the gray area
are from MG-1-14.43, January 1968. Data in the ?? area are a composite of electic motor manufacturers data. They are from MG-1-14.43, January 1968. Data in the ?? area are a composite of electic motor manufacturers data. They
are generally conservative, and specific motors and bearings may permit the use of a smaller motor sheave. Consult are generally conservative, and specific motors and bearings may permit the use of a smaller motor sheave. Consult
the motor manufacturer. See Page ??. the motor manufacturer. See Page ??.
53
EF3328EN.2
MINIMUM RECOMMENDED DIAMETERS
Minimum Recommended Minimum Recommended

Sheave Diameter By Belt Sprocket Sizes
Cross Section

Min Recommended Min Recommended Sprocket Size
Belt Datum Diameter Belt Pitch (No. of Teeth)
Cross (Standard Groove)
Section (in) PowerGrip® Timing
Classical V-Belts MXL 12
AX 2.20 XL 12
A 3.00 L 12
BX 4.00 H 14
B 5.40 XH 18
CX 6.80 XXH 18
C 9.00 PowerGrip® HTD®
D 13.00 3M 12
E 21.00 5M 14
Min Recommended 8M 22
Belt Outside Diameter
Cross (Standard Groove)
14M 28
Section (in) 20M 34
Narrow V-Belts PowerGrip® GT®2
3VX 2.20 2M 12
3V 2.65 3M 16
5VX 4.40 5M 18
5V 7.10 8M 22
8V 12.50 14M 28
Light Duty V-Belts Poly Chain® GT® Carbon™
2L 0.8 8M 22
3L 1.5 14M 28
4L 2.5 Synchro-Power® Polyurethane
5L 3.5 MXL 10
Micro-V® Belts XL 10
J 0.8 L 10
L 3.00 H 14
M 7.00 T2.5 12
Polyflex® JB® Belts T5 10
3M 0.67 T10 16
5M 1.04 T20 15
7M 1.67 AT5 12
11M 2.64 AT10 18
AT20 18
5mm HTD 10
8mm HTD 16
14mm HTD 28
54
EF3328EN.2
MINIMUM RECOMMENDED DIAMETERS
Minimum Recommended Idler Diameters
Table No. 10
Minimum Min. O.D. Minimum Min. O.D.
Grooved Min. O.D. Flat Grooved Min. O.D. Flat
Inside Flat Inside Backside Inside Flat Inside Backside
Belt Cross Section (grooves) Idler (in) Idler (in) Belt Cross Section (grooves) Idler (in) Idler (in)
Classical MXL PowerGrip Timing 12 1.00 0.50
A 3.00 2.25 4.25 XL PowerGrip Timing 12 2.50 1.00
B 5.400 3.75 6.00 L PowerGrip Timing 10 4.75 1.60
C 9.00 5.75 8.50 H PowerGrip Timing 14 6.38 2.88
D 13.00 7.50 13.50 XH PowerGrip Timing 18 11.00 6.38
E 21.00 19.00 27.30 XXH PowerGrip Timing 18 15.75 9.25
2M PowerGrip GT2 12 1.00 0.50
AX 2.20 --- 4.25
3M PowerGrip GT2 + HTD 12 1.50 0.75
BX 4.00 --- 6.00
CX 7.00 --- 8.50
AA 3.00 2.25 --- 14M PowerGrip GT2 + HTD 28 7.00 6.50
BB 5.40 3.75 --- 20M PowerGrip HTD 34 10.00 11.00
CC 9.00 5.75 --- 5M Poly Chain GT2 16 2.50 1.88
SuperHC 8M Poly Chain GT Carbon 25 4.00 3.00
3V 2.65 --- 4.25 14M Poly Chain GT Carbon 28 7.00 6.50
5V 7.10 --- 10.00
8V 12.50 --- 17.50
3VX 2.20 --- 4.25
5VX 4.40 --- 10.00
Predator
CP 9.00 5.75 8.50
3VP 2.65 --- 4.25
5VP 7.10 --- 8.50
8VP 12.50 --- 17.50
55
EF3328EN.2
INSTALLATION & TENSIONING ALLOWANCES
Minimum Center Distance Allowances

for Belt Installation and Takeup
Table No. 11
Minimum Center Distance
Minimum Center Distance Allowance Allowance For Initial
For Installation (inches) Tensioning and
Subsequent
V-Belt Takeup (Inches)
Number
3V/3VX 5V/5VX 8V All Cross Sections
Super HC® Super HC® ®
Super HC® ®
Super HC®
Super HC V-Belts Super HC V-Belts All Types
V-Belts PowerBand® Belt* PowerBand® Belt* PowerBand® Belt*
Up To and Incl. 475 0.5 1.2 1.0

Over 475 To and Incl. 710 0.8 1.4 1.0 2.1 1.2
Over 710 To and Incl. 1060 0.8 1.4 1.0 2.1 1.5 3.4 1.5
Over 1060 To and Incl. 1250 0.8 1.4 1.0 2.1 1.5 3.4 1.8
Over 1250 To and Incl. 1700 0.8 1.4 1.0 2.1 1.5 3.4 2.2
Over 1700 To and Incl. 2000 1.0 2.1 1.8 3.6 2.5
Over 2000 To and Incl. 2360 1.2 2.4 1.8 3.6 3.0
Over 2360 To and Incl. 2650 1.2 2.4 1.8 3.6 3.2
Over 2650 To and Incl. 3000 1.2 2.4 1.8 3.6 3.5
Over 3000 To and Incl. 3550 1.2 2.4 2.0 4.0 4.0
Over 3550 To and Incl. 3750 2.0 4.0 4.5
Over 3750 To and Incl. 5000 2.0 4.0 5.5
Over 5000 To and Incl. 6000 2.0 4.0 6.0
*Also use these figures for individual Super HC V-Belts in deep groove sheaves.

Allowances for Belt
Installation and Takeup
Table No. 12
Minimum Center Distance Allowance Allowance For Initial
For Installation (inches) Tensioning and
Subsequent
Takeup (Inches)
A B C D E All Cross Sections
V-Belt
Number Hi- Hi- Hi- Hi-
Power II Power II Power II Power II
and Hi-Power II and Hi-Power II and Hi-Power II and Hi-Power II Hi-Power II
Tri-Power® PowerBand Tri-Power® PowerBand Tri-Power® PowerBand Tri-Power® PowerBand Hi-Power II PowerBand All Types
Belt* Belt* Belt* Belt* V-Belts Belt*
Molded Molded Molded Molded
Notch Notch Notch Notch
V-Belts V-Belts V-Belts V-Belts
Up To and Incl. 35 0.75 1.20 1.00 1.50 1.00

Over 35 To and Incl. 55 0.75 1.20 1.00 1.50 1.50 2.00 1.50
Over 55 To and Incl. 85 0.75 1.30 1.25 1.60 1.50 2.00 2.00
Over 85 To and Incl. 112 1.00 1.30 1.25 1.60 1.50 2.00 2.50
Over 112 To and Incl. 144 1.00 1.50 1.25 1.80 1.50 2.10 2.00 2.90 3.00
Over 144 To and Incl. 180 1.25 1.80 2.00 2.20 2.00 3.00 2.50 3.40 3.50
Over 180 To and Incl. 210 1.50 1.90 2.00 2.30 2.00 3.20 2.50 3.50 4.00
Over 210 To and Incl. 240 1.50 2.00 2.00 2.50 2.50 3.20 2.50 3.60 4.50
Over 240 To and Incl. 300 1.50 2.20 2.00 2.50 2.50 3.50 3.00 3.90 5.00
Over 300 To and Incl. 390 2.00 2.70 2.50 3.60 3.00 4.00 6.00
Over 390 2.50 2.90 3.00 4.10 3.50 4.40 1.5% of belt length
*Also use these figures for individual Hi-Power II and Tri-Power Molded Notch V-Belts in deep groove sheaves.
56
EF3328EN.2
Table No. 13
Micro-V® Belts
V-Belt Minimum Center Distance Allowance Allowance For Initial
Number For Installation (inches) Tensioning and Subsequent
Takeup (Inches)
Standard Effective Length (in.) J L M All Cross Sections
Up through 20.0 0.4 — — 0.3

20.1 through 40.0 0.5 — — 0.5
40.1 through 60.0 0.6 0.9 — 0.7
60.1 through 80.0 0.7 1.0 — 0.9
80.1 through 100.0 0.8 1.2 1.5 1.1
100.1 through 120.0 — 1.2 1.6 1.3
120.1 through 160.0 — 1.4 1.7 1.7
160.1 through 200.0 — — 1.8 2.2
200.1 through 240.0 — — 1.9 2.6
240.1 through 300.0 — — 2.2 3.3
300.1 through 360.0 — — 2.5 3.9
60.1 through 370.0 — — 2.7 4.6
Polyflex® JB® Belts

3M 5M 7M 11M
180-300 .18 0.4 — — 0.2

307-750 .28 0.6 0.6 1.0 0.6
750-1090 — 0.9 0.9 1.2 1.1
1120-1500 — 1.1 1.1 1.4 1.4
1550-1900 — — 1.1 1.5 1.4
1950-2300 — — 1.5 1.9 1.8
Table No. 14
Poly Chain® GT® Carbon™ Belt Standard Installation Allowance Tensioning

Length (Flanged Sprockets Removed Allowance
Installation & Tensioning For Installation) (Any Drive)
Allowances 40" and
under 0.07" 0.03"
Center Distance Allowance For
Installation and Tensioning (1000mm and 1.8mm 0.8mm
under)
Over 40"
to 70" 0.11" 0.03"
(Over 1000mm 2.8mm 0.8mm

to 1780mm)
Over 70"
to 100" 0.13" 0.04"

to 2540mm)
Over 100"
to 130" 0.16" 0.04"

to 3300mm)
Over 130”
to 180” 0.21" 0.05"

to 4600mm)
57
EF3328EN.2
Table No. 15
Additional Center Distance Belt
Both
Pitch One Sprocket Flanged Sprockets
Allowance For Installation Over Flanged
Flanged Sprocket* 8mm 0.86" 1.31"
8mm 21.8mm 33.3mm
(Add to Installation Allowance in
Above Table) 14mm 1.23" 1.97"
14mm 31.2mm 50.0mm
* For drives that require installation of the belt over one sprocket at a time, use the value for both sprockets
flanged — even if only one sprocket is flanged.
Table No. 16
Power Grip GT®2 and HTD
Center Distance Allowance For
Installation and Tensioning
Table No. 17
Additional Center Distance

allowance For Installation Over
Flanged Sprockets*
(Add to Installation Allowance in
Above Table)
58
EF3328EN.2
Table No. 18
Power Grip® Timing Belts Belt Standard Installation Allowance Tensioning
Length (Flanged Pulleys Removed Allowance
Center Distance Allowance for (in.) For Installation) (Any Drive)
Installation and Tensioning 3.6 to 5.0 .02" .02"
Over 5.0 .03" .03"
to 10.0
Over 10.0 .04" .03"
to 20.0
Over 20.0 .05" .04"
to 40.0
Over 40.0 .07" .05"
to 60.0
Over 60.0 .12" .08"
to 180.0
Table No. 19
Additional Center Distance Belt Pitch Small Pulley Flanged Both Pulleys Flanged
Allowance for Installation Over 0.080" (MXL) .33" .49"

Flanged Pulleys* 0.200" (XL) .46" .71"
(Add to Installation Allowance in 0.375" (L) .64" .85"

Above Table) 0.500" (H) .64" .96"
0.875" (XH) 1.14” 1.92"
1.250" (XXH) 1.53" 2.65"
* For drives that require installation of the belt over one sprocket at a time, use the value for both pulleys
flanged — even if only one pulley is flanged.
Table No. 20
Estimating Belt Length from 2
Belt Length = 2C + 1.57 (D + d) + (D - d)
Drive Dimensions 4C
(2 Pulleys) Where: C = Shaft Center Distance
a.) For Super HC®: Belt Length = Belt Outside Diameter

D = O.D. of Larger Pulley
d = O.D. of Smaller Pulley
b.) For Hi-Power® II Belt Length = Datum Length

and Tri-Power® D = Datum Diameter of Larger Pulley
Molded Notch: d = Datum Diameter of Smaller Pulley
c.) For Synchronous Belt Length = Pitch Length

Belts: D = Pitch Diameter of Larger Sprocket
d = Pitch Diameter of Smaller Sprocket
59
EF3328EN.2
IDLER HARDWARE
Flat Idler Pulley
Flat Idler Pulley

Use with Synchronous Belt Face Wt.
Part Product Outside Width Bearing Ea.
No. No. Pitch Width Use with V-Belt Dia. (In.) (In) A B C D E Threads Number (Lbs.)
4.25X1.25-IDL-FLAT 7723-4125 8mm, L, H Up to 21mm (0.85") 1-2 Strand 3V/3VX, 4.25 1.25 1.13 1.13 .64 1.30 3.75 3/4-16 6304 5.20
1 Strand A/AX
2 Strand A/AX
3 Strand A/AX
4.25X4.00-IDL-FLAT 7723-4400 8mm, L, H Up to 85mm (3.3") 8 Strand 3V/3VX, 4.25 4.00 1.50 1.13 .75 1.32 6.63 3/4-16 6304 13.60
4 Strand A/AX
6.50X1.75-IDL-FLAT 7723-6175 14mm Up to 20mm 1 Strand B/BX 6.50 1.75 2.00 1.50 1.04 1.96 5.69 1-14 6308 17.10
6.50X2.75-IDL-FLAT 7723-6275 14mm Up to 55mm 2-3 Strand B/BX 6.50 2.75 2.00 1.50 .13 2.10 5.69 1-14 6308 23.00
6.50X4.25-IDL-FLAT 7723-6425 14mm Up to 90mm 4-5 Strand B/BX 6.50 4.25 2.38 1.50 .13 1.98 7.06 1-14 6308 33.00
6.50X5.75-IDL-FLAT 7723-6575 14mm Up to 125mm 6 Strand B/BX 6.50 5.75 2.38 1.50 .99 1.98 9.31 1-14 6308 45.00
6.50X7.50-IDL-FLAT 7723-6750 14mm Up to 170mm 8 Strand B/BX 6.50 7.50 2.38 1.50 1.00 1.98 11.19 1-14 6308 57.01
Idler Bushings
Idler Bushings
Wt.
Part Product D L M Bearing Ea.
No. No. Style Size (In) (In) (In) Threads Number (Lbs.)
20-IDLR-BUSH(SK) 7720-1120 20 SK 2.81 1.94 1.44 3/4-16 6003 11.00
30-IDLR-BUSH(SF) 7720-1130 20 SF 3.13 2.08 2.13 1-14 6204 8.60
40-IDLR-BUSH(E) 7720-1140 20 E 3.83 2.75 2.19 1-14 6304 8.62
1610-IDLR-BUSH 7720-2610 20 1610 2.25 1.00 1.38 5/8-18 6304 1.30
2012-IDLR-BUSH 7720-2012 20 2012 2.75 1.25 1.56 3/4-16 6206 2.30
2517-IDLR-BUSH 7720-2517 20 2517 3.38 1.75 1.56 3/4-16 6306 3.90
60
EF3328EN.2
IDLER HARDWARE
Idler Sprockets
Poly Chain® GT® Carbon™ Idler Sprocket

F G Wt.
Part Product Belt No. of Outside B Ref. C D E Ref. (Threads) Ref. H J Bearing Ea.
No. No. Use With Width Teeth Dia. (In.) (In) (In) (In) (In) (In) (In) (In) (In) Number (Lbs.)
12-IDL-SPRK 7720-1500 8mm Pitch 12 32 3.145 1.25 .50 .85 1.56 3/4 - 16 .94 2.75 — 6304 3.80
21-IDL-SPRK 7720-1510 8mm Pitch 21 32 3.145 1.25 .50 1.24 1.56 3/4 - 16 .56 2.75 — 6304 3.88
36-IDL-SPRK 7720-1520 8mm Pitch 36 36 3.546 1.91 .75 1.86 1.63 3/4 - 16 — — — 6306 5.14
62-IDL-SPRK 7720-1530 8mm Pitch 62 36 3.546 1.91 .75 2.91 1.69 3/4 - 16 .69 3.13 — 6306 9.69
20-IDL-SPRK 7720-1600 14mm Pitch 20 30 5.153 2.55 1.00 1.36 2.25 1 - 14 1.00 4.38 — 6308 12.55
37-IDL-SPRK 7720-1610 14mm Pitch 37 30 5.153 2.55 1.00 2.06 2.25 1 - 14 .25 4.38 — 6308 13.46
68-IDL-SPRK 7720-1620 14mm Pitch 68 34 5.855 3.38 .56 3.33 2.25 1 - 14 1.00 4.88 4.34 6310 26.03
90-IDL-SPRK 7720-1640 14mm Pitch 90 34 5.855 3.38 .31 4.20 2.25 1 - 14 1.00 4.88 4.34 6310 32.18
125-IDL-SPRK 7720-1630 14mm Pitch 125 34 5.855 3.38 .19 5.63 2.25 1 - 14 1.09 4.88 4.34 6310 36.45
Nickel Plate Poly Chain® GT® Carbon™ Idler

Sprocket
F G Wt.
Part Product Belt No. of Outside B Ref. C D E Ref. (Threads) Ref. H J Ea.
No. No. Use With Width Teeth Dia. (In.) (In) (In) (In) (In) (In) (In) (In) (In) (Lbs.)
NP-12-IDLR-SPRK 7720-1501 8mm Pitch Poly Chain GT Carbon — 32 3.145 1.25 .50 .85 1.56 3/4 - 16 .94 2.75 — 3.80
NP-21-IDLR-SPRK 7720-1511 8mm Pitch Poly Chain GT Carbon — 32 3.145 1.25 .50 1.24 1.56 3/4 - 16 .56 2.75 — 3.88
PowerGrip® GT®2 Idler Sprocket

F G Wt.
Part Product Belt No. of Outside B Ref. C D E Ref. (Threads) Ref. H J Bearing Ea.
No. No. Use With Width Teeth Dia. (In.) (In) (In) (In) (In) (In) (In) (In) (In) Number (Lbs.)
20-SPK2-IDL 7720-1740 8mm Pitch 20 32 3.154 1.25 .50 1.24 1.56 3/4 - 16 .56 2.75 — 6304 1.10
30-SPK2-IDL 7720-1750 8mm Pitch 30 36 3.555 1.91 .75 1.86 1.63 3/4 - 16 — — — 6306 2.00
40-SPK2-IDL 7720-1850 14mm Pitch 40 30 5.153 2.55 1.00 2.06 2.25 1 - 14 .25 4.38 — 6308 12.00
55-SPK2-IDL 7720-1860 14mm Pitch 55 34 5.855 3.38 .56 3.33 2.25 1 - 14 1.00 4.88 4.34 6310 15.60
61
EF3328EN.2
IDLER HARDWARE
Idler Brackets
Idler Brackets
Wt.
Part Tensioner A B C D E F G H J M N P Q Ea.
No. Part No. Use With (In) (In) (In) (In) (In) (In) (In) (In) (In) (Threads) (In) (In) (In) (Lbs.)
5-IDL-BRAK 7720-1005 1610-IDL-BUSH 4.62 3.50 1.75 2.00 2.06 3.06 .38 1.63 .62 5/8 - 18 1.16 2.01 2.00 2.80
10-IDL-BRAK 7720-1010 8mm Pitch Idler Sprockets, 4.63 3.50 1.75 2.00 2.06 3.06 .38 1.50 .56 3/4 - 16 1.00 1.88 1.75 3.40
4.25" OD Flat Idler Pulleys,
2012-IDL-BUSH,
2517-IDL-BUSH,
20-IDL-BUSH (SK)
20-IDL-BRAK 7720-1020 14mm Pitch Idler Sprockets, 6.94 5.25 2.63 5.00 3.00 4.56 .63 2.38 1.00 1 - 14 1.63 2.94 2.75 11.20
6.50" OD Flat Idler Pulleys,
30-IDL-BUSH (SF),
40-IDL-BUSH (E)
Nickel Plated Idler Brackets

Wt.
Part Tensioner A B C D E F G H J M N P Q Ea.
No. Part No. Use With (In) (In) (In) (In) (In) (In) (In) (In) (In) (Threads) (In) (In) (In) (Lbs.)
NP-10-IDLR-BRACKET 7720-1011 8mm Pitch Idler Sprockets 4.63 3.50 1.75 2.00 2.06 3.06 .38 1.50 .56 3/4 - 16 1.00 1.88 1.75 3.40
2012-IDL-BUSH,
2517-IDL-BUSH,
20-IDL-BUSH (SK)
NP-20-IDLR-BRACKET 7720-1021 14mm Pitch Idler Sprockets, 6.94 5.25 2.63 5.00 3.00 4.56 .63 2.38 1.00 1 - 14 1.63 2.94 2.75 11.20
30-IDL-BUSH (SF),
40-IDL-BUSH (E)
62
EF3328EN.2
DRIVE SURVEY WORKSHEET

High Speed Drive Survey and Energy Savings Worksheet
CUSTOMER INFORMATION
Distributor _________________________________________________________________________________________________
Customer __________________________________________________________________________________________________
DRIVE INFORMATION
I.D. of Drive (location, number, etc.) ___________________________________________________________________________

Description of DriveN Equipment ___________________________________________________________________________
Manufacturer of DriveN Equipment _________________________________________________________________________
Horsepower Rating of Motor _______________ DriveN HP Load (Peak) _________________ (Normal) ______________
Motor Frame Size _______________ Motor Shaft Dia. _______________ DriveN Shaft Dia. ___________________
Speed:
DriveR RPM _______________ ___________________ RPM Measured with Contact or Strobe Tachometer Yes No
DriveN RPM _______________ __________________ RPM Measured with Contact or Strobe Tachometer Yes No
Speed Ratio _______________ Speed Up _______________________ or Speed Down ___________________
Center Distance: Minimum _______________ Nominal ____________________ Maximum ________________________
Existing Drive Components: DriveR _______________________________ DriveN _______________________________
Belts ________________________________________ Belt Manufacturer _____________________________________
Ambient Conditions:
Temperature _________________ Moisture _____________________ Oil, etc. _______________________________
Abrasives __________________________________________________ Shock Load ___________________________
Static Conductivity Required? Yes No
Maximum Sprocket Diameter (OD) and Width Limitations (for guard clearance):
DriveR: Max. OD __________ Max. Width ___________ DriveN: Max. OD ___________ Max. Width ____________
Guard Description _______________________________________________________________________________________
Motor Mount:
Double Screw Base? Yes No Motor Mounted on Sheet Metal? Yes No
Adequate Structure? Yes No Floating/Pivot Motor Base? Yes No
Start Up Load:
%Motor Rating at Start Up __________ AC Inverter? Yes No Soft Start? Yes No
Duty Cycle:
Number of Starts/Stops _________________________ times per _______________________ (hour, day, week, etc.)
ENERGY SAVINGS INFORMATION
Energy Cost per KW-Hour __________________________________________________________________________________
Hours of Operation: ______ Hours per Day ______ Days per Week ______ Weeks per Year
63
EF3328EN.2

Low Speed Drive Design Information Sheet
For Drive Selections with Shaft Speeds Less Than 500 rpm
Distributor: Drive Layout

Customer: (check one)
Drive Identification (location, number, etc.)
DriveR Information: Motor Reducer Belt

Drive Driven
Motor Nameplate Data
Rated Horsepower = Rated RPM = Efficiency =
Rated Voltage = Rated Amps = Rated Torque =
Actual Motor Load =
Motor Type: AC DC Gear Motor
Output Speed: Constant Variable
Reducer Information:
Reducer Type (worm, right angle helical, cycloidal, etc):
Reducer Efficiency = Output RPM = Reducer Ratio = Belt Drive on Reducer

Output Shaft
Rated Input HP/Torque = Rated Output HP/Torque =
Existing Drive Information:
Drive Type: Chain V-Belt Synchronous Belt
If chain, type; 2/#60. #80, etc. Lubed Unlubed
Current Drive Service Life =
DriveR Sprocket/Sheave = (teeth/OD) DriveR Shaft Diameter =
Motor Belt Drive

DriveN Sprocket/Sheave = (teeth/OD) DriveN Shaft Diameter = Reducer Driven
Center Distance = + -
Type of Center Distance Adjustment:
Idler used: Yes No Inside Backside
DriveN Information:
Type of Equipment: Actual Horsepower Required =
DriveN RPM =
Hours/Day = Days/Week = Weeks/Year =
Special Requirements:
Space Limitations:
Maximum DriveR Dia. = Maximim DriveN Dia =
Maximum DriveR Width = Maximum DriveN Width =
Environmental Conditions:
Temperature Range = Belt Conductivity Required Belt Drive on Reducer
Oil Mist Oil Splash Moisture Abrasives
Input Shaft
62
64
EF3328EN.2

Gates Design IQ Data Worksheet
Account: Contact:
Address: Title:
Phone: Fax:
E-mail:
Application Summary
General Description:
Product Type: Production Volume:
Prototype Schedule: Production Time Schedule:
Design Parameters
DriveR:
Motor Type & Description: (Servo, Stepper, DC, AC, etc.) Reversing: (Y/N)
Nominal Motor Torque / Power Output: rpm:
Max / Peak Motor Torque/Power Output: rpm:
Motor Stall Torque (If applicable): Driver Rotation: (CW / CCW / Rev)
DriveN's / Idlers: (Specify appropriate units for each field; in, mm / hp, kw / lb-ft, lb-in, N-m, etc.)
Pulley Sprocket Inside/ Load Conditions Shaft
Description X Y Diameter Pitch Grooves Outside rpm (driven) Units # % Time Diameter
Driver
Note: For complex drive layouts use additional pages as needed

Drive Sketch Idler Details
Min Position Max Position
Slot Movement: X Y X Y
Spring:
Pivot Point Movement Angle

Pivoting Movement: X Y Min Deg Max Deg
Spring:
Pivot Arm Radius: (in/mm):
Special Requirements
Product Design Life: Belt Life: Hours/Day: Hours/Year:
Pulley Materials: Prototype Production
Belt Construction Considerations:
Temperature: Moisture: Oil: Static Dissipation: Abrasives:
Special Requirements:
Page Of
6563
EF3328EN.2
TRADEMARKS
• HT100®, Taper−Lock® and Ringfeder® are registered trademarks of Reliance Electric.
• Nu−T−Link® is a registered trademark of Fenner Manheim.
• QD® is a registered trademark of Emerson Electric.
• RPP® and Panther® are registered trademarks of Carlisle Power Transmission Products, Inc.
• KEVLAR® is a registered trademark of E. I. du Pont de Nemours and Company.
• Goodyear®, BlackHawk PdTM, Poly−V® and Flexten® are registered trademarks of Goodyear
Tire & Rubber Company.
• Browning® is a registered trademark of Emerson Power Transmission Manufacturing L.P.
• Dayco® is a registered trademark of Dayco Products LLC.
• TB Wood’s® and QT Power Chain® are registered trademarks of T.B. Wood’s, Inc.
• Trantorque® is a registered trademark of BTL, a subsidiary of Fenner PLC
WARRANTY
Gates warrants that its power transmission products will be free from defects in materials and
workmanship for the life of the product. If the product does not meet this standard, Gates will
repair or replace the product free of charge!
Please note that this warranty is customer’s exclusive remedy and does not apply in the event of
misuse or abuse of the product. Gates disclaims all other warranties (express or implied) including
the implied warranties of fitness for a particular purpose and merchantability.
For further details of the Gates Warranty, please see www.gates.com/warranty.
66
EF3328EN.2
Allen-Bradley PowerFlex4 Adjustable Frequency AC Drive User Manual
Adjustable
Frequency AC
Drive
FRN 4.xx
User Manual
www.abpowerflex.com
Source: Allen-Bradley publication 22A-UM001F-EN-E – October 2005.
EF3339EN.0.1 1
2 Allen-Bradley PowerFlex4 Adjustable Frequency AC Drive User Manual
Important User Information

Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
WARNING: Identifies information about practices or circumstances

that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and

understanding of the product.
ATTENTION: Identifies information about practices or circumstances

that can lead to personal injury or death, property damage, or economic
loss. Attentions help you:
x identify a hazard
x avoid the hazard
x recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,

drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,

drive or motor) to alert people that surfaces may be at dangerous
temperatures.
PowerFlex is a registered trademark of Rockwell Automation, Inc.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
EF3339EN.0.1
Allen-Bradley PowerFlex4 Adjustable Frequency AC Drive User Manual 3
Summary of Changes
The information below summarizes changes made for the September

2005 PowerFlex 4 User Manual, Publication 22A-UM001F-EN-E.
Description of New or Updated Information See Page(s)

Attention statement clarified. 1-3
240V AC – 3-Phase 3.7 kW (5.0 Hp) drive fuse rating revised to 30 amps. 1-7, A-2
Analog Input, PTC wiring example added. 1-14
Attention statement added to Multiple Digital Input Connections wiring 1-17
example.
Parameter P043 [Motor OL Ret] added. 3-12
Attention statement added to parameter A082 [DB Resistor Sel]. 3-18
External Comm Options, Compact I/O added to Table B.G. B-4
Modbus function code 16 added. C-2
EF3339EN.0.1
soc-2
The information below summarizes changes made for the October 2003
PowerFlex 4 User Manual, Publication 22A-UM001E-EN-E.
Description of New or Updated Information See Page(s)

240V, 1-Phase, No Brake drive ratings added. P-4, P-7, A-2, B-1
Position 12 of the Catalog Number now indicates drive type. P-4
Flange Mount drive enclosure added. P-4, B-6
Analog Input wiring examples updated. 1-14
All drive ratings now support dynamic braking. B-2
Frame C EMC Line Filter dimensions added. B-12
Remote Small HIM, Cat. No. 22-HIM-C2S, dimensions added. B-14
EF3339EN.0.1
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . P-1
Reference Materials . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . P-2
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-4
Chapter 1 Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-2
AC Supply Source Considerations . . . . . . 1-3
General Grounding Requirements . . . . . . 1-4
Fuses and Circuit Breakers . . . . . . . . . . . . 1-6
Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-8
I/O Wiring Recommendations . . . . . . . . 1-11
Start and Speed Reference Control . . . . . 1-18
EMC Instructions . . . . . . . . . . . . . . . . . . 1-20
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-3
Viewing and Editing Parameters . . . . . . . . 2-4
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-8
Advanced Program Group. . . . . . . . . . . . 3-13
Parameter Cross Reference – by Name. . 3-27
Chapter 4 Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and
Corrective Actions . . . . . . . . . . . . . . . . 4-5
Appendix A Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings . . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions . . . . . . . . . . . . . . . . . B-5
Appendix C RS485 (DSI) Protocol
Appendix D RJ45 DSI Splitter Cable
Index
EF3339EN.0.1
ii
EF3339EN.0.1
Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 4 Adjustable
Frequency AC Drive.
For information on… See page…

Who Should Use this Manual? P-1
Reference Materials P-1
Manual Conventions P-2
Drive Frame Sizes P-2
General Precautions P-3
Catalog Number Explanation P-4
Who Should Use this Manual?

This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In
addition, you must have an understanding of the parameter settings and
functions.
Reference Materials
The following manuals are recommended for general drive information:
Title Publication Available Online at …

Wiring and Grounding DRIVES-IN001…
Guidelines for Pulse Width
Modulated (PWM) AC Drives
Preventive Maintenance of DRIVES-SB001…
Industrial Control and Drive
System Equipment
Safety Guidelines for the SGI-1.1 www.rockwellautomation.com/
Application, Installation and literature
Maintenance of Solid State
Control
A Global Reference Guide for 0100-2.10
Reading Schematic Diagrams
Guarding Against Electrostatic 8000-4.5.2
Damage
EF3339EN.0.1
P-2 Overview
Manual Conventions
x In this manual we refer to the PowerFlex 4 Adjustable Frequency AC
Drive as: drive, PowerFlex 4 or PowerFlex 4 Drive.
x Parameter numbers and names are shown in this format:

P031 [Motor NP Volts]
Name
Number
Group
d = Display Group
P = Basic Program Group
A = Advanced Program Group
x The following words are used throughout the manual to describe an

action:
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not Recommended
Drive Frame Sizes

Similar PowerFlex 4 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in
Appendix B.
EF3339EN.0.1
Overview P-3
General Precautions
ATTENTION: The drive contains high voltage capacitors which take

time to discharge after removal of mains supply. Before working on
! drive, ensure isolation of mains supply from line inputs [R, S, T (L1,
L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage
levels. Failure to do so may result in personal injury or death.
Darkened display LEDs is not an indication that capacitors have

discharged to safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
! implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
! when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
! errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
EF3339EN.0.1
P-4 Overview
Catalog Number Explanation
1-3 4 5 6-8 9 10 11 12 (1) 13-14

22A - A 1P5 N 1 1 4 AA
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional
Code Code Version

22A PowerFlex 4 3 No Brake IGBT
4 Standard
Code Rating
Code Voltage Ph. 0 Not Filtered
V 120V AC 1 1 Filtered
A 240V AC 1
B 240V AC 3
D 480V AC 3 Code Interface Module Code Purpose
1 Fixed Keypad AA Reserved for
thru custom firmware
ZZ
Code Enclosure
N Panel Mount - IP 20 (NEMA Type Open)
F Flange Mount - IP 20 (NEMA Type Open)
H Replacement Plate Drive - IP 20 (NEMA Type Open)
- Contact factory for ordering information.
Output Current @ 100-120V Input Output Current @ 200-240V Input, NO BRAKE

Code Amps kW (HP) Code Amps kW (HP)
1P5 1.5 0.2 (0.25) 1P4 1.4 0.2 (0.25)
2P3 2.3 0.4 (0.5) 2P1 2.1 0.4 (0.5)
4P5 4.5 0.75 (1.0) 3P6 3.6 0.75 (1.0)
6P0 6.0 1.1 (1.5) 6P8 6.8 1.5 (2.0)
9P6 9.6 2.2 (3.0)
Output Current @ 200-240V Input Output Current @ 380-480V Input

Code Amps kW (HP) Code Amps kW (HP)
1P5 1.5 0.2 (0.25) 1P4 1.4 0.4 (0.5)
2P3 2.3 0.4 (0.5) 2P3 2.3 0.75 (1.0)
4P5 4.5 0.75 (1.0) 4P0 4.0 1.5 (2.0)
8P0 8.0 1.5 (2.0) 6P0 6.0 2.2 (3.0)
012 12.0 2.2 (3.0) 8P7 8.7 3.7 (5.0)
017 17.5 3.7 (5.0)
(1)
Position 12 of the Catalog Number now indicates drive type. All PowerFlex 4 drives
are equipped with RS485 communication.
EF3339EN.0.1
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 4 Drive.
For information on… See page For information on… See page
Opening the Cover 1-1 Fuses and Circuit Breakers 1-6
Mounting Considerations 1-2 Power Wiring 1-8
AC Supply Source Considerations 1-3 I/O Wiring 1-11
Recommendations
General Grounding Requirements 1-4 EMC Instructions 1-20
Most start-up difficulties are the result of incorrect wiring. Every

precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.
ATTENTION: The following information is merely a guide for proper

installation. Rockwell Automation, Inc. cannot assume responsibility
! for the compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated
equipment. A hazard of personal injury and/or equipment damage
exists if codes are ignored during installation.
Opening the Cover

1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
EF3339EN.0.1
1-2 Installation/Wiring
Mounting Considerations
x Mount the drive upright on a flat, vertical and level surface.
– Install on 35 mm DIN Rail.
or
– Install with screws.
Table 1.A Screw Mounting Recommendations
Minimum Panel Thickness Screw Size Mounting Torque
1.9 mm (0.0747 in.) M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.)
x Protect the cooling fan by avoiding dust or metallic particles.
x Do not expose to a corrosive atmosphere.
x Protect from moisture and direct sunlight.
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.
25 mm
(1.0 in.)
120 mm 120 mm
(4.7 in.) (4.7 in.)
Mounting Option A
No clearance required
between drives.
Mounting Option B
120 mm 120 mm
(4.7 in.) (4.7 in.)
Ambient Operating Temperatures

Table 1.B Enclosure and Clearance Requirements
Ambient Temperature Enclosure Rating Minimum Mounting
Minimum Maximum Clearances
IP 20/Open Type Use Mounting Option A

40°C (104°F)
-10°C (14°F) IP 30/NEMA 1/UL Type 1(1) Use Mounting Option B
50°C (122°F) IP 20/Open Type Use Mounting Option B
(1)
Rating requires installation of the PowerFlex 4 IP 30/NEMA 1/UL Type 1 option kit.
Debris Protection
A plastic top panel is included with the drive. Install the panel to prevent
debris from falling through the vents of the drive housing during
installation. Remove the panel for IP 20/Open Type applications.
Storage
x Store within an ambient temperature range of -40° to +85°C.
x Store within a relative humidity range of 0% to 95%,
non-condensing.
x Do not expose to a corrosive atmosphere.
EF3339EN.0.1
Installation/Wiring 1-3
AC Supply Source Considerations

Ungrounded Distribution Systems
ATTENTION: PowerFlex 4 drives contain protective MOVs that are

referenced to ground. These devices must be disconnected if the drive is
! installed on an ungrounded or resistive grounded distribution system.
Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures 1.1 and 1.2.
1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Figure 1.1 Jumper Location (A Frame Shown)
Important:
Tighten screw after
jumper removal.
Figure 1.2 Phase to Ground MOV Removal

R/L1
Three-Phase
AC Input S/L2
T/L3
Jumper 1 2 3 4
EF3339EN.0.1
Input Power Conditioning

The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in Table 1.C are certain
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in
Table 1.C, install one of the devices listed under the heading Corrective
Action on the line side of the drive.
Important: Only one device per branch circuit is required. It should be

mounted closest to the branch and sized to handle the total
current of the branch circuit.
Table 1.C Input Power Conditions
Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance) x Install Line Reactor(1)
Greater than 120 kVA supply transformer x or Isolation Transformer
Line has power factor correction capacitors

Line has frequent power interruptions
Line has intermittent noise spikes in excess of
6000V (lightning)
Phase to ground voltage exceeds 125% of normal x Remove MOV jumper to ground.
line to line voltage x or Install Isolation Transformer
with grounded secondary if
Ungrounded distribution system
necessary.
(1)
Refer to Appendix B for accessory ordering information.
General Grounding Requirements

The drive Safety Ground - (PE) must be connected to system ground.
Ground impedance must conform to the requirements of national and
local industrial safety regulations and/or electrical codes. The integrity
of all ground connections should be periodically checked.
Figure 1.3 Typical Grounding
R/L1 U/T1
S/L2 V/T2
T/L3 W/T3
SHLD
EF3339EN.0.1
Ground Fault Monitoring

If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Safety Ground - (PE)

This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with national
and local industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.
Shield Termination - SHLD

Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the motor frame (motor end). Use a shield terminating or
EMI clamp to connect the shield to the safety ground terminal. The
conduit box option may be used with a cable clamp for a grounding
point for the cable shield.
When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.
RFI Filter Grounding

Using single phase drives with integral filter, or an external filter with
any drive rating, may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded
AC supply systems and be permanently installed and solidly
grounded (bonded) to the building power distribution ground. Ensure
that the incoming supply neutral is solidly connected (bonded) to the
same building power distribution ground. Grounding must not rely on
flexible cables and should not include any form of plug or socket that
would permit inadvertent disconnection. Some local codes may require
redundant ground connections. The integrity of all connections should
be periodically checked.
EF3339EN.0.1
Fuses and Circuit Breakers

The PowerFlex 4 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit
breaker. National and local industrial safety regulations and/or electrical
codes may determine additional requirements for these installations.
ATTENTION: To guard against personal injury and/or equipment

damage caused by improper fusing or circuit breaker selection, use only
! the recommended line fuses/circuit breakers specified in this section.
Fusing
The PowerFlex 4 has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the minimum
recommended values for use with each drive rating. The devices listed in
this table are provided to serve as a guide.
Bulletin 140M (Self-Protected Combination Controller)/UL489

Circuit Breakers
When using Bulletin 140M or UL489 rated circuit breakers, the
guidelines listed below must be followed in order to meet the NEC
requirements for branch circuit protection.
x Bulletin 140M can be used in single and group motor applications.

x Bulletin 140M can be used up stream from the drive without the
need for fuses.
EF3339EN.0.1
Table 1.D Minimum Recommended Branch Circuit Protective Devices
Voltage Drive Rating Fuse Rating(1) 140M(2) Recommended

Rating kW (HP) Amps Catalog No. MCS Contactors
Catalog No.
120V AC – 0.2 (0.25) 10 140M-C2E-C10 100-C09
1-Phase 0.4 (0.5) 15 140M-C2E-C16 100-C12
0.75 (1.0) 30 140M-D8E-C20 100-C23
1.1 (1.5) 40 140M-D8E-C25 100-C37
240V AC – 0.2 (0.25) 6 140M-C2E-B40 100-C09
1-Phase 0.4 (0.5) 10 140M-C2E-B63 100-C09
NO BRAKE 0.75 (1.0) 15 140M-C2E-C16 100-C12
1.5 (2.0) 25 140M-C2E-C16 100-C16
2.2 (3.0) 30 140M-D8E-C25 100-C23
240V AC – 0.2 (0.25) 10 140M-C2E-B63 100-C09
1-Phase 0.4 (0.5) 10 140M-C2E-B63 100-C09
0.75 (1.0) 15 140M-C2E-C16 100-C12
1.5 (2.0) 30 140M-D8E-C20 100-C23
240V AC – 0.2 (0.25) 3 140M-C2E-B25 100-C09
3-Phase 0.4 (0.5) 6 140M-C2E-B40 100-C09
0.75 (1.0) 10 140M-C2E-C10 100-C09
1.5 (2.0) 15 140M-C2E-C16 100-C12
2.2 (3.0) 25 140M-C2E-C16 100-C16
3.7 (5.0) 30 140M-F8E-C25 100-C23
480V AC – 0.4 (0.5) 3 140M-C2E-B25 100-C09
3-Phase 0.75 (1.0) 6 140M-C2E-B40 100-C09
1.5 (2.0) 10 140M-C2E-B63 100-C09
2.2 (3.0) 15 140M-C2E-C10 100-C09
3.7 (5.0) 15 140M-C2E-C16 100-C16
(1)
Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or
equivalent.
(2)
The AIC ratings of the 140M are based on a maximum 100 kA AIC with the exception
of 140M-D… and 140M-F… which have a maximum of 50 kA AIC. See Publication
140M-SG001… for other ratings suitable for your particular application.
EF3339EN.0.1
Power Wiring
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.)
and local codes outline provisions for safely installing electrical
! equipment. Installation must comply with specifications regarding wire
types, conductor sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal injury and/or equipment
damage.
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
! For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.
Motor Cable Types Acceptable for 200-600 Volt Installations
General
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than
three sets of motor leads in a single conduit to minimize “cross talk”. If
more than three drive/motor connections per conduit are required,
shielded cable must be used.
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Use copper wire only. Wire gauge requirements and recommendations
are based on 75 degree C. Do not reduce wire gauge when using higher
temperature wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of
15 mils and should not have large variations in insulation concentricity.
Shielded
Location Rating/Type Description
Standard 600V, 75°C or 90°C (167°F x Four tinned copper conductors with XLPE insulation
(Option 1) or 194°F) RHH/RHW-2 x Foil shield and tinned copper drain wire with 85% braid
Belden 29501-29507 or coverage
equivalent x PVC jacket
Standard Tray rated 600V, 75°C or x Three tinned copper conductors with XLPE insulation
(Option 2) 90°C (167°F or 194°F) x 5 mil single helical copper tape (25% overlap min.)
RHH/RHW-2 with three bare copper grounds in contact with shield
Shawflex 2ACD/3ACD or x PVC jacket
equivalent
Class I & II; Tray rated 600V, 75°C or x Three tinned copper conductors with XLPE insulation
Division I & II 90°C (167°F or 194°F) x 5 mil single helical copper tape (25% overlap min.)
RHH/RHW-2 with three bare copper grounds in contact with shield
x PVC copper grounds on #10 AWG and smaller
EF3339EN.0.1
Reflected Wave Protection

The drive should be installed as close to the motor as possible.
Installations with long motor cables may require the addition of external
devices to limit voltage reflections at the motor (reflected wave
phenomena). See Table 1.E for recommendations.
The reflected wave data applies to all frequencies 2 to 16 kHz.
For 240V ratings, reflected wave effects do not need to be considered.
Table 1.E Maximum Cable Length Recommendations
Reflected Wave
380-480V Ratings Motor Insulation Rating Motor Cable Only(1)
1000 Vp-p 15 meters (49 feet)
(1)
Longer cable lengths can be achieved by installing devices on the output of the drive.
Consult factory for recommendations.
Output Disconnect
The drive is intended to be commanded by control input signals that will
start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and
stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, an auxiliary contact
should be used to simultaneously disable drive control run commands.
EF3339EN.0.1
Power Terminal Block

The drive utilizes a finger guard over the power wiring terminals. To
remove:
1. Press in and hold the locking tab.

2. Slide finger guard down and out.
Replace the finger guard when wiring is complete.
Figure 1.4 Power Terminal Block (A Frame Shown)
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3
BR+ BR-
Terminal Description
R/L1, S/L2 1-Phase Input
R/L1, S/L2, T/L3 3-Phase Input
U/T1 To Motor U/T1 Switch any two motor
V/T2 To Motor V/T2 = leads to change
forward direction.
W/T3 To Motor W/T3
BR+, BR- Dynamic Brake Resistor Connection
Safety Ground - PE
Table 1.F Power Terminal Block Specifications
Frame Maximum Wire Size (1) Minimum Wire Size (1) Torque
A 3.3 mm2 (12 AWG) 0.8 mm2 (18 AWG)
1.7-2.2 N-m (16-19 lb.-in.)
B 5.3 mm2 (10 AWG) 1.3 mm2 (16 AWG)
(1) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
EF3339EN.0.1
I/O Wiring Recommendations

Motor Start/Stop Precautions
ATTENTION: A contactor or other device that routinely disconnects

and reapplies the AC line to the drive to start and stop the motor can
! cause drive hardware damage. The drive is designed to use control input
signals that will start and stop the motor. If used, the input device must
not exceed one operation per minute or drive damage can occur.
ATTENTION: The drive start/stop control circuitry includes
solid-state components. If hazards due to accidental contact with
! moving machinery or unintentional flow of liquid, gas or solids exist,
an additional hardwired stop circuit may be required to remove the AC
line to the drive. When the AC line is removed, there will be a loss of
any inherent regenerative braking effect that might be present - the
motor will coast to a stop. An auxiliary braking method may be
required.
Important points to remember about I/O wiring:
x Always use copper wire.

x Wire with an insulation rating of 600V or greater is recommended.
x Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).
Important: I/O terminals labeled “Common” are not referenced to the

safety ground (PE) terminal and are designed to greatly
reduce common mode interference.
ATTENTION: Driving the 4-20mA analog input from a voltage

source could cause component damage. Verify proper configuration
! prior to applying input signals.
EF3339EN.0.1
Control Wire Types
Table 1.G Recommended Control and Signal Wire(1)
Wire Type(s) Description Minimum

Insulation Rating
Belden 8760/9460 0.8 mm2 (18AWG), twisted pair, 100% 300V
(or equiv.) shield with drain. (1) 60 degrees C
Belden 8770 0.8 mm2 (18AWG), 3 conductor, shielded for (140 degrees F)
(or equiv.) remote pot only.
(1) If the wires are short and contained within a cabinet which has no sensitive circuits,
the use of shielded wire may not be necessary, but is always recommended.
I/O Terminal Block

Table 1.H I/O Terminal Block Specifications
Maximum Wire Size (1) Minimum Wire Size (1) Torque
2
1.3 mm (16 AWG) 0.13 mm2 (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
(1)
Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Maximum Control Wire Recommendations

Do not exceed control wiring length of 30 meters (100 feet). Control
signal cable length is highly dependent on electrical environment and
installation practices. To improve noise immunity, the I/O terminal block
Common must be connected to ground terminal/protective earth. If using
the RS485 (DSI) port, I/O Terminal 16 should also be connected to
ground terminal/protective earth.
EF3339EN.0.1
Figure 1.5 Control Wiring Block Diagram
(1)
Important: I/O Terminal 01 is P036 I/O Terminal 01
always a coast to stop input except [Start Source] Stop Stop
when P036 [Start Source] is set to Keypad Per P037 Coast
“3-Wire” control. In three wire 3-Wire Per P037 Per P037
control, I/O Terminal 01 is controlled 2-Wire Per P037 Coast
by P037 [Stop Mode]. All other stop RS485 Port Per P037 Coast
sources are controlled by P037

[Stop Mode]. Typical Typical
Stop (1) SRC Wiring SNK Wiring
Important: The drive is shipped with 01
a jumper installed between I/O Start/Run FWD (2)
02
Terminals 01 and 11. Remove this Direction/Run REV
03
jumper when using I/O Terminal 01 SNK SRC Digital Common
04
as a stop or enable input. Digital Input 1
05
(2)
Two wire control shown. For three 06
Digital Input 2
wire control use a momentary input +24V +24V DC
on I/O Terminal 02 to 11
command a start. Use a maintained +10V +10V DC
12
input for I/O Terminal 03 to 0-10V In
13
change direction. Relay N.O. Analog Common
R1 14
Relay Common 4-20mA In Potentiometer
R2 15 must be
Relay N.C. RS485 Shield 1-10k ohm
R3 16
2 Watt Min.
01 02 03 04 05 06
R1 R2 R3
30V DC 125V AC 240V AC RS485
SNK 11 12 13 14 15 16 (DSI)
Resistive 3.0A 3.0A 3.0A
Inductive 0.5A 0.5A 0.5A SRC (1) 8 1
No. Signal Default Description Param.

R1 Relay N.O. Fault Normally open contact for output relay. A055
R2 Relay Common – Common for output relay.
R3 Relay N.C. Fault Normally closed contact for output relay. A055
Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch
Sink/Source DIP Switch Source (SRC)
setting.
The factory installed jumper or a normally closed input

01 Stop (1) Coast P036
(1)
must be present for the drive to start.
02 Start/Run FWD Not Active P036, P037
Command comes from the integral keypad by default. To
03 Direction/Run REV Not Active disable reverse operation, see A095 [Reverse Disable]. P036, P037,
A095
For digital inputs. Electronically isolated with digital inputs
04 Digital Common –
from analog I/O.
05 Digital Input 1 Preset Freq Program with A051 [Digital In1 Sel]. A051
06 Digital Input 2 Preset Freq Program with A052 [Digital In2 Sel]. A052
Drive supplied power for digital inputs.
11 +24V DC –
Maximum output current is 100mA.
Drive supplied power for 0-10V external potentiometer.
12 +10V DC – P038
Maximum output current is 15mA.
For external 0-10V input supply
13 0-10V In (3) Not Active P038
(input impedance = 100k ohm) or potentiometer wiper.
For 0-10V In or 4-20mA In. Electronically isolated with
14 Analog Common –
analog inputs from digital I/O.
For external 4-20mA input supply
15 4-20mA In (3) Not Active P038
(input impedance = 250 ohm).
Terminal should be connected to safety ground - PE
16 RS485 (DSI) Shield –
when using the RS485 (DSI) communications port.
(3)
Only one analog frequency source may be connected at a time. If more than one reference is connected at the same
time, an undetermined frequency reference will result.
EF3339EN.0.1
I/O Wiring Examples

Input Connection Example
Potentiometer P038 [Speed Reference] = 2 “0-10V Input”
1-10k Ohm Pot.
Recommended
12
(2 Watt minimum)
13
14
Analog Input Voltage Current

0 to +10V, 100k ohm P038 [Speed Reference] = 2 “0-10V P038 [Speed Reference] = 3
impedance Input” “4-20mA Input”
4-20 mA, 100 ohm
impedance
+ 13
14 Common 14
Common
+ 15
Analog Input, PTC Wire the PTC and External Resistor (typically matched to the PTC Hot
For Drive Fault Resistance) to I/O Terminals 12, 13, 14.
Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11.
A051 [Digital In1 Sel] = 3 “Aux Fault”
A055 [Relay Out Sel] = 10 “Above Anlg V”
A056 [Relay Out Level] = % Voltage Trip
R2
R3
11
Re 12
RPTC (hot)
13 VTrip = × 100
14 RPTC (hot) + Re
RPTC
05
EF3339EN.0.1

2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)
Non-Reversing
P036 [Start Source] = 2, 3 11 01 01
or 4 02 02
Stop-Run
Input must be active for Stop-Run
the drive to run. When 04
input is opened, the drive
will stop as specified by +24V Common
P037 [Stop Mode].
If desired, a User Supplied Each digital input draws 6 mA.
24V DC power source can
be used. Refer to the
“External Supply (SRC)”
example.
2 Wire SNK Control - Internal Supply (SNK)
Non-Reversing
01
02
Stop-Run
04

Run FWD/Run REV
P036 [Start Source] = 2, 3 11 01 01
or 4 02 02
03 Stop-Run
Input must be active for Forward 03
Stop-Run
Forward 04
the drive to run. When
Stop-Run
input is opened, the drive Reverse
will stop as specified by Stop-Run
Reverse
P037 [Stop Mode]. +24V Common
If both Run Forward and
Run Reverse inputs are Each digital input draws 6 mA.
closed at the same time,
an undetermined state
could occur.
Run FWD/Run REV
01
02
Stop-Run
Forward 03
04
Stop-Run
Reverse
EF3339EN.0.1

Non-Reversing
P036 [Start Source] = 1
A momentary input will Stop 11 01 Stop 01
start the drive. A stop 02 02
input to I/O Terminal 01 Start Start
will stop the drive as 04
specified by P037 [Stop
Mode]. +24V Common
Each digital input draws 6 mA.

Non-Reversing
Stop 01
02
03
Start
04

Reversing
P036 [Start Source] = 1 Stop 01
Stop 11 01
A momentary input will 02
02
start the drive. A stop 03 Start
03
input to I/O Terminal 01 Start 04
will stop the drive as Direction
specified by P037 [Stop Direction
Mode]. I/O Terminal 03 +24V Common
determines direction.
Each digital input draws 6 mA.
Reversing
Stop 01
02
03
Start
04
Direction
EF3339EN.0.1
Typical Multiple Drive Connection Examples

Multiple Digital 02 04 02 04 02 04 02 04
Input Connections
Customer Inputs can
be wired per
External Supply
(SRC) or Internal
Supply (SNK) Customer Inputs Optional Ground Connection
examples on
page 1-15. When connecting a single input such as Run, Stop, Reverse or Preset Speeds to
multiple drives, it is important to connect I/O Terminal 04 common together for all
drives. If they are to be tied into another common (such as earth ground or
separate apparatus ground) only one point of the daisy chain of I/O Terminal 04
should be connected.
ATTENTION: I/O Common terminals should not be tied together

when using SNK (Internal Supply) mode. In SNK mode, if power is
! removed from one drive, inadvertent operation of other drives that
share the same I/O Common connection may occur.
Multiple Analog
Connections
12 13 14 13 14 13 14 13 14
Remote Potentiometer Optional Ground Connection
When connecting a single potentiometer to multiple drives it is important to

connect I/O Terminal 14 common together for all drives. I/O Terminal 14 common
and I/O Terminal 13 (potentiometer wiper) should be daisy-chained to each drive.
All drives must be powered up for the analog signal to be read correctly.
EF3339EN.0.1
Start and Speed Reference Control

The drive speed command can be obtained from a number of different
sources. The source is normally determined by P038 [Speed Reference].
However, when A051 or A052 [Digital Inx Sel] is set to option 2, 4, 5 or
6, and the digital input is active, A051 or A052 will override the speed
reference commanded by P038 [Speed Reference]. See the chart below
for the override priority.
Drive will Start and Run at Jog Speed.

Jog Input Yes
Enabled and Active:
Direction comes from
A051 or A052 = 2
Terminal 03 Dir/Run REV
No
Local/Remote Input Yes Start, Speed and Direction commands

Enabled and Active: come from Integral Keypad.
A051 or A052 = 5
No
Comm Select Input Yes Start, Speed and Direction commands

Enabled and Active:
come from RS485 (DSI) port.
A051 or A052 = 6
No
Run as specified by
Yes P038 [Speed Reference].
P038 [Speed Reference]
= 4 or 5 Start and Direction commands come
from P036 [Start Source].
No
Run as specified by
A051 / A052 Yes A071-A073 [Preset Freq 1-3].
Preset Inputs Active
Start and Direction commands come
No
Run as specified by
P038 [Speed Reference].
Start and Direction commands come

EF3339EN.0.1
Accel/Decel Selection
The selection of Accel/Decel rates can be made through digital inputs,
RS485 (DSI) communications and/or parameters.
Jog Input Yes A079 [Jog Accel/Decel] used.

Enabled and Active:
A051 or A052 = 2
No
Yes Active when

RS485 (DSI) Port
A067 [Accel Time 2]/A068 [Decel Time 2]
Controls Speed
is selected by RS485 (DSI) port.
No
Input is programmed Yes A067 [Accel Time 2]/A068 [Decel Time 2]

as “Accel 2 & Decel 2”
is active when input is active.
A051 or A052 = 1
No
P039 [Accel Time 1]/P040 [Decel Time 1];

A067 [Accel Time 2]/A068 [Decel Time 2]
Speed is controlled Yes determined by the active
by [Preset Freq x] Preset Frequency.
A051 or A052 = 4 See A070-A073 [Preset Freq 0-3]
on page 3-16.
No
P039 [Accel Time 1]/P040 [Decel Time 1]

are used.
EF3339EN.0.1
EMC Instructions
CE Conformity
Conformity with the Low Voltage (LV) Directive and Electromagnetic
Compatibility (EMC) Directive has been demonstrated using
harmonized European Norm (EN) standards published in the Official
Journal of the European Communities. PowerFlex Drives comply with
the EN standards listed below when installed according to the User
Manual.
CE Declarations of Conformity are available online at:

http://www.ab.com/certification/ce/docs.
Low Voltage Directive (73/23/EEC)

x EN50178 Electronic equipment for use in power installations
EMC Directive (89/336/EEC)
x EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Notes
x If the plastic top panel is removed or the optional conduit box is not
installed, the drive must be installed in an enclosure with side
openings less than 12.5 mm (0.5 in.) and top openings less than 1.0
mm (0.04 in.) to maintain compliance with the LV Directive.
x The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
x Use of line filters in ungrounded systems is not recommended.
x Conformity of the drive with CE EMC requirements does not
guarantee an entire machine installation complies with CE EMC
requirements. Many factors can influence total machine/installation
compliance.
EF3339EN.0.1
Essential Requirements for CE Compliance

Conditions 1-3 listed below must be satisfied for PowerFlex drives to
meet the requirements of EN61800-3.
1. Grounding as described in Figure 1.6. Refer to page 1-5 for

additional grounding recommendations.
2. Output power, control (I/O) and signal wiring must be braided,
shielded cable with a coverage of 75% or better, metal conduit or
equivalent attenuation.
3. Allowable cable length in Table 1.I is not exceeded.
Table 1.I Allowable Cable Length
Filter Type EN61800-3 First Environment EN61800-3 First Environment

Restricted Distribution or Unrestricted Distribution (3)
Second Environment (2)
Integral 10 meters (33 feet) 1 meter (3 feet)
External - S Type(1) 10 meters (33 feet) 1 meter (3 feet)
External - L Type(1) 100 meters (328 feet) 5 meters (16 feet)
(1)
Refer to Appendix B for details on optional external filters.
(2) Equivalent to EN55011 Class A.
(3)
Equivalent to EN55011 Class B.
Figure 1.6 Connections and Grounding
(1)
Shielded Enclosure
IP 30/NEMA 1/UL Type 1

Option Kit
(2)
EMI Fittings and Metal Conduit
EMI Filter
L1 L1' R/L1 U/T1
S/L2 V/T2
L2 L2'
T/L3 W/T3
L3 L3'
Enclosure Ground Connection Shielded Motor Cable
Building Structure Steel
(1)
First Environment Unrestricted Distribution installations require a shielded enclosure.
Keep wire length as short as possible between the enclosure entry point and the EMI
filter.
(2) Integral EMI filters are available on 240V, 1-Phase drives.
EF3339EN.0.1
EN61000-3-2
x 0.75 kW (1 HP) 240V 1-Phase and 3-Phase drives and 0.37 kW (0.5
HP) 240V 1-Phase drives are suitable for installation on a private low
voltage power network. Installations on a public low voltage power
network may require additional external harmonic mitigation.
x Other drive ratings meet the current harmonic requirements of
EN61000-3-2 without additional external mitigation.
EF3339EN.0.1
Chapter 2
Start Up
This chapter describes how to start up the PowerFlex 4 Drive. To
simplify drive setup, the most commonly programmed parameters are
organized in a single Basic Program Group.
Important: Read the General Precautions section before proceeding.
ATTENTION: Power must be applied to the drive to perform the

following start-up procedures. Some of the voltages present are at
! incoming line potential. To avoid electric shock hazard or damage to
equipment, only qualified service personnel should perform the
following procedure. Thoroughly read and understand the procedure
before beginning. If an event does not occur while performing this
procedure, Do Not Proceed. Remove All Power including user
supplied control voltages. User supplied voltages may exist even when
main AC power is not applied to the drive. Correct the malfunction
before continuing.
Prepare For Drive Start-Up

Before Applying Power to the Drive
❏ 1. Confirm that all inputs are connected to the correct terminals and are
secure.
❏ 2. Verify that AC line power at the disconnect device is within the rated
value of the drive.
❏ 3. Verify that any digital control power is 24 volts.

❏ 4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to
match your control wiring scheme. See Figure 1.5 on page 1-13 for
location.
Important: The default control scheme is Source (SRC). The Stop

terminal is jumpered (I/O Terminals 01 and 11) to allow
starting from the keypad. If the control scheme is changed
to Sink (SNK), the jumper must be removed from I/O
Terminals 01 and 11 and installed between I/O Terminals
01 and 04.
❏ 5. Verify that the Stop input is present or the drive will not start.
Important: If I/O Terminal 01 is used as a stop input, the jumper
between I/O Terminals 01 and 11 must be removed.
EF3339EN.0.1
2-2 Start Up
Applying Power to the Drive

❏ 6. Apply AC power and control voltages to the drive.
❏ 7. Familiarize yourself with the integral keypad features (see page 2-3)
before setting any Program Group parameters.
Start, Stop, Direction and Speed Control

Factory default parameter values allow the drive to be controlled from
the integral keypad. No programming is required to start, stop, change
direction and control speed directly from the integral keypad.
Important: To disable reverse operation, see A095 [Reverse Disable].
If a fault appears on power up, refer to Fault Descriptions on page 4-3

for an explanation of the fault code.
Variable Torque Fan/Pump Applications

For improved motor tuning performance when using a premium efficient
motor on a variable torque load, set A084 [Boost Select] to option 2
“35.0, VT”.
EF3339EN.0.1
Start Up 2-3
Integral Keypad
➋
➊
RUN
➌
VOLTS
Menu Description
FWD AMPS Display Group (View Only)
REV HERTZ
Consists of commonly viewed drive operating
PROGRAM FAULT conditions.
➍ ➎ Basic Program Group
Consists of most commonly used
programmable functions.
➏ ➐ ➑ Advanced Program Group
Consists of remaining programmable functions.
➒ Fault Designator
Consists of list of codes for specific fault
conditions. Displayed only when fault is present.
No. LED LED State Description

➊ Run/Direction
Status
Steady Red Indicates drive is running and commanded motor direction.
Flashing Red Drive has been commanded to change direction. Indicates
actual motor direction while decelerating to zero.
➋ Alphanumeric
Display
Steady Red Indicates parameter number, parameter value, or fault code.
Flashing Red Single digit flashing indicates that digit can be edited.
All digits flashing indicates a fault condition.
➌ Displayed Units Steady Red Indicates the units of the parameter value being displayed.
➍ Program Status Steady Red Indicates parameter value can be changed.
➎ Fault Status Flashing Red Indicates drive is faulted.
➏ Pot Status Steady Green Indicates potentiometer on Integral Keypad is active.
➐ Start Key Status Steady Green Indicates Start key on Integral Keypad is active.
The Reverse key is also active unless disabled by A095
[Reverse Disable].
No. Key Name Description

➑ Escape Back one step in programming menu.
Cancel a change to a parameter value and exit Program
Mode.
Select Advance one step in programming menu.
Select a digit when viewing parameter value.
Up Arrow Scroll through groups and parameters.
Down Arrow Increase/decrease the value of a flashing digit.
Enter Advance one step in programming menu.
Save a change to a parameter value.
➒ Potentiometer Used to control speed of drive. Default is active.
Controlled by parameter P038 [Speed Reference].
Start Used to start the drive. Default is active.

Controlled by parameter P036 [Start Source].
Reverse Used to reverse direction of the drive. Default is active.
Controlled by parameters P036 [Start Source] and A095
[Reverse Disable].
Stop Used to stop the drive or clear a fault.
This key is always active.
Controlled by parameter P037 [Stop Mode].
EF3339EN.0.1
2-4 Start Up
Viewing and Editing Parameters

The last user-selected Display Group parameter is saved when power is removed and is displayed by
default when power is reapplied.
The following is an example of basic integral keypad and display functions. This example provides basic
navigation instructions and illustrates how to program the first Program Group parameter.
Step Key(s) Example Displays
1. When power is applied, the last user-selected VOLTS
Display Group parameter number is briefly AMPS
HERTZ
displayed with flashing characters. The display PROGRAM FAULT
then defaults to that parameter’s current value.
(Example shows the value of d001 [Output
Freq] with the drive stopped.)
2. Press Esc once to display the Display Group VOLTS
AMPS
parameter number shown on power-up. The HERTZ
parameter number will flash. PROGRAM FAULT
3. Press Esc again to enter the group menu. The VOLTS

AMPS
group menu letter will flash. HERTZ
4. Press the Up Arrow or Down Arrow to scroll PROGRAM FAULT
through the group menu (d, P and A).

or
5. Press Enter or Sel to enter a group. The right or VOLTS
AMPS
digit of the last viewed parameter in that group HERTZ
will flash. PROGRAM FAULT
6. Press the Up Arrow or Down Arrow to scroll or

through the parameters that are in the group.
7. Press Enter or Sel to view the value of a
parameter. If you do not want to edit the value,
or VOLTS
AMPS
HERTZ
press Esc to return to the parameter number. PROGRAM FAULT
8. Press Enter or Sel to enter program mode to

edit the parameter value. The right digit will or VOLTS
AMPS
HERTZ
flash and the Program LED will illuminate if the PROGRAM FAULT
parameter can be edited.
9. Press the Up Arrow or Down Arrow to change
the parameter value. If desired, press Sel to
or
move from digit to digit or bit to bit. The digit or
bit that you can change will flash.
10. Press Esc to cancel a change. The digit will
stop flashing, the previous value is restored and
the Program LED will turn off.
Or
Press Enter to save a change. The digit will stop VOLTS
AMPS
flashing and the Program LED will turn off. HERTZ
PROGRAM FAULT
11. Press Esc to return to the parameter list. VOLTS

AMPS
Continue to press Esc to back out of the HERTZ
programming menu. PROGRAM FAULT
If pressing Esc does not change the display,

then d001 [Output Frequency] is displayed.
Press Enter or Sel to enter the group menu.
The Basic Program Group (page 3-8) contains the most commonly changed parameters.
EF3339EN.0.1
Chapter 3
Programming and Parameters
Chapter 3 provides a complete listing and description of the PowerFlex 4

parameters. Parameters are programmed (viewed/edited) using the
integral keypad. As an alternative, programming can also be performed
using DriveExplorer™ or DriveExecutive™ software, a personal
computer and a serial converter module. Refer to Appendix B for catalog
numbers.

About Parameters 3-1
Parameter Organization 3-2
Basic Program Group 3-8
Advanced Program Group 3-13
Parameter Cross Reference – by Name 3-27
About Parameters
To configure a drive to operate in a specific way, drive parameters may
have to be set. Three types of parameters exist:
x ENUM
ENUM parameters allow a selection from 2 or more items. Each item
is represented by a number.
x Numeric Parameters
These parameters have a single numerical value (i.e. 0.1 Volts).
x Bit Parameters
Bit parameters have four individual bits associated with features or
conditions. If the bit is 0, the feature is off or the condition is false. If
the bit is 1, the feature is on or the condition is true.
Some parameters are marked as follows.
= Stop drive before changing this parameter.

32
= 32 bit parameter. Parameters marked 32 bit will have two
parameter numbers when using RS485 communications and
programming software.
EF3339EN.0.1
3-2 Programming and Parameters
Parameter Organization
Ad
Progrvanced
B am G
Progr asic roup
Displa am G
y Gro roup
up
See page 3-3 See page 3-8 See page 3-13

Output Freq d001 Motor NP Volts P031 Digital In1 Sel A051
Commanded Freq d002 Motor NP Hertz P032 Digital In2 Sel A052
Output Current d003 Motor OL Current P033 Relay Out Sel A055
Output Voltage d004 Minimum Freq P034 Relay Out Level A056
DC Bus Voltage d005 Maximum Freq P035 Accel Time 2 A067
Drive Status d006 Start Source P036 Decel Time 2 A068
Fault 1 Code d007 Stop Mode P037 Internal Freq A069
Fault 2 Code d008 Speed Reference P038 Preset Freq 0 A070
Fault 3 Code d009 Accel Time 1 P039 Preset Freq 1 A071
Process Display d010 Decel Time 1 P040 Preset Freq 2 A072
Control Source d012 Reset To Defalts P041 Preset Freq 3 A073
Contrl In Status d013 Motor OL Ret P043 Jog Frequency A078
Dig In Status d014 Jog Accel/Decel A079
Comm Status d015 DC Brake Time A080
Control SW Ver d016 DC Brake Level A081
Drive Type d017 DB Resistor Sel A082
Elapsed Run Time d018 S Curve % A083
Testpoint Data d019 Boost Select A084
Analog In 0-10V d020 Maximum Voltage A088
Analog In 4-20mA d021 Current Limit A089
Drive Temp d024 Motor OL Select A090
PWM Frequency A091
Auto Rstrt Tries A092
Auto Rstrt Delay A093
Start At PowerUp A094
Reverse Disable A095
Flying Start En A096
Compensation A097
SW Current Trip A098
Process Factor A099
Fault Clear A100
Program Lock A101
Testpoint Sel A102
Comm Data Rate A103
Comm Node Addr A104
Comm Loss Action A105
Comm Loss Time A106
Comm Format A107
Anlg In 0-10V Lo A110
Anlg In 0-10V Hi A111
Anlg In 4-20mA Lo A112
Anlg In 4-20mA Hi A113
Slip Hertz @ FLA A114
Process Time Lo A115
Process Time Hi A116
EF3339EN.0.1
Programming and Parameters 3-3
Display Group
d001 [Output Freq] Related Parameter(s): d002, d010, P034, P035, P038
Output frequency present at T1, T2 & T3 (U, V & W).
Values Default Read Only
Min/Max: 0.0/P035 [Maximum Freq]
Display: 0.1 Hz
d002 [Commanded Freq] Related Parameter(s): d001, d013, P034, P035, P038
Value of the active frequency command. Displays the commanded frequency even if the drive is not
running.
Important: The frequency command can come from a number of sources. Refer to Start and Speed
Reference Control on page 1-18 for details.
Display: 0.1 Hz
d003 [Output Current]

The output current present at T1, T2 & T3 (U, V & W).
Min/Max: 0.00/(Drive Rated Amps u 2)
Display: 0.01 Amps
d004 [Output Voltage] Related Parameter(s): P031, A084, A088

Output voltage present at terminals T1, T2 & T3 (U, V & W).
Min/Max: 0/Drive Rated Volts
Display: 1 VAC
d005 [DC Bus Voltage]

Present DC bus voltage level.
Min/Max: Based on Drive Rating
Display: 1 VDC
EF3339EN.0.1
Display Group (continued)

d006 [Drive Status] Related Parameter(s): A095
Present operating condition of the drive.
1 = Condition True, 0 = Condition False

Running Bit 0
Forward Bit 1
Accelerating Bit 2
Decelerating Bit 3

Min/Max: 0/1
Display: 1
d007 [Fault 1 Code]

d008 [Fault 2 Code]
d009 [Fault 3 Code]
A code that represents a drive fault. The codes will appear in these parameters in the order they occur
(d007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.
Refer to Chapter 4 for fault code descriptions.
Min/Max: F2/F122
Display: F1
d010 [Process Display] Related Parameter(s): d001, A099, A115, A116

32 32 bit parameter.
The output frequency scaled by A099 [Process Factor] or by A115 [Process Time Lo] and A116
[Process Time Hi].
Output Process Process
Freq x Factor = Display

Min/Max: 0.00/9999
Display: 0.01 – 1
EF3339EN.0.1

d012 [Control Source] Related Parameter(s): P036, P038, A051, A052
Displays the active source of the Start Command and Speed Command which are normally defined
by the settings of P036 [Start Source] and P038 [Speed Reference] but may be overridden by digital
inputs. Refer to the flowcharts on pages 1-18 and 1-19 for details.
Start Command Digit 0

0 = Keypad
1 = 3-Wire
2 = 2-Wire
3 = 2-Wire Level Sensitive
4 = 2-Wire High Speed
5 = RS485 (DSI) Port
9 = Jog
Speed Command Digit 1
0 = Drive Potentiometer
1 = A069 [Internal Freq]
2 = 0-10V Input/Remote Potentiometer
3 = 4-20mA Input
4 = A070 - A073 [Preset Freq x]
(A051 - A052 [Digital Inx Sel] must be set to 4)
5 = RS485 (DSI) Port
9 = Jog Freq
Reserved Digit 2
Reserved Digit 3

Min/Max: 0/9
Display: 1
d013 [Contrl In Status] Related Parameter(s): d002, P034, P035

Status of the control terminal block control inputs.
Important: Actual control commands may come from a source other than the control terminal block.
1 = Input Present, 0 = Input Not Present

Start / Run FWD Input (I/O Terminal 02) Bit 0
Direction / Run REV Input (I/O Terminal 03) Bit 1
Stop Input(1) (I/O Terminal 01) Bit 2
Reserved Bit 3
(1)
The stop input must be present in order to start the drive.
When this bit is a 1 the drive can be started.
When this bit is a 0 the drive will stop.

Min/Max: 0/1
Display: 1
EF3339EN.0.1

d014 [Dig In Status] Related Parameter(s): A051, A052
Status of the control terminal block digital inputs.
1 = Input Present, 0 = Input Not Present

Digital In1 Sel (I/O Terminal 05) Bit 0
Digital In2 Sel (I/O Terminal 06) Bit 1
Reserved Bit 2
Reserved Bit 3

Min/Max: 0/1
Display: 1
d015 [Comm Status] Related Parameter(s): A103 - A107

Status of the communications ports.
1 = Condition True, 0 = Condition False

Receiving Data Bit 0
Transmitting Data Bit 1
RS485 (DSI) Based Option Connected Bit 2
(Allen-Bradley devices only.)
Communication Error Occurred Bit 3

Min/Max: 0/1
Display: 1
d016 [Control SW Ver]

Main Control Board software version.
Min/Max: 1.00/99.99
Display: 0.01
d017 [Drive Type]

Used by Rockwell Automation field service personnel.
Min/Max: 1001/9999
Display: 1
EF3339EN.0.1

d018 [Elapsed Run Time]
Accumulated time drive is outputting power. Time is displayed in 10 hour increments.
Min/Max: 0/9999 Hrs
Display: 1 = 10 Hrs
d019 [Testpoint Data] Related Parameter(s): A102

The present value of the function selected in A102 [Testpoint Sel].
Min/Max: 0/FFFF
Display: 1 Hex
d020 [Analog In 0-10V] Related Parameter(s): A110, A111

The present value of the voltage at I/O Terminal 13 (100.0% = 10 volts).
Min/Max: 0.0/100.0%
Display: 0.1%
d021 [Analog In 4-20mA] Related Parameter(s): A112, A113

The present value of the current at I/O Terminal 15 (0.0% = 4mA, 100.0% = 20mA).
Min/Max: 0.0/100.0%
Display: 0.1%
d024 [Drive Temp]

Present operating temperature of the drive power section.
Min/Max: 0/120 degC
Display: 1 degC
EF3339EN.0.1
Basic Program Group

P031 [Motor NP Volts] Related Parameter(s): d004, A084
Stop drive before changing this parameter.
Set to the motor nameplate rated volts.
Values Default Based on Drive Rating
Display: 1 VAC
P032 [Motor NP Hertz] Related Parameter(s): A084, A090

Set to the motor nameplate rated frequency.
Values Default 60 Hz
Min/Max: 10/240 Hz
Display: 1 Hz
P033 [Motor OL Current] Related Parameter(s): P043, A055, A089, A090, A098, A114
Set to the maximum allowable motor current.
The drive will fault on an F7 Motor Overload if the value of this parameter is exceeded by 150% for 60
seconds or 200% for 3 seconds.
Values Default Based on Drive Rating
Min/Max: 0.0/(Drive Rated Amps u 2)
Display: 0.1 Amps
P034 [Minimum Freq] Related Parameter(s): d001, d002, d013, P035, A110, A112, A115
Sets the lowest frequency the drive will output continuously.
Values Default 0.0 Hz
Min/Max: 0.0/240.0 Hz
Display: 0.1 Hz
P035 [Maximum Freq] Related Parameter(s): d001, d002, d013, P034, A078,
A111, A113, A115
Sets the highest frequency the drive will output.
Values Default 60 Hz
Min/Max: 0/240 Hz
Display: 1 Hz
EF3339EN.0.1
Basic Program Group (continued)

P036 [Start Source] Related Parameter(s): d012, P037
Sets the control scheme used to start the drive.
Refer to Start and Speed Reference Control on page 1-18 for details about how other drive settings
can override the setting of this parameter.
Important: For all settings except option 3, the drive must receive a leading edge from the start input
for the drive to start after a stop input, loss of power or fault condition.
Options 0 “Keypad” (Default) x Integral keypad controls drive operation.
x I/O Terminal 1 “Stop” = coast to stop.
x When active, the Reverse key is also active unless
disabled by A095 [Reverse Disable].
1 “3-Wire” I/O Terminal 1 “Stop” = stop according to the value set in
P037 [Stop Mode].
2 “2-Wire” I/O Terminal 1 “Stop” = coast to stop.
3 “2-W Lvl Sens” Drive will restart after a “Stop” command when:
x Stop is removed
and
x Start is held active
ATTENTION: Hazard of injury exists due to unintended operation. When

P036 [Start Source] is set to option 3, and the Run input is maintained, the
! Run inputs do not need to be toggled after a Stop input for the drive to run
again. A Stop function is provided only when the Stop input is active (open).
4 “2-W Hi Speed” Important: There is greater potential voltage on the output

terminals when using this option.
x Outputs are kept in a ready-to-run state. The drive will
respond to a “Start” command within 10 ms.
5 “Comm Port” x Remote communications. Refer to Appendix C for details.
Important: When commanding Jog via the RS485 communications port on drives with firmware
version 1.02 or earlier, the Jog command will follow the commanded direction from I/O Terminal 03.
On firmware versions 1.03 and later, the commanded direction will be provided via the RS485
communications port.
Important: When sending a continuous start command via the RS485 communications port on drives
with firmware version 1.02 or earlier, a maintained stop input is required to stop the drive. Once the
stop input is inactive, the drive will restart. On firmware versions 1.03 and later, once a stop input is
received, the start command must transition from high to low to high for the drive to start.
EF3339EN.0.1

P037 [Stop Mode] Related Parameter(s): P036, A080, A081, A082, A105
Active stop mode for all stop sources [e.g. keypad, run forward (I/O Terminal 02), run reverse (I/O
Terminal 03), RS485 port] except as noted below.
Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set for
“3-Wire” control. When in three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode].
Hardware Enable Circuitry

By default, I/O Terminal 01 is a coast to stop input. The status of the input is interpreted by drive
software. If the application requires the drive to be disabled without software interpretation, a “dedicat-
ed” hardware enable configuration can be utilized. This is accomplished by removing the ENBL
enable jumper on the control board. In this case, the drive will always coast to a stop regardless of the
settings of P036 [Start Source] and P037 [Stop Mode].
Options 0 “Ramp, CF”(1) (Default) Ramp to Stop. “Stop” command clears active fault.
1 “Coast, CF”(1) Coast to Stop. “Stop” command clears active fault.
2 “DC Brake, CF”(1) DC Injection Braking Stop. “Stop” command clears active
fault.
3 “DCBrkAuto,CF”(1) DC Injection Braking Stop with Auto Shutoff.
x Standard DC Injection Braking for value set in A080 [DC
Brake Time].
OR
x Drive shuts off if the drive detects that the motor is
stopped.
“Stop” command clears active fault.
4 “Ramp” Ramp to Stop.
5 “Coast” Coast to Stop.
6 “DC Brake” DC Injection Braking Stop.
7 “DC BrakeAuto” DC Injection Braking Stop with Auto Shutoff.
x Standard DC Injection Braking for value set in A080 [DC
Brake Time].
OR
x Drive shuts off if current limit is exceeded.
(1) Stop input also clears active fault.
EF3339EN.0.1

P038 [Speed Reference] Related Parameter(s): d001, d002, d012, P039, P040, A051, A052,
A069, A070-A073, A110, A111, A112, A113
Sets the source of the speed reference to the drive.
The drive speed command can be obtained from a number of different sources. The source is
normally determined by P038 [Speed Reference]. However, when A051 - A052 [Digital Inx Sel] is set
to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, the speed reference commanded
by P038 [Speed Reference] will be overridden. Refer to the flowchart on page 1-18 for more
information on speed reference control priority.
Options 0 “Drive Pot” (Default) Internal frequency command from the potentiometer on the
integral keypad.
1 “InternalFreq” Internal frequency command from A069 [Internal Freq].
2 “0-10V Input” External frequency command from the 0-10V analog input or
remote potentiometer.
3 “4-20mA Input” External frequency command from the 4-20mA analog input.
4 “Preset Freq” External frequency command as defined by A070 - A073
[Preset Freq x] when A051 and A052 [Digital Inx Sel] are
programmed as “Preset Frequencies” and the digital inputs
are active.
5 “Comm Port” External frequency command from the communications port.
P039 [Accel Time 1] Related Parameter(s): P038, P040, A051, A052, A067, A070-A073
Sets the rate of acceleration for all speed increases.
Maximum Freq
= Accel Rate
Accel Time
Values Default 10.0 Secs

Min/Max: 0.0/600.0 Secs
Display: 0.1 Secs
P035 [Maximum Freq]

De
n
ratio
cele
Speed
ele
ratio
Acc
0
P039 or A067 Time P040 or A068
[Accel Time x] [Decel Time x]
0
EF3339EN.0.1

P040 [Decel Time 1] Related Parameter(s): P038, P039, A051, A052, A068, A070-A073
Sets the rate of deceleration for all speed decreases.
Maximum Freq
= Decel Rate
Decel Time

Display: 0.1 Secs
P035 [Maximum Freq]

De
n
ratio
cele
Speed
ele
ratio
Acc
0
0
P041 [Reset To Defalts]

Resets all parameter values to factory defaults.
Options 0 “Idle State” (Default)
1 “Reset Defaults” x After the reset function is complete, this parameter will set
itself back to “0”.
x Causes an F48 Params Defaulted fault.
P043 [Motor OL Ret] Related Parameter(s): P033

Enables/disables the Motor Overload Retention function. When Enabled, the value held in the motor
overload counter is saved at power-down and restored at power-up. A change to this parameter
setting resets the counter.
Options 0 “Disabled” (Default)
1 “Enabled”
EF3339EN.0.1
Advanced Program Group

A051 [Digital In1 Sel] Related Parameter(s): d012, d014, P038, P039, P040,
(I/O Terminal 5) A067, A068, A070-A073, A078, A079
A052 [Digital In2 Sel] Stop drive before changing this parameter.
(I/O Terminal 6)
Selects the function for the digital inputs. Refer to the flowchart on page 1-18 for more information on
speed reference control priority.
Options 0 “Not Used” Terminal has no function but can be read over network
communications via d014 [Dig In Status]
1 “Acc 2 & Dec 2” x When active, A067 [Accel Time 2] and A068 [Decel Time
2] are used for all ramp rates except Jog.
x Can only be tied to one input.
Refer to the flowchart on page 1-19 for more information on
Accel/Decel selection.
2 “Jog” x When input is present, drive accelerates according to the
value set in A079 [Jog Accel/Decel] and ramps to the
value set in A078 [Jog Frequency].
x When input is removed, drive ramps to a stop according to
the value set in A079 [Jog Accel/Decel].
x A valid “Start” command will override this input.
3 “Aux Fault” When enabled, an F2 Auxiliary Input fault will occur when the
input is removed.
4 “Preset Freq” (Default) Refer to A070 - A073 [Preset Freq x].
Important: Digital Inputs have priority for frequency control
when programmed as a Preset Speed and are active. Refer to
the flowchart on 1-18 for more information on speed
reference control priority.
5 “Local” When active, sets integral keypad as start source and
potentiometer on the integral keypad as speed source.
6 “Comm Port” x When active, sets communications device as default start/
speed command source.
x Can only be tied to one input.
7 “Clear Fault” When active, clears an active fault.
8 “RampStop,CF” Causes drive to immediately ramp to a stop regardless of how
P037 [Stop Mode] is set.
9 “CoastStop,CF” Causes drive to immediately coast to a stop regardless of
how P037 [Stop Mode] is set.
10 “DCInjStop,CF” Causes drive to immediately begin a DC Injection stop
regardless of how P037 [Stop Mode] is set.
11 “Jog Forward” Drive accelerates to A078 [Jog Frequency] according to A079
[Jog Accel/Decel] and ramps to stop when input becomes
inactive. A valid start will override this command.
12 “Jog Reverse” Drive accelerates to A078 [Jog Frequency] according to A079
[Jog Accel/Decel] and ramps to stop when input becomes
inactive. A valid start will override this command.
EF3339EN.0.1
A051 & 13 “10V In Ctrl” Selects 0-10V or ±10V control as the frequency reference.
A052 Start source is not changed.
Options 14 “20mA In Ctrl” Selects 4-20mA control as the frequency reference. Start
(Cont.) source is not changed.
15 - 25 Reserved
26 “Anlg Invert” Inverts the scaling of the analog input levels set in
A110 [Anlg In 0-10V Lo] and A111 [Anlg In 0-10V Hi] or
A112 [Anlg In4-20mA Lo] and A113 [Anlg In4-20mA Hi].
A055 [Relay Out Sel] Related Parameter(s): P033, A056, A092

Sets the condition that changes the state of the output relay contacts.
Options 0 “Ready/Fault” Relay changes state when power is applied. This indicates
(Default) that the drive is ready for operation. Relay returns drive to
shelf state when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency.
2 “MotorRunning” Motor is receiving power from the drive.
3 “Reverse” Drive is commanded to run in reverse direction.
4 “Motor Overld” Motor overload condition exists.
5 “Ramp Reg” Ramp regulator is modifying the programmed accel/decel
times to avoid an overcurrent or overvoltage fault from
occurring.
6 “Above Freq” Drive exceeds the frequency (Hz) value set in A056 [Relay
Out Level].
7 “Above Cur” Drive exceeds the current (% Amps) value set in A056 [Relay
Out Level].
Important: Value for A056 [Relay Out Level] must be entered
in percent of drive rated output current.
8 “Above DCVolt” Drive exceeds the DC bus voltage value set in A056 [Relay
Out Level].
9 “Retries Exst” Value set in A092 [Auto Rstrt Tries] is exceeded.
10 “Above Anlg V” x Analog input voltage (I/O Terminal 13) exceeds the value
set in A056 [Relay Out Level].
x This parameter setting can also be used to indicate a PTC
trip point when the input (I/O Terminal 13) is wired to a
PTC and external resistor.
x Use A056 to set threshold.
11-19 Reserved
20 “ParamControl” Enables the output to be controlled over network
communications by writing to A056 [Relay Out Level].
(0 = Off, 1 = On.)
21 “NonRec Fault”” Value set in A092 [Auto Rstrt Tries] is exceeded.
EF3339EN.0.1
Advanced Program Group (continued)

A056 [Relay Out Level] Related Parameter(s): A055
32 32 bit parameter.
Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7, 8, 10 or 20.
A055 Setting A056 Min/Max

6 0/240 Hz
7 0/180%
8 0/815 Volts
10 0/100%
20 0/1
Values Default 0.0

Min/Max: 0.0/9999
Display: 0.1
A067 [Accel Time 2] Related Parameter(s): P039

When active, sets the rate of acceleration for all speed increases except jog. Refer to the flowchart on
page 1-19 for details.
Maximum Freq
= Accel Rate
Accel Time
Display: 0.1 Secs
P035 [Maximum Freq]

De
n
ratio
cele
Speed
ele
ratio
Acc
0
0
A068 [Decel Time 2] Related Parameter(s): P040

When active, sets the rate of deceleration for all speed decreases except jog. Refer to the flowchart on
page 1-19 for details.
Maximum Freq
= Decel Rate
Decel Time
Display: 0.1 Secs
P035 [Maximum Freq]

De
n
ratio
cele
Speed
ele
ratio
Acc
0
0
EF3339EN.0.1

A069 [Internal Freq] Related Parameter(s): P038
Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “Internal
Freq”. When enabled, this parameter will change the frequency command in “real time” using the
integral keypad Up Arrow or Down Arrow when in program mode.
Important: Once the desired command frequency is reached, the Enter key must be pressed to store
this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return
to the original value following the normal accel/decel curve.
Min/Max: 0.0/240.0 Hz
Display: 0.1 Hz
A070 [Preset Freq 0](1) Related Parameter(s): P038, P039, P040, A051, A052,
A071 [Preset Freq 1] A067, A068
A072 [Preset Freq 2]
A073 [Preset Freq 3]
Values A070 Default 0.0 Hz
A071 Default 5.0 Hz
A072 Default 10.0 Hz
A073 Default 20.0 Hz
Min/Max: 0.0/240.0 Hz
Display: 0.1 Hz
Provides a fixed frequency command value when A051 - A052 [Digital Inx Sel] is set to 4 “Preset
Frequencies”.
An active preset input will override speed command as shown in the flowchart on page 1-19.
(1) To activate A070 [Preset Freq 0] set P038 [Speed Reference] to option 4 “Preset Freq 0-3”.
Input State of Digital In 1 Input State of Digital In 2

(I/O Terminal 05) (I/O Terminal 06) Frequency Source Accel / Decel Parameter Used(2)
0 0 A070 [Preset Freq 0] [Accel Time 1] / [Decel Time 1]
(2)
When a Digital Input is set to “Accel 2 & Decel 2”, and the input is active, that input overrides the settings in
this table.
A078 [Jog Frequency] Related Parameter(s): P035, A051, A052, A079

Sets the output frequency when a jog command is issued.
Display: 0.1 Hz
EF3339EN.0.1

A079 [Jog Accel/Decel] Related Parameter(s): A051, A052, A078
Sets the acceleration and deceleration time when a jog command is issued.
Display: 0.1 Secs
A080 [DC Brake Time] Related Parameter(s): P037, A081

Sets the length of time that DC brake current is “injected” into the motor. Refer to parameter A081 [DC
Brake Level].
Display: 0.1 Secs
A081 [DC Brake Level] Related Parameter(s): P037, A080

Defines the maximum DC brake current, in amps, applied to the motor when P037 [Stop Mode] is set
to either “Ramp” or “DC Brake”.
Values Default Drive Rated Amps u 0.05
Min/Max: 0.0/(Drive Rated Amps u 1.8)
Display: 0.1 Amps
Ramp-to-Stop Mode DC Injection Braking Mode

Voltage
Volts/Speed
Volts/Speed
Vo
lta Speed [DC Brake Time]
ge
Spe [DC Brake Time]
ed
[DC Brake Level] [DC Brake Level]
Time Time
Stop Command Stop Command
ATTENTION: If a hazard of injury due to movement of equipment or material exists,

an auxiliary mechanical braking device must be used.
!
ATTENTION: This feature should not be used with synchronous or permanent
magnet motors. Motors may be demagnetized during braking.
!
EF3339EN.0.1

A082 [DB Resistor Sel]
Enables/disables external dynamic braking.
Setting Min/Max
0 “Disabled”
1 “Normal RA Res” (5% Duty Cycle) - Refer to Table B.C on page B-2
2 “No Protection” (100% Duty Cycle)
3-99 “x%Duty Cycle” Limited (3% – 99% of Duty Cycle)
The drive is able to provide full braking indefinitely. Braking power is limited by the external DB
resistor. When this parameter is set to 1 “Normal RA Res” and an appropriate RA resistor is used (see
selection Table B.C), the drive provides calculated resistor overload protection. However, the drive
cannot protect against a brake IGBT failure.
ATTENTION: A risk of fire exists if external braking resistors are not protected. The
external resistor package must be self-protected from over temperature or the protective
! circuit shown in Figure B.7 on page B-9, or equivalent, must be supplied.
Values Default 0
Min/Max: 0/99
Display: 1
A083 [S Curve %]
Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve. Time
is added, 1/2 at the beginning and 1/2 at the end of the ramp.
Values Default 0% (Disabled)
Min/Max: 0/100%
Display: 1%
Example:
50% S Curve
Accel Time = 10 Seconds
Target
S Curve Setting = 50%
S Curve Time = 10 u 0.5 = 5 Seconds
Total Time = 10 + 5 = 15 Seconds
Target/2
1/2 S Curve Time Accel Time 1/2 S Curve Time

2.5 Seconds 10 Seconds 2.5 Seconds
Total Time to Accelerate = Accel Time + S Curve Time
EF3339EN.0.1

A084 [Boost Select] Related Parameter(s): d004, P031, P032
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve.(1)
(1)
Drive may add additional voltage unless option 5 is selected.
Options 1 “30.0, VT”
2 “35.0, VT”
Variable Torque
3 “40.0, VT”
4 “45.0, VT”
5 “0.0 no IR”
6 “0.0”
7 “2.5, CT”
[Default for 3.7kW
(5HP) Drives]
8 “5.0, CT” (Default)
9 “7.5, CT” Constant Torque
10 “10.0, CT”
11 “12.5, CT”
12 “15.0, CT”
13 “17.5, CT”
14 “20.0, CT”
100
% P031 [Motor NP Volts]
1/2 [Motor NP Volts]

50
4
3
2
1
[Motor NP Hertz]
1/2
Settings
5-14
0 50 100
% P032 [Motor NP Hertz]
A088 [Maximum Voltage]

Sets the highest voltage the drive will output.
Values Default Drive Rated Volts
Display: 1 VAC
EF3339EN.0.1

A089 [Current Limit]
Maximum output current allowed before current limiting occurs.
Values Default Drive Rated Amps u 1.5
Min/Max: 0.1/(Drive Rated Amps u 1.8)
Display: 0.1 Amps
A090 [Motor OL Select] Related Parameter(s): P032

Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I2t
overload function.
Options 0 “No Derate” (Default)
1 “Min Derate”
2 “Max Derate”
No Derate Min Derate Max Derate

% of P033 [Motor OL Curent]
100 100 100
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
A091 [PWM Frequency]

Sets the carrier frequency for the PWM output waveform. The chart below provides derating
guidelines based on the PWM frequency setting.
Important: Ignoring derating guidelines can cause reduced drive performance.
Values Default 4.0 kHz
Min/Max: 2.0/16.0 kHz
Display: 0.1 kHz
100
96
92
88
84
80
76
72
68
64
60
56
52
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
EF3339EN.0.1

A092 [Auto Rstrt Tries]
Sets the maximum number of times the drive attempts to reset a fault and restart.
Clear a Type 1 fault and restart the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to a value other than “0”.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.
2. Set A093 [Auto Rstrt Delay] to “0”.
ATTENTION: Equipment damage and/or personal injury may result if this parameter
is used in an inappropriate application. Do not use this function without considering
! applicable local, national and international codes, standards, regulations or industry
guidelines.
Values Default 0
Min/Max: 0/9
Display: 1
A093 [Auto Rstrt Delay] Related Parameter(s): A092

Sets the time between restart attempts when A092 [Auto Rstrt Tries] is set to a value other than zero.
Display: 0.1 Secs
A094 [Start At PowerUp]

Enables/disables a feature that allows a Start or Run command to automatically cause the drive to
resume running at commanded speed after drive input power is restored. Requires a digital input
configured for Run or Start and a valid start contact.
This parameter will not function if parameter P036 [Start Source] is set to 4 “2-W High Speed”.
ATTENTION: Equipment damage and/or personal injury may result if this parameter
is used in an inappropriate application. Do not use this function without considering
! applicable local, national and international codes, standards, regulations or industry
guidelines.

1 “Enabled”
EF3339EN.0.1

A095 [Reverse Disable] Related Parameter(s): d006
Enables/disables the function that allows the direction of motor rotation to be changed. The reverse
command may come from a digital command, the keypad or a serial command. All reverse inputs
including two-wire Run Reverse will be ignored with reverse disabled.
Options 0 “Rev Enabled” (Default)
1 “Rev Disabled”
A096 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.
1 “Enabled”
A097 [Compensation]
Enables/disables correction options that may improve problems with motor instability.
Options 0 “Disabled”
1 “Electrical” (Default) Some drive/motor combinations have inherent instabilities
which are exhibited as non-sinusodial motor currents. This
setting attempts to correct this condition.
2 “Mechanical” Some motor/load combinations have mechanical resonances
which can be excited by the drive current regulator. This
setting slows down the current regulator response and
attempts to correct this condition.
3 “Both”
A098 [SW Current Trip] Related Parameter(s): P033

Enables/disables a software instantaneous (within 100 ms) current trip.
Values Default 0.0 (Disabled)
Min/Max: 0.0/(Drive Rated Amps u2)
Display: 0.1 Amps
A099 [Process Factor] Related Parameter(s): d010

Scales the value displayed by d010 [Process Display].
Output Process Process
Freq x Factor = Display
Values Default 30.0

Min/Max: 0.1/999.9
Display: 0.1
EF3339EN.0.1

A100 [Fault Clear]
Resets a fault and clears the fault queue. Used primarily to clear a fault over network communications.
Options 0 “Ready/Idle” (Default)
1 “Reset Fault”
2 “Clear Buffer” (Parameters d007-d009 [Fault x Code])
A101 [Program Lock]

Protects parameters against change by unauthorized personnel.
Options 0 “Unlocked” (Default)
1 “Locked”
A102 [Testpoint Sel]

Used by Rockwell Automation field service personnel.
Values Default 400
Min/Max: 0/FFFF
Display: 1 Hex
A103 [Comm Data Rate] Related Parameter(s): d015

Sets the serial port rate for the RS485 (DSI) port.
Important: Power to drive must be cycled before any changes will affect drive operation.
Options 0 “1200”
1 “2400”
2 “4800”
3 “9600” (Default)
4 “19.2K”
5 “38.4K”
A104 [Comm Node Addr] Related Parameter(s): d015

Sets the drive node address for the RS485 (DSI) port if using a network connection.
Values Default 100
Min/Max: 1/247
Display: 1
EF3339EN.0.1

A105 [Comm Loss Action] Related Parameter(s): d015, P037, A106
Selects the drive’s response to a loss of the communication connection or excessive communication
errors.
Options 0 “Fault” (Default) Drive will fault on an F81 Comm Loss and coast to stop.
1 “Coast to Stop” Stops drive via coast to stop.
2 “Stop” Stops drive via P037 [Stop Mode] setting.
3 “Continu Last” Drive continues operating at communication commanded
speed saved in RAM.
A106 [Comm Loss Time] Related Parameter(s): d015, A105

Sets the time that the drive will remain in communication loss before implementing the option selected
in A105 [Comm Loss Action].
Display: 0.1 Secs
A107 [Comm Format]

Selects the protocol (RTU only), data bits (8 data bits only), parity (None, Even, Odd), and stop bits (1
stop bit only) used by the RS485 port on the drive.
Refer to Appendix C for details on using the drive communication features.
Options 0 “RTU 8-N-1” (Default)
1 “RTU 8-E-1”
2 “RTU 8-O-1”
3 “RTU 8-N-2”
4 “RTU 8-E-2”
5 “RTU 8-O-2”
EF3339EN.0.1
A110 [Anlg In 0-10V Lo] Related Parameter(s): d020, P034, P038, A051, A052
Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038
[Speed Reference].
Analog inversion can be accomplished by setting this value larger than A111 [Anlg In 0-10V Hi] or by
setting A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”
Values Default 0.0%
Min/Max: 0.0/100.0%
Display: 0.1%
P035 [Maximum Freq]
ce
en
fer
d Re
ee
Sp
P034 [Minimum Freq]

0
0
A110 [Anlg In 0-10V Lo] A111 [Anlg In 0-10V Hi]
A111 [Anlg In 0-10V Hi] Related Parameter(s): d020, P035, P038, A051, A052
Sets the analog input level that corresponds to P035 [Maximum Freq] if a 0-10V input is used by P038
[Speed Reference].
Analog inversion can be accomplished by setting this value smaller than A110 [Anlg 0-10V In Lo] or by
setting A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”.
Values Default 100.0%
Min/Max: 0.0/100.0%
Display: 0.1%
A112 [Anlg In4-20mA Lo] Related Parameter(s): d021, P034, P038, A051, A052
Sets the analog input level that corresponds to P034 [Minimum Freq] if a 4-20mA input is used by
Analog inversion can be accomplished by setting this value larger than A113 [Anlg In4-20mA Hi] or by
setting A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”.
Values Default 0.0%
Min/Max: 0.0/100.0%
Display: 0.1%
A113 [Anlg In4-20mA Hi] Related Parameter(s): d021, P035, P038, A051, A052
Sets the analog input level that corresponds to P035 [Maximum Freq] if a 4-20mA input is used by
Analog inversion can be accomplished by setting this value smaller than A112 [Anlg In4-20mA Lo] or
by setting A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”.
Values Default 100.0%
Min/Max: 0.0/100.0%
Display: 0.1%
EF3339EN.0.1
A114 [Slip Hertz @ FLA] Related Parameter(s): P033

Compensates for the inherent slip in an induction motor. This frequency is added to the commanded
output frequency based on motor current.
Min/Max: 0.0/10.0 Hz
Display: 0.1 Hz
A115 [Process Time Lo] Related Parameter(s): d010, P034

Scales the time value when the drive is running at P034 [Minimum Freq]. When set to a value other
than zero, d010 [Process Display] indicates the duration of the process.
Values Default 0.00
Min/Max: 0.00/99.99
Display: 0.01
A116 [Process Time Hi] Related Parameter(s): d010, P035

Scales the time value when the drive is running at P035 [Maximum Freq]. When set to a value other
than zero, d010 [Process Display] indicates the duration of the process.
Values Default 0.00
Min/Max: 0.00/99.99
Display: 0.01
EF3339EN.0.1
Parameter Cross Reference – by Name
Parameter Name No. Group Parameter Name No. Group

Accel Time 1 P039 Basic Program Fault Clear A100 Advanced Program
Accel Time 2 A067 Advanced Program Flying Start En A096 Advanced Program
Analog In 0-10V d020 Display Internal Freq A069 Advanced Program
Analog In 4-20mA d021 Display Jog Accel/Decel A079 Advanced Program
Anlg In 0-10V Hi A111 Advanced Program Jog Frequency A078 Advanced Program
Anlg In 0-10V Lo A110 Advanced Program Maximum Freq P035 Basic Program
Anlg In4-20mA Hi A113 Advanced Program Maximum Voltage A088 Advanced Program
Anlg In4-20mA Lo A112 Advanced Program Minimum Freq P034 Basic Program
Auto Rstrt Delay A093 Advanced Program Motor NP Hertz P032 Basic Program
Auto Rstrt Tries A092 Advanced Program Motor NP Volts P031 Basic Program
Boost Select A084 Advanced Program Motor OL Current P033 Basic Program
Comm Data Rate A103 Advanced Program Motor OL Ret P043 Basic Program
Comm Format A107 Advanced Program Motor OL Select A090 Advanced Program
Comm Loss Action A105 Advanced Program Output Current d003 Display
Comm Loss Time A106 Advanced Program Output Freq d001 Display
Comm Node Addr A104 Advanced Program Output Voltage d004 Display
Comm Status d015 Display Preset Freq x A070-A073 Advanced Program
Commanded Freq d002 Display Process Display d010 Display
Compensation A097 Advanced Program Process Factor A099 Advanced Program
Contrl In Status d013 Display Process Time Hi A116 Advanced Program
Control Source d012 Display Process Time Lo A115 Advanced Program
Control SW Ver d016 Display Program Lock A101 Advanced Program
Current Limit A089 Advanced Program PWM Frequency A091 Advanced Program
DB Resistor Sel A082 Advanced Program Relay Out Level A056 Advanced Program
DC Brake Level A081 Advanced Program Relay Out Sel A055 Advanced Program
DC Brake Time A080 Advanced Program Reset To Defalts P041 Basic Program
DC Bus Voltage d005 Display Reverse Disable A095 Advanced Program
Decel Time 1 P040 Basic Program S Curve % A083 Advanced Program
Decel Time 2 A068 Advanced Program Slip Compensation A114 Advanced Program
Dig In Status d014 Display Speed Reference P038 Basic Program
Digital Inx Sel A051, A052 Advanced Program Start At PowerUp A094 Advanced Program
Drive Status d006 Display Start Source P036 Basic Program
Drive Temp d024 Display Stop Mode P037 Basic Program
Drive Type d017 Display SW Current Trip A098 Advanced Program
Elapsed Run Time d018 Display Testpoint Data d019 Display
Fault x Code d007-d009 Display Testpoint Sel A102 Advanced Program
EF3339EN.0.1
Notes:
EF3339EN.0.1
Chapter 4
Troubleshooting
Chapter 4 provides information to guide you in troubleshooting the
PowerFlex 4 drive. Included is a listing and description of drive faults
(with possible solutions, when applicable).
For information on… See page… For information on… See page…
Drive Status 4-1 Fault Descriptions 4-3
Faults 4-1 Common Symptoms and 4-5
Corrective Actions
Drive Status
The condition or state of your drive is constantly monitored. Any
changes will be indicated through the integral keypad.
LED Indications
See page 2-3 for information on drive status indicators and controls.
Faults
A fault is a condition that stops the drive. There are two fault types.
Type Fault Description

➀ Auto-Reset/Run When this type of fault occurs, and A092 [Auto Rstrt Tries] is
set to a value greater than “0,” a user-configurable timer, A093
[Auto Rstrt Delay], begins. When the timer reaches zero, the
drive attempts to automatically reset the fault. If the condition
that caused the fault is no longer present, the fault will be reset
and the drive will be restarted.
➁ Non-Resetable This type of fault may require drive or motor repair, or is
caused by wiring or programing errors. The cause of the fault
must be corrected before the fault can be cleared.
EF3339EN.0.1
4-2 Troubleshooting
Fault Indication
Condition Display
Drive is indicating a fault.
RUN VOLTS
The integral keypad provides visual notification of a FWD
REV
AMPS
HERTZ
fault condition by displaying the following. PRGOGRAM FAULT
x Flashing fault number

x Flashing fault indicator
Press the Escape key to regain control of the
integral keypad.
Manually Clearing Faults

Step Key(s)
1. Press Esc to acknowledge the fault. The fault information will be
removed so that you can use the integral keypad.
Access d007 [Fault 1 Code] to view the most recent fault information.
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared.
See Table 4.A.
3. After corrective action has been taken, clear the fault by one of these
methods.
x Press Stop if P037 [Stop Mode] is set to a value between “0” and “3”.
x Cycle drive power.
x Set A100 [Fault Clear] to “1” or “2”.
x Cycle digital input if A051 - A052 [Digital Inx Select] is set to option 7
“Clear Fault”.
Automatically Clearing Faults

Option / Step
Clear a Type 1 fault and restart the drive.
2. Set A093 [Auto Rstrt Delay] to a value other than “0”.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault

without restarting the drive.
2. Set A093 [Auto Rstrt Delay] to “0”.
Auto Restart (Reset/Run)

The Auto Restart feature provides the ability for the drive to
automatically perform a fault reset followed by a start attempt without
user or application intervention. This allows remote or “unattended”
operation. Only certain faults are allowed to be reset. Certain faults
(Type 2) that indicate possible drive component malfunction are not
resettable.
Caution should be used when enabling this feature, since the drive will
attempt to issue its own start command based on user selected
programming.
EF3339EN.0.1
Troubleshooting 4-3
Fault Descriptions
Table 4.A Fault Types, Descriptions and Actions
Type(1)
No. Fault Description Action
F2 Auxiliary Input ➀ Auxiliary input interlock is open. 1. Check remote wiring.
2. Verify communications
programming for intentional fault.
F3 Power Loss ➁ DC bus voltage remained below 1. Monitor the incoming AC line for
85% of nominal. low voltage or line power
interruption.
2. Check input fuses.
F4 UnderVoltage ➀ DC bus voltage fell below the Monitor the incoming AC line for low
minimum value. voltage or line power interruption.
F5 OverVoltage ➀ DC bus voltage exceeded Monitor the AC line for high line
maximum value. voltage or transient conditions. Bus
overvoltage can also be caused by
motor regeneration. Extend the
decel time or install dynamic brake
option.
F6 Motor Stalled ➀ Drive is unable to accelerate Increase P039 - A067 [Accel Time x]
motor. or reduce load so drive output
current does not exceed the current
set by parameter A089 [Current
Limit].
F7 Motor Overload ➀ Internal electronic overload trip. 1. An excessive motor load exists.
Reduce load so drive output
current does not exceed the
current set by parameter P033
[Motor OL Current].
2. Verify A084 [Boost Select] setting
F8 Heatsink ➀ Heatsink temperature exceeds a 1. Check for blocked or dirty heat
OvrTmp predefined value. sink fins. Verify that ambient
temperature has not exceeded
40qC (104qF) for IP 30/NEMA 1/UL
Type 1 installations or 50°C (122°F)
for IP20/Open type installations.
2. Check fan.
F12 HW OverCurrent ➁ The drive output current has Check programming. Check for
exceeded the hardware current excess load, improper A084 [Boost
limit. Select] setting, DC brake volts set
too high or other causes of excess
current.
F13 Ground Fault ➁ A current path to earth ground Check the motor and external wiring
has been detected at one or to the drive output terminals for a
more of the drive output grounded condition.
terminals.
(1) See page 4-1 for a description of fault types.
EF3339EN.0.1
4-4 Troubleshooting
Type(1)
No. Fault Description Action
F33 Auto Rstrt Tries ➁ Drive unsuccessfully attempted Correct the cause of the fault and
to reset a fault and resume manually clear.
running for the programmed
number of A092 [Auto Rstrt
Tries].
F38 Phase U to Gnd ➁ A phase to ground fault has been 1. Check the wiring between the
F39 Phase V to Gnd detected between the drive and drive and motor.
F40 Phase W to Gnd motor in this phase. 2. Check motor for grounded
phase.
3. Replace drive if fault cannot be
cleared.
F41 Phase UV Short ➁ Excessive current has been 1. Check the motor and drive output
F42 Phase UW Short detected between these two terminal wiring for a shorted
F43 Phase VW Short output terminals. condition.
2. Replace drive if fault cannot be
cleared.
F48 Params The drive was commanded to 1. Clear the fault or cycle power to
Defaulted write default values to EEPROM. the drive.
2. Program the drive parameters as
needed.
F63 SW OverCurrent ➀ Programmed A098 [SW Current Check load requirements and A098
Trip] has been exceeded. [SW Current Trip] setting.
F64 Drive Overload ➁ Drive rating of 150% for 1 minute Reduce load or extend Accel Time.
or 200% for 3 seconds has been
exceeded.
F70 Power Unit ➁ Failure has been detected in the 1. Cycle power.
drive power section. 2. Replace drive if fault cannot be
cleared.
F71 Net Loss The communication network has 1. Cycle power.
faulted. 2. Check communications cabling.
3. Check network adapter setting.
4. Check external network status.
F81 Comm Loss ➁ RS485 (DSI) port stopped 1. If adapter was not intentionally
communicating. disconnected, check wiring to the
port. Replace wiring, port
expander, adapters or complete
drive as required.
2. Check connection.
3. An adapter was intentionally
disconnected.
4. Turn off using A105 [Comm Loss
Action].
F100 Parameter ➁ The checksum read from the Set P041 [Reset To Defalts] to option
Checksum board does not match the 1 “Reset Defaults”.
checksum calculated.
F122 I/O Board Fail ➁ Failure has been detected in the 1. Cycle power.
drive control and I/O section. 2. Replace drive if fault cannot be
cleared.
(1)
See page 4-1 for a description of fault types.
EF3339EN.0.1
Troubleshooting 4-5
Common Symptoms and Corrective Actions

Motor does not Start.
Cause(s) Indication Corrective Action
No output voltage to the motor. None Check the power circuit.
x Check the supply voltage.
x Check all fuses and disconnects.
Check the motor.
x Verify that the motor is
connected properly.
Check the control input signals.
x Verify that a Start signal is
present. If 2-Wire control is used,
verify that either the Run
Forward or Run Reverse signal is
active, but not both.
x Verify that I/O Terminal 01 is
active.
x Verify that P036 [Start Source]
matches your configuration.
x Verify that A095 [Reverse
Disable] is not prohibiting
movement.
Improper boost setting at initial None Set A084 [Boost Select] to option 2
start-up. “35.0, VT”.
Drive does not Start from Integral Keypad.

Integral keypad is not enabled. Green LED above Start key is x Set parameter P036 [Start
not illuminated. Source] to option 0 “Keypad”.
x Set parameter A051 - A052
[Digital Inx Select] to option 5
“Local” and activate the input.
I/O Terminal 01 “Stop” input is None Wire inputs correctly and/or install
not present. jumper.
EF3339EN.0.1
4-6 Troubleshooting
Drive does not Start from Start or Run Inputs wired to the terminal block.
Drive is Faulted Flashing red status light Clear fault.
x Press Stop
x Cycle power
x Set A100 [Fault Clear] to option 1
“Clear Faults”.
x Cycle digital input if A051 - A052
[Digital Inx Select] is set to option
7 “Clear Fault”.
Incorrect programming. None Check parameter settings.
x P036 [Start Source] is set to
option 0 “Keypad” or option 5
“RS485 (DSI) Port”.
x A051 - A052 [Digital Inx Select]
is set to option 5 “Local” and the
input is active.
Incorrect input wiring. None Wire inputs correctly and/or install
See 1-14 for wiring examples. jumper.
x 2 wire control requires Run
Forward, Run Reverse or Jog
input.
x 3 wire control requires Start and
Stop inputs
x Stop input is always required.
Incorrect Sink/Source DIP switch None Set switch to match wiring scheme.
setting.
Drive does not respond to changes in speed command.

No value is coming from the The drive “Run” indicator is lit x Check d012 d012 [Control
source of the command. and output is 0 Hz. Source] for correct source.
x If the source is an analog input,
check wiring and use a meter to
check for presence of signal.
x Check d002 [Commanded Freq]
to verify correct command.
Incorrect reference source is None x Check d012 [Control Source] for
being selected via remote correct source.
device or digital inputs. x Check d014 [Dig In Status] to
see if inputs are selecting an
alternate source. Verify settings
for A051 - A052 [Digital Inx
Select].
x Check P038 [Speed Reference]
for the source of the speed
reference. Reprogram as
necessary.
x Review the Speed Reference
Control chart on page 1-18.
EF3339EN.0.1
Troubleshooting 4-7
Motor and/or drive will not accelerate to commanded speed.

Acceleration time is excessive. None Reprogram P039 [Accel Time 1] or
A067 [Accel Time 2].
Excess load or short None Compare d003 [Output Current] with
acceleration times force the A089 [Current Limit].
drive into current limit, slowing Remove excess load or reprogram
or stopping acceleration. P039 [Accel Time 1] or A067 [Accel
Time 2].
Check for improper A084 [Boost
Select] setting.
Speed command source or None Verify d002 [Commanded Freq].
value is not as expected. Check d012 [Control Source] for the
proper Speed Command.
Programming is preventing the None Check P035 [Maximum Freq] to
drive output from exceeding insure that speed is not limited by
limiting values. programming.
Motor operation is unstable.

Motor data was incorrectly None 1. Correctly enter motor nameplate
entered. data into P031, P032 and P033.
2. Enable A097 [Compensation].
3. Use A084 [Boost Select] to
reduce boost level.
Drive will not reverse motor direction.

Digital input is not selected for None Check [Digital Inx Sel] (See
reversing control. page 3-13). Choose correct input
and program for reversing mode.
Digital input is incorrectly None Check input wiring. (See page 1-13)
wired.
Motor wiring is improperly None Switch two motor leads.
phased for reverse.
Reverse is disabled. None Check A095 [Reverse Disable].
EF3339EN.0.1
4-8 Troubleshooting
Notes:
EF3339EN.0.1
Appendix A
Supplemental Drive Information

Drive, Fuse & Circuit Breaker Ratings A-1
Specifications A-2
Drive, Fuse & Circuit Breaker Ratings

The tables on the following pages provide drive ratings and
recommended AC line input fuse and circuit breaker information. Both
types of short circuit protection are acceptable for UL and IEC
requirements. Sizes listed are the recommended sizes based on 40 degree
C and the U.S. N.E.C. Other country, state or local codes may require
different ratings.
Fusing
If fuses are chosen as the desired protection method, refer to the
recommended types listed below. If available amp ratings do not match
the tables provided, the closest fuse rating that exceeds the drive rating
should be chosen.
x IEC – BS88 (British Standard) Parts 1 & 2 (1), EN60269-1, Parts 1 &
2, type gG or equivalent should be used.
x UL – UL Class CC, T or J must be used. (2)
Circuit Breakers
Refer to listings in the following tables for recommended circuit
breakers (inverse time or instantaneous trip) and 140M Self-Protecting
Motor Starters.
(1)
Typical designations include, but may not be limited to the following; Parts 1 & 2: AC,
AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.
(2)
Typical designations include; Type CC - KTK-R, FNQ-R
Type J - JKS, LPJ
Type T - JJS, JJN
EF3339EN.0.1
A-2 Supplemental Drive Information
Specifications
Drive Ratings
Output Ratings Input Ratings Branch Circuit Protection
Catalog
Number Voltage 140M Motor
kW (HP) Amps Range kVA Amps Fuses Protectors(2) Contactors
100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output
22A-V1P5N104 0.2 (0.25) 1.5 90-126 0.75 6.0 10 140M-C2E-C10 100-C09
22A-V2P3N104 0.4 (0.5) 2.3 90-126 1.15 9.0 15 140M-C2E-C16 100-C12
22A-V4P5N104 0.75 (1.0) 4.5 90-126 2.25 18.0 30 140M-D8E-C20 100-C23
22A-V6P0N104 1.1 (1.5) 6.0 90-126 3.0 24.0 40 140M-D8E-C25 100-C37
200 - 240V AC (±10%) – 1-Phase(1) Input, 0 - 230V 3-Phase Output, NO BRAKE
22A-A1P4N103 0.2 (0.25) 1.4 180-265 0.7 3.2 6 140M-C2E-B40 100-C09
22A-A2P1N103 0.4 (0.5) 2.1 180-265 1.05 5.3 10 140M-C2E-B63 100-C09
22A-A3P6N103 0.75 (1.0) 3.6 180-265 1.8 9.2 15 140M-C2E-C16 100-C12
22A-A6P8N103 1.5 (2.0) 6.8 180-265 3.4 14.2 25 140M-C2E-C16 100-C16
22A-A9P6N103 2.2 (3.0) 9.6 180-265 4.8 19.6 30 140M-D8E-C25 100-C23
200 - 240V AC (±10%) – 1-Phase(1) Input, 0 - 230V 3-Phase Output
22A-A1P5N104 0.2 (0.25) 1.5 180-265 0.75 5.0 10 140M-C2E-B63 100-C09
22A-A2P3N104 0.4 (0.5) 2.3 180-265 1.15 6.0 10 140M-C2E-B63 100-C09
22A-A4P5N104 0.75 (1.0) 4.5 180-265 2.25 10.0 15 140M-C2E-C16 100-C12
22A-A8P0N104 1.5 (2.0) 8.0 180-265 4.0 18.0 30 140M-D8E-C20 100-C23
22A-B1P5N104 0.2 (0.25) 1.5 180-265 0.75 1.8 3 140M-C2E-B25 100-C09
22A-B2P3N104 0.4 (0.5) 2.3 180-265 1.15 2.5 6 140M-C2E-B40 100-C09
22A-B4P5N104 0.75 (1.0) 4.5 180-265 2.25 5.2 10 140M-C2E-C10 100-C09
22A-B8P0N104 1.5 (2.0) 8.0 180-265 4.0 9.5 15 140M-C2E-C16 100-C12
22A-B012N104 2.2 (3.0) 12.0 180-265 5.5 15.5 25 140M-C2E-C16 100-C16
22A-B017N104 3.7 (5.0) 17.5 180-265 8.6 21.0 30 140M-F8E-C25 100-C23
22A-D1P4N104 0.4 (0.5) 1.4 340-528 1.4 1.8 3 140M-C2E-B25 100-C09
22A-D2P3N104 0.75 (1.0) 2.3 340-528 2.3 3.2 6 140M-C2E-B40 100-C09
22A-D4P0N104 1.5 (2.0) 4.0 340-528 4.0 5.7 10 140M-C2E-B63 100-C09
22A-D6P0N104 2.2 (3.0) 6.0 340-528 5.9 7.5 15 140M-C2E-C10 100-C09
22A-D8P7N104 3.7 (5.0) 8.7 340-528 8.6 9.0 15 140M-C2E-C16 100-C16
Input/Output Ratings Approvals
Output Frequency: 0-240 Hz (Programmable) UL508C EMC Directive 89/336/EEC, LV Dir. 73/23/EEC
UL CSA 22.2 LV: EN 50178
Efficiency: 97.5% (Typical) C
®
US No. 14 EMC: EN 61800-3
Digital Control Inputs (Input Current = 6mA) Analog Control Inputs

SRC (Source) Mode: SNK (Sink) Mode: 4-20mA Analog: 250 ohm input impedance
18-24V = ON 0-6V = ON 0-10V DC Analog: 100k ohm input impedance
0-6V = OFF 18-24V = OFF External Pot: 1-10k ohms, 2 Watt minimum
Control Output (Programmable Output, form C relay)
Resistive Rating: 3.0A at 30V DC, 125V AC and 240V AC Inductive Rating: 0.5A at 30V DC, 125V AC, and 240V AC
Recommended Fuses and Circuit Breakers
Fuse: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. Circuit Breakers: HMCP or Bulletin 140U or equivalent.
Protective Features
Motor Protection: I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection)
Overcurrent: 200% hardware limit, 300% instantaneous fault
Over Voltage: 100-120V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line)
200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line)
Under Voltage: 100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)
Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs
Faultless Power Ride Through: 100 milliseconds
Dynamic Braking
Internal brake IGBT included with all ratings except No Brake versions. Refer to Appendix B of the PowerFlex 4 User Manual on
CD for ordering information.
(1) 200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N103 to N113
and N104 to N114.
(2) Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001… to determine the frame and
breaking capacity required for your application.
EF3339EN.0.1
Supplemental Drive Information A-3
Category Specification
Environment Altitude: 1000 m (3300 ft) max. without derating
Maximum Surrounding Air
Temperature without derating:
IP20: –10 to 50° C (14 to 122° F)
NEMA 1: –10 to 40° C (14 to 104° F)
Flange Mount: Heatsink: –10 to 40° C (14 to 104° F)
Drive: –10 to 50° C (14 to 122° F)
Cooling Method
Convection: 0.2 kW (0.25 HP) drives
Flange Mount drives, all ratings
Fan: All other drive ratings.
Storage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)
Atmosphere: Important: Drive must not be installed in an
area where the ambient atmosphere contains
volatile or corrosive gas, vapors or dust. If the
drive is not going to be installed for a period of
time, it must be stored in an area where it will not
be exposed to a corrosive atmosphere.
Relative Humidity: 0 to 95% non-condensing
Shock (operating): 15G peak for 11ms duration (±1.0ms)
Vibration (operating): 1G peak, 5 to 2000 Hz
Control Carrier Frequency 2-16 kHz. Drive rating based on 4 kHz.
Frequency Accuracy
Digital Input: Within ±0.05% of set output frequency.
Analog Input: Within 0.5% of maximum output frequency.
Speed Regulation - Open Loop ±2% of base speed across a 40:1 speed range.
with Slip Compensation:
Stop Modes: Multiple programmable stop modes including -
Ramp, Coast, DC-Brake, Ramp-to-Hold and
S Curve.
Accel/Decel: Two independently programmable accel and
decel times. Each time may be programmed from
0 - 600 seconds in 0.1 second increments.
Intermittent Overload: 150% Overload capability for up to 1 minute
200% Overload capability for up to 3 seconds
Electronic Motor Overload Class 10 protection with speed sensitive
Protection response and power-down overload retention
function.
EF3339EN.0.1
A-4 Supplemental Drive Information
PowerFlex 4 Estimated Watts Loss (Rated Load, Speed & PWM)

Voltage kW (HP) External Watts Internal Watts Total Watts Loss
100–120V 0.2 (0.25) 16 16 32
0.4 (0.5) 22 18 40
0.75 (1.0) 35 20 55
1.1 (1.5) 58 22 80
200–240V 0.2 (0.25) 16 16 32
0.4 (0.5) 22 18 40
0.75 (1.0) 35 20 55
1.5 (2.0) 63 22 85
2.2 (3.0) 100 25 125
3.7 (5.0) 150 30 180
380–480V 0.4 (0.5) 17 18 35
0.75 (1.0) 30 20 50
1.5 (2.0) 48 22 70
2.2 (3.0) 75 25 100
3.7 (5.0) 125 25 150
EF3339EN.0.1
Appendix B
Accessories and Dimensions

For information on… See page
Product Selection B-1
Product Dimensions B-5
Product Selection
Table B.A Catalog Number Description
22A - A 1P5 N 1 1 4
Drive Voltage Rating Rating Enclosure HIM Emission Class Type
Table B.B PowerFlex 4 Drives
Drive Ratings Catalog Number
Output Frame
Input Voltage kW HP Current Panel Mount Flange Mount (1) Size
120V 50/60 Hz 0.2 0.25 1.5A 22A-V1P5N104 22A-V1P5F104 A
1-Phase 0.4 0.5 2.3A 22A-V2P3N104 22A-V2P3F104 A
No Filter
0.75 1.0 4.5A 22A-V4P5N104 22A-V4P5F104 B
1.1 1.5 6.0A 22A-V6P0N104 22A-V6P0F104 B
240V 50/60 Hz 0.2 0.25 1.4A 22A-A1P4N113 – A
1-Phase 0.4 0.5 2.1A 22A-A2P1N113 – A
NO BRAKE
0.75 1.0 3.6A 22A-A3P6N113 – A
With Integral “S Type”
EMC Filter 1.5 2.0 6.8A 22A-A6P8N113 – B
2.2 3.0 9.6A 22A-A9P6N113 – B
240V 50/60 Hz 0.2 0.25 1.4A 22A-A1P4N103 22A-A1P4F103 A
1-Phase 0.4 0.5 2.1A 22A-A2P1N103 22A-A2P1F103 A
NO BRAKE
0.75 1.0 3.6A 22A-A3P6N103 22A-A3P6F103 A
No Filter
1.5 2.0 6.8A 22A-A6P8N103 22A-A6P8F103 B
2.2 3.0 9.6A 22A-A9P6N103 22A-A9P6F103 B
240V 50/60 Hz 0.2 0.25 1.5A 22A-A1P5N114 – A
1-Phase 0.4 0.5 2.3A 22A-A2P3N114 – A
With Integral “S Type”
EMC Filter 0.75 1.0 4.5A 22A-A4P5N114 – A
1.5 2.0 8.0A 22A-A8P0N114 – B
240V 50/60 Hz 0.2 0.25 1.5A 22A-A1P5N104 22A-A1P5F104 A
1-Phase 0.4 0.5 2.3A 22A-A2P3N104 22A-A2P3F104 A
No Filter
0.75 1.0 4.5A 22A-A4P5N104 22A-A4P5F104 A
1.5 2.0 8.0A 22A-A8P0N104 22A-A8P0F104 B
240V 50/60 Hz 0.2 0.25 1.5A 22A-B1P5N104 22A-B1P5F104 A
3-Phase 0.4 0.5 2.3A 22A-B2P3N104 22A-B2P3F104 A
No Filter
0.75 1.0 4.5A 22A-B4P5N104 22A-B4P5F104 A
1.5 2.0 8.0A 22A-B8P0N104 22A-B8P0F104 A
2.2 3.0 12.0A 22A-B012N104 22A-B012F104 B
3.7 5.0 17.5 22A-B017N104 22A-B017F104 B
480V 50/60 Hz 0.4 0.5 1.4A 22A-D1P4N104 22A-D1P4F104 A
3-Phase 0.75 1.0 2.3A 22A-D2P3N104 22A-D2P3F104 A
No Filter
1.5 2.0 4.0A 22A-D4P0N104 22A-D4P0F104 A
2.2 3.0 6.0A 22A-D6P0N104 22A-D6P0F104 B
3.7 5.0 8.7A 22A-D8P7N104 22A-D8P7F104 B
(1)
Replacement Plate drives are also available. Contact factory for ordering information.
EF3339EN.0.1
B-2 Accessories and Dimensions
Table B.C Dynamic Brake Modules

Drive Ratings
Minimum
Input Voltage kW HP Resistance : Catalog Number (1) (2)
120V 50/60 Hz 0.2 0.25 60 AK-R2-091P500
1-Phase
0.4 0.5 60 AK-R2-091P500
0.75 1.0 60 AK-R2-091P500
1.1 1.5 60 AK-R2-091P500
240V 50/60 Hz 0.2 0.25 60 AK-R2-091P500
1-Phase 0.4 0.5 60 AK-R2-091P500
0.75 1.0 60 AK-R2-091P500
1.5 2.0 60 AK-R2-091P500
240V 50/60 Hz 0.2 0.25 60 AK-R2-091P500
3-Phase 0.4 0.5 60 AK-R2-091P500
0.75 1.0 60 AK-R2-091P500
1.5 2.0 60 AK-R2-091P500
2.2 3.0 48 AK-R2-047P500
3.7 5.0 32 AK-R2-047P500
480V 50/60 Hz 0.4 0.5 121 AK-R2-091P500
3-Phase
0.75 1.0 121 AK-R2-360P500
1.5 2.0 121 AK-R2-360P500
2.2 3.0 97 AK-R2-120P1K2
3.7 5.0 97 AK-R2-120P1K2
(1)
The resistors listed in this table are rated for 5% duty cycle.
(2)
Use of Rockwell resistors is always recommended. The resistors listed have been carefully
selected for optimizing performance in a varity of applications. Alternative resistors may be used,
however care must be taken when making a selection. Refer to the PowerFlex Dynamic Braking
Resistor Calculator, publication PFLEX-AT001….
Table B.D Bulletin 1321-3R Series Line Reactors

Maximum
Fundamental Continuous Watts Catalog
Input Voltage kW HP Amps Amps Inductance Loss Number (1)
240V 50/60 Hz 0.2 0.25 2 3 12.0 mh 7.5 W 1321-3R2-A
3-Phase
0.4 0.5 4 6 12.0 mh 21 W 1321-3R4-D
0.75 1.0 8 12 3.0 mh 29 W 1321-3R8-B
1.5 2.0 8 12 1.5 mh 19.5 W 1321-3R8-A
2.2 3.0 12 18 1.25 mh 26 W 1321-3R12-A
3.7 5.0 18 27 0.8 mh 36 W 1321-3R18-A
480V 50/60 Hz 0.4 0.5 2 3 20.0 mh 11.3 W 1321-3R2-B
3-Phase
0.75 1.0 4 6 9.0 mh 20 W 1321-3R4-C
1.5 2.0 4 6 6.5 mh 20 W 1321-3R4-B
2.2 3.0 8 12 5.0 mh 25.3 W 1321-3R8-C
3.7 5.0 18 27 3.0 mh 29 W 1321-3R-12-B
(1) Catalog numbers listed are for 3% impedance open style units. NEMA Type 1 and 5% impedance
reactor types are also available. Refer to publication 1321-TD001….
EF3339EN.0.1
Accessories and Dimensions B-3
Table B.E EMC Line Filters

Drive Ratings S Type Filter L Type Filter
Input Voltage kW HP Catalog Number (1) Catalog Number (3)
120V 50/60 Hz 0.2 0.25 – 22-RF010-AL
1-Phase 0.4 0.5 – 22-RF010-AL
0.75 1.0 – 22-RF018-BL
1.1 1.5 – 22-RF025-CL (4)
(2)
240V 50/60 Hz 0.2 0.25 22-RF010-AL
1-Phase 0.4 0.5 (2)
22-RF010-AL
0.75 1.0 (2) 22-RF010-AL
(2)
1.5 2.0 22-RF018-BL
(2)
240V 50/60 Hz 0.2 0.25 22-RF010-AL
1-Phase 0.4 0.5 (2) 22-RF010-AL
NO BRAKE (2)
0.75 1.0 22-RF010-AL
(2)
1.5 2.0 22-RF018-BL
2.2 3.0 (2) 22-RF025-CL (4)
240V 50/60 Hz 0.2 0.25 22-RF9P5-AS 22-RF9P5-AL
3-Phase 0.4 0.5 22-RF9P5-AS 22-RF9P5-AL
0.75 1.0 22-RF9P5-AS 22-RF9P5-AL
1.5 2.0 22-RF9P5-AS 22-RF9P5-AL
2.2 3.0 22-RF021-BS 22-RF021-BL
3.7 5.0 22-RF021-BS 22-RF021-BL
480V 50/60 Hz 0.4 0.5 22-RF5P7-AS 22-RF5P7-AL
3-Phase 0.75 1.0 22-RF5P7-AS 22-RF5P7-AL
1.5 2.0 22-RF5P7-AS 22-RF5P7-AL
2.2 3.0 22-RF012-BS 22-RF012-BL
3.7 5.0 22-RF012-BS 22-RF012-BL
(1)
This filter is suitable for use with a cable length up to 10 meters (33 feet) for Class A and 1 meter
for Class B environments.
(2) These ratings can be ordered with internal “S Type” filters. Refer to the Catalog Number
explanation on page P-4 and Table B.B for details.
(3)
This filter is suitable for use with a cable length up to 100 meters for Class A and 5 meters for
Class B environments.
(4)
The piggyback mounting option cannot be used with Frame B PowerFlex 4 drives and Frame C
EMC Line Filters.
Table B.F Human Interface Module (HIM) Option Kits and Accessories
Item Description Catalog Number
LCD Display, Remote Panel Digital speed control 22-HIM-C2
Mount CopyCat capable 22-HIM-C2S (1)
IP66 (NEMA Type 4X/12) indoor use only
22-HIM-C2 includes 2.9 meter cable.
22-HIM-C2S includes 2 meter cable.
LCD Display, Remote Handheld Digital speed control 22-HIM-A3
Full numeric keypad
CopyCat capable
IP30 (NEMA Type 1)
Includes 1.0 meter cable
Panel mount with optional Bezel Kit
Bezel Kit Panel mount for LCD Display, Remote 22-HIM-B1
Handheld unit, IP30 (NEMA Type 1)
DSI HIM Cable 1.0 Meter (3.3 Feet) 22-HIM-H10
(DSI HIM to RJ45 cable) 2.9 Meter (9.51 Feet) 22-HIM-H30
(1) The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement.
EF3339EN.0.1
Table B.G Communication Option Kits

Item Description Catalog Number (2)
External DSI™ External mounting kit for 22-COMM-C, -D, -E, -P. 22-XCOMM-DC-BASE
Communications Kit
External Comms Power Optional 100-240V AC Power Supply for External 20-XCOMM-AC-PS1
Supply DSI Communications Kit.
Compact I/O Module Three channel. 1769-SM2
Serial Converter Module Provides serial communication via DF1 protocol 22-SCM-232
(RS485 to RS232) for use with DriveExplorer and DriveExecutive
software. Includes:
DSI to RS232 serial converter (1)
1203-SFC serial cable (1)
22-RJ45CBL-C20 cable (1)
DriveExplorer Lite CD (1)
DSI Cable 2.0 meter RJ45 to RJ45 cable, male to male 22-RJ45CBL-C20
connectors.
Serial Cable 2.0 meter serial cable with a locking low profile 1203-SFC
connector to connect to the serial converter and a
9-pin sub-miniature D female connector to connect
to a computer.
Null Cable Converter For use when connecting the serial converter to 1203-SNM
DriveExplorer on a handheld PC.
Splitter Cable RJ45 one to two port splitter cable AK-U0-RJ45-SC1
Terminating Resistors RJ45 120 Ohm resistors (2 pieces) AK-U0-RJ45-TR1
Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P
DriveExplorer Software Windows based software package that provides 9306-4EXP01ENE
(CD-ROM) Version 3.01 an intuitive means for monitoring or configuring
or later Allen-Bradley drives and communication adapters
online.
Compatibility:
Windows 95, 98, ME, NT 4.0 (Service Pack 3 or
later), 2000, XP and CE(1)
DriveExecutive software Windows based software package that provides 9303-4DTE01ENE
(CD-ROM) Version 1.01 an intuitive means for monitoring or configuring
or later Allen-Bradley drives and communication adapters
online and offline.
Compatibility:
Windows 98, ME, NT 4.0 (Service Pack 3 or
later), 2000 and XP
(1) See www.ab.com/drives/driveexplorer.htm for supported devices.
(2) For pricing information, refer to the PowerFlex 4-Class Price List, Publication 22-PL001….
Table B.H IP30/NEMA 1/UL Type 1 Kit

Drive
Item Description Frame Catalog Number (1)
IP30/NEMA 1/UL Type 1 Field installed kit. Converts drive to IP30/ A 22-JBAA
Kit NEMA 1/UL Type 1 enclosure. Includes
conduit box with mounting screws and B 22-JBAB
plastic top panel.
(1)
For pricing information, refer to the PowerFlex 4-Class Price List, Publication 22-PL001….
EF3339EN.0.1
Product Dimensions
Table B.I PowerFlex 4 Panel Mount Drives – Ratings are in kW and (HP)
Frame
240V AC – 1-Phase
120V AC – 1-Phase 240V AC – 1-Phase 240V AC – 3-Phase 480V AC – 3-Phase
No Brake
A 0.2 (0.25) 0.2 (0.25) 0.2 (0.25) 0.2 (0.25) 0.37 (0.5)
0.37(0.5) 0.37 (0.5) 0.37 (0.5) 0.37 (0.5) 0.75 (1.0)
0.75 (1.0) 0.75 (1.0) 0.75 (1.0) 1.5 (2.0)
1.5 (2.0)
B 0.75(1.0) 1.5 (2.0) 1.5 (2.0) 2.2 (3.0) 2.2 (3.0)
1.1 (1.5) 2.2 (3.0) 3.7 (5.0) 3.7 (5.0)
Figure B.1 PowerFlex 4 Panel Mount Drives – Dimensions are in millimeters and
(inches). Weights are in kilograms and (pounds).
A
D C
GEB
5.5 (0.22)
Shipping
Frame A B(1) C D E(2) F G
Weight
A 80 (3.15) 185 (7.28) 136 (5.35) 67 (2.64) 152 (5.98) 59.3 (2.33) 140 (5.51) 1.4 (3.1)
B 100 (3.94) 213 (8.39) 136 (5.35) 87 (3.43) 180 (7.09) 87.4 (3.44) 168 (6.61) 2.2 (4.9)
(1)
Overall height of drive with IP 30/NEMA 1/UL Type 1 option kit installed.
(2) Overall height of standard IP 20/Open Type drive.
Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit – Dimensions are in millimeters and
(inches)
79.1
(3.11)
59.2 64.1
(2.33) (2.52)
40.0 40.6
(1.57) ∅ 22.2 (1.60) ∅ 22.2
20.7 (0.87) 25.6 (0.87)
(0.81) (1.01)
109.3 109.9
(4.30) (4.33)
75.3 74.3
(2.96) (2.93)
Frame A - 22-JBAA Frame B - 22-JBAB
EF3339EN.0.1
Figure B.3 PowerFlex 4 Flange Mount Drives – Dimensions are in millimeters and
(inches)
Frame A
175 92.8 54.7
(6.89) (3.65) (2.15)
145
(5.71)
210
(8.27)
Frame B
244 94.3 63.1

(9.61) (3.71) (2.48)
214
(8.43)
250
(9.84)
EF3339EN.0.1
Figure B.4 PowerFlex 4 Cutout Dimensions – Dimensions are in millimeters and

(inches)
Frame A
8 114 5.3
(0.31) (4.49) (0.21)
195
(7.68)
179
(7.05)
97.5
(3.84)
16 49 8
(0.63) (1.93) (0.31)
98
(3.86) 130
(5.12)
Frame B
145
6.5 (5.71)
(0.26) 23.5
(0.93)
197
(7.76)
210
225 (8.27)
(8.86)
98.5
(3.88)
5.3
(0.21)
14 31 49 7.5
(0.55) (1.22) (1.93) (0.30)
98
(3.86)
160
(6.30)
EF3339EN.0.1
Figure B.5 PowerFlex 4 Replacement Plate Drive Dimensions – Dimensions are in

millimeters and (inches)
Frame A
104.8
(4.13)
92
(3.62)
50
(1.97) 88 6
(3.46) (0.24)
163
(6.42)
152
(5.98)
175
(6.89)
81.5
(3.21)
80 5.3
(3.15) (0.21)
Frame B
125
(4.92)
112
(4.41)
80
(3.15) 88 9.5
(3.46) (0.37)
192
(7.56)
204 180
(8.03) (7.09)
96
(3.78)
100 5.3
(3.94) (0.21)
EF3339EN.0.1
Figure B.6 Dynamic Brake Modules – Dimensions are in millimeters and (inches)
Frame A Frame B
30.0 61.0
17.0 (1.18) 60.0 31.0 (2.40) 59.0
(0.67) (2.36) (1.22) (2.32)
US
C
US
C
316.0 335.0 386.0 405.0
(12.44) (13.19) (15.20) (15.94)
AUTOMATION
ROCKWELL
SURFACES MAY BE
AUTOMATION
ROCKWELL
13.0
(0.51)
Frame Catalog Number

A AK-R2-091P500, AK-R2-047P500, AK-R2-360P500
B AK-R2-030P1K2, AK-R2-120P1K2
Figure B.7 Recommended External Brake Resistor Circuitry
Three-Phase
AC Input
(Input Contactor) M
R (L1)
S (L2)
T (L3)
Power Off Power On
Power Source DB Resistor Thermostat
EF3339EN.0.1
Figure B.8 Bulletin 1321-3R Series Line Reactors

– Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).
A
B
E
D
C
Catalog Number A B C D E Weight

1321-3R2-A 112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 1.8 (4)
1321-3R2-B 112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 1.8 (4)
1321-3R4-B 112 (4.40) 104 (4.10) 76 (3.00) 50 (1.98) 37 (1.44) 1.8 (4)
1321-3R4-C 112 (4.40) 104 (4.10) 86 (3.38) 60 (2.35) 37 (1.44) 2.3 (5)
1321-3R4-D 112 (4.40) 104 (4.10) 92 (3.62) 66 (2.60) 37 (1.44) 2.7 (6)
1321-3R8-A 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 3.1 (7)
1321-3R8-B 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 3.6 (8)
1321-3R8-C 152 (6.00) 127 (5.00) 85 (3.35) 63 (2.48) 51 (2.00) 4.9 (11)
1321-3R12-A 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 4.1 (9)
1321-3R18-A 152 (6.00) 133 (5.25) 79 (3.10) 54 (2.13) 51 (2.00) 4.1 (9)
EF3339EN.0.1
Figure B.9 Frame A EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL
50 80
(1.97) 60 (3.15)
29.8
(1.17) (2.36)
208 220
(8.19) (8.66)
208
(8.19)
17.8 5.5 (0.22)

(0.70) 24
(0.94)
Figure B.10 Frame B EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF012-BS, -BL (Series B); 22-RF018-BS; 22-RF021-BS, -BL
50 100
(1.97) 78 (3.94)
29.8
(1.17) (3.07)
217 229
(8.54) (9.02)
216
(8.50)
17.8 5.5 (0.22)

(0.70) 24.0
(0.94)
EF3339EN.0.1
Figure B.11 Frame C EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Number: 22-RF025-CL
60 130
(2.36) 90 (5.12)
32
(1.26) (3.54)
297 309
(11.69) (12.17)
297
(11.69)
17 5.5 (0.22)
(0.67) 30
(1.18)
Important: The piggyback mounting option cannot be used with

Frame B PowerFlex 4 drives and Frame C EMC Line
Filters.
EF3339EN.0.1
Figure B.12 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches)
Catalog Number: 22-HIM-C2
17.6 104
(0.69) (4.09)
220
(8.66)
2.9m
78
(3.07)
66
(2.60)
194
(7.64)
125
(4.92)
60.5
(2.38)
38
19.1 (1.50)
(0.75)
4.8
(0.19)
EF3339EN.0.1
Figure B.13 Remote (Panel Mount) Small HIM – Dimensions are in millimeters and
(inches) Catalog Number: 22-HIM-C2S
25 93
(0.98) (3.66)
180
(7.09)
2m
67
(2.64)
60
(2.36)
154
(6.06)
77
19.1 (3.03)
(0.75)
4.8
(0.19)
23.5
(0.93)
Important: The 22-HIM-C2S is smaller than the 22-HIM-C2 and

cannot be used as a direct replacement.
EF3339EN.0.1
Figure B.14 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches)
Catalog Number: 22-HIM-B1
11.1
93 (0.44)
25.2 (3.66)
(0.99)
180
(7.09)
2m
67
(2.64)
60
(2.36)
154
(6.06)
77
19.1 (3.03)
(0.75)
4.8
(0.19)
23.5
(0.93)
EF3339EN.0.1
Notes:
EF3339EN.0.1
Appendix C
RS485 (DSI) Protocol

PowerFlex 4 drives support the RS485 (DSI) protocol to allow efficient
operation with Rockwell Automation peripherals. In addition, some
Modbus functions are supported to allow simple networking. PowerFlex
4 drives can be multi-dropped on an RS485 network using Modbus
protocol in RTU mode.
Controller
For information regarding DeviceNet or other communication protocols,

refer to the appropriate usr manual.
Network Wiring
Network wiring consists of a shielded 2-conductor cable that is
daisy-chained from node to node.
Figure C.1 Network Wiring Diagram

PowerFlex 4 PowerFlex 4 PowerFlex 4
Master Node 1 Node 2 Node "n" FRONT
TxRxD+ TxRxD+ 120 ohm resistor
TxRxD+ 4 4 4
120 ohm resistor
TxRxD- TxRxD-
TxRxD- 5 5 5 PIN 1
Shield Shield Shield PIN 8
X X X
NOTE: The shield is connected at ONLY ONE end of each cable segment.
Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on
the PowerFlex 4 RJ45 socket contain power, etc. for other Rockwell
Automation peripheral devices and must not be connected.
Wiring terminations on the master controller will vary depending on the

master controller used and “TxRxD+” and “TxRxD-” are shown for
illustration purposes only. Refer to the master controller’s user manual
for network terminations. Note that there is no standard for the “+” and
“-” wires, and consequently Modbus device manufacturers interpret
them differently. If you have problems with initially establishing
communications, try swapping the two network wires at the master
controller.
EF3339EN.0.1
C-2 RS485 (DSI) Protocol
Standard RS485 wiring practices apply. Termination resistors need to be

applied at each end of the network cable. RS485 repeaters may need to
be used for long cable runs, or if greater than 32 nodes are needed on the
network.
Control Terminal 16 on the PowerFlex 4 must also be connected to PE

ground (there are two PE terminals on the drive). See Figure 1.5 for more
information.
Parameter Configuration
The following PowerFlex 4 parameters are used to configure the drive to
operate on a network.
Parameter Details Reference

P036 [Start Source] Set to 5 “RS485 (DSI) Port” if Start is controlled from Page 3-9
the network.
P038 [Speed Reference] Set to 5 “RS485 (DSI) Port” if the Speed Reference is Page 3-11
controlled from the network.
A103 [Comm Data Rate] Sets the data rate for the RS485 (DSI) Port. All nodes Page 3-23
on the network must be set to the same data rate.
A104 [Comm Node Addr] Sets the node address for the drive on the network. Page 3-23
Each device on the network requires a unique node
address.
A105 [Comm Loss Action] Selects the drive’s response to communication Page 3-24
problems.
A106 [Comm Loss Time] Sets the time that the drive will remain in Page 3-24
communication loss before the drive implements A105
[Comm Loss Action].
A107 [Comm Format] Sets the transmission mode, data bits, parity and stop Page 3-24
bits for the RS485 (DSI) Port. All nodes on the network
must be set to the same setting.
Supported Modbus Function Codes

The peripheral interface (DSI) used on PowerFlex 4 drives supports
some of the Modbus function codes.
Modbus Function Code (Decimal) Command

03 Read Holding Registers
06 Preset (Write) Single Register
16 (10 Hexadecimal) Preset (Write) Multiple Registers
Important: Modbus devices can be 0-based (registers are numbered

starting at 0) or 1-based (registers are numbered starting at
1). Depending on the Modbus Master used, the register
addresses listed on the following pages may need to be
offset by +1. For example, Logic Command may be register
address 8192 for some master devices (e.g. ProSoft
3150-MCM SLC Modbus scanner) and 8193 for others
(e.g. PanelViews).
EF3339EN.0.1
RS485 (DSI) Protocol C-3
Writing (06) Logic Command Data

The PowerFlex 4 drive can be controlled via the network by sending
Function Code 06 writes to register address 8192 (Logic Command).
P036 [Start Source] must be set to 5 “RS485 (DSI) Port” in order to
accept the commands.
Logic Command
Address (Decimal) Bit(s) Description
0 1 = Stop, 0 = Not Stop
1 1 = Start, 0 = Not Start
2 1 = Jog, 0 = No Jog
3 1 = Clear Faults, 0 = Not Clear Faults
00 = No Command
01 = Forward Command
5,4
10 = Reverse Command
11 = No Command
6 Not Used
7 Not Used
00 = No Command
01 = Accel Rate 1 Enable
9,8
10 = Accel Rate 2 Enable
8192 11 = Hold Accel Rate Selected
00 = No Command
01 = Decel Rate 1 Enable
11,10
10 = Decel Rate 2 Enable
11 = Hold Decel Rate Selected
000 = No Command
001 = Freq. Source = P036 [Start Source]
010 = Freq. Source = A069 [Internal Freq]
011 = Freq. Source = Comms (Addr 8193)
14,13,12
100 = A070 [Preset Freq 0]
15 Not Used
Writing (06) Reference

The Speed Reference to a PowerFlex 4 drive can be controlled via the
network by sending Function Code 06 writes to register address 8193
(Reference). P038 [Speed Reference] must be set to 5 “RS485 (DSI)
Port” in order to accept the Speed Reference.
Reference
Address (Decimal) Description
A decimal value entered as xxx.x where the decimal point is fixed. For
8193
example, a decimal “100” equals 10.0 Hz and “543” equals 54.3 Hz.
EF3339EN.0.1
Reading (03) Logic Status Data

The PowerFlex 4 Logic Status data can be read via the network by
sending Function Code 03 reads to register address 8448 (Logic Status).
Logic Status
Address (Decimal) Bit(s) Description
0 1 = Ready, 0 = Not Ready
1 1 = Active (Running), 0 = Not Active
2 1 = Cmd Forward, 0 = Cmd Reverse
3 1 = Rotating Forward, 0 = Rotating Reverse
4 1 = Accelerating, 0 = Not Accelerating
5 1 = Decelerating, 0 = Not Decelerating
6 1 = Alarm, 0 = No Alarm
7 1 = Faulted, 0 = Not Faulted
8448
8 1 = At Reference, 0 = Not At Reference
9 1 = Reference Controlled by Comm
10 1 = Operation Cmd Controlled by Comm
11 1 = Parameters have been locked
12 Digital Input 1 Status
13 Digital Input 2 Status
14 Not Used
15 Not Used
Reading (03) Feedback

The Feedback (Output Frequency) from the PowerFlex 4 drive can be
read via the network by sending Function Code 03 reads to register
address 8451 (Feedback).
Feedback(1)
Address (Decimal) Description
8451 A xxx.x decimal value where the decimal point is fixed. For example, a decimal
“123” equals 12.3 Hz and “300” equals 30.0 Hz.
(1) Returns the same data as Reading (03) Parameter d001 [Output Freq].
EF3339EN.0.1
RS485 (DSI) Protocol C-5
Reading (03) Drive Error Codes

The PowerFlex 4 Error Code data can be read via the network by
sending Function Code 03 reads to register address 8449 (Drive Error
Codes).
Logic Status
Address (Decimal) Value (Decimal) Description
0 No Fault
2 Auxiliary Input
3 Power Loss
4 Undervoltage
5 Overvoltage
6 Motor Stalled
7 Motor Overload
8 Heatsink Overtemperature
12 HW Overcurrent (300%)
13 Ground Fault
29 Analog Input Loss
33 Auto Restart Tries
8449 38 Phase U to Ground Short
39 Phase V to Ground Short
40 Phase W to Ground Short
41 Phase UV Short
42 Phase UW Short
43 Phase VW Short
63 Software Overcurrent
64 Drive Overload
70 Power Unit Fail
80 AutoTune Fail
81 Communication Loss
100 Parameter Checksum Error
122 I/O Board Fail
Reading (03) and Writing (06) Drive Parameters

To access drive parameters, the Modbus register address equals the
parameter number. For example, a decimal “1” is used to address
Parameter d001 [Output Freq] and decimal “39” is used to address
Parameter P039 [Accel Time 1].
Additional Information
Refer to http://www.ab.com/drives/ for additional information.
EF3339EN.0.1
Notes:
EF3339EN.0.1
Appendix D
RJ45 DSI Splitter Cable
The PowerFlex 4 drive provides a RJ45 port to allow the connection of a

single peripheral device. The RJ45 DSI Splitter Cable can be used to
connect a second DSI peripheral device to the drive.
Connectivity Guidelines
ATTENTION: Risk of injury or equipment damage exists. The

peripherals may not perform as intended if these Connectivity
! Guidelines are not followed. Precautions should be taken to follow
these Connectivity Guidelines.
x Two peripherals maximum can be attached to a drive.

x If a single peripheral is used, it must be connected to the Master port
(M) on the splitter and configured for “Auto” (default) or “Master.”
Parameter 9 [Device Type] on the DSI / MDI keypads and Parameter
1 [Adapter Cfg] on the Serial Converter are used to select the type
(Auto / Master / Slave).
x If two peripherals will be powered up at the same time, one must be
configured as the “Master” and connected to the Master port (M) and
the other must be connected as the “Slave” and connected to the
Slave port (S).
EF3339EN.0.1
D-2 RJ45 DSI Splitter Cable
DSI Cable Accessories
RJ45 Splitter Cable – Catalog Number: AK-U0-RJ45-SC1
S
Slave Port
Master Port
M
PIN 1 PIN 8
RJ45 Two-Position Terminal Block Adapter –

Catalog Number: AK-U0-RJ45-TB2P
TB2
(PIN 5) PIN 8
TB1
(PIN 4) PIN 1
RJ45 Adapter with Integrated Termination Resistor –

Catalog Number: AK-U0-RJ45-TR1
PIN 8
PIN 1
EF3339EN.0.1
RJ45 DSI Splitter Cable D-3
Connecting an RS-485 Network

DSI / MDI Drives
AK-U0-RJ45-TB2P
Two-position
Terminal Block
AK-U0-RJ45-TR1
Terminating Resistor
(end of network) or or
Customer supplied RJ45 male-to-RJ45 male

cables with wires connected at pins 4 and 5 only.
Both the Master (M) and Slave (S) ports on the RJ45 Splitter
Cable operate as standard RS-485 ports in this configuration.
EF3339EN.0.1
D-4 RJ45 DSI Splitter Cable
Notes:
EF3339EN.0.1
Index
A Distribution Systems, Ungrounded,

1-3
AC Supply
Drive Frame Size, P-2, B-5
Ground, 1-4
Drive Grounding, 1-4
Source, 1-3
Drive Overload Fault, 4-4
Ungrounded, 1-3
Drive Ratings, P-4, A-1
Advanced Program Group
Parameters, 3-13 DriveExecutive, 3-1
Ambient Temperatures, 1-2 DriveExplorer, 3-1
Armored Cable, 1-8
Auto Rstrt Tries Fault, 4-4
E
Earthing, see Grounding
Auxiliary Input Fault, 4-3
EMC/RFI
B Grounding, Filter, 1-5
Before Applying Power, 2-1, 2-2 Interference, 1-20
Bus Capacitors, Discharging, P-3 Enclosure Rating, Changing, 1-2
ESD, Static Discharge, P-3
C
Cable Length, 1-12 F
Cable, Power, 1-8 Faults
Capacitors, Discharging, P-3 Auto Rstrt Tries, 4-4
Catalog Number Explanation, P-4 Auxiliary Input, 4-3
CE Conformity, 1-20 Comm Loss, 4-4
Checklist, Start-Up, 2-1, 2-2 Drive Overload, 4-4
Circuit Breakers Ground Fault, 4-3
Input, 1-6 Heatsink OvrTmp, 4-3
Comm Loss Fault, 4-4 HW OverCurrent, 4-3
Command Sources for Start and I/O Board Fail, 4-4
Speed, 1-18 Motor Overload, 4-3
Contactors, Input, 1-11 Motor Stalled, 4-3
Control, 2 and 3 Wire, 1-14, 1-17 OverVoltage, 4-3
Conventions, Manual, P-2 Parameter Checksum, 4-4
Cover, Opening, 1-1 Phase Short, 4-4
Cross Reference, Parameter Phase to Ground Short, 4-4
by Name, 3-27 Power Loss, 4-3
Power Unit, 4-4
D SW OverCurrent, 4-4
Dimensions
UnderVoltage, 4-3
Drive, B-5
Filter, RFI, 1-5
Minimum Clearances, 1-2
Frame Designations, P-2, A-1, B-5
Discharging Bus Capacitors, P-3
Fuses
Display, 2-3
Input, 1-6
Display Group Parameters, 3-3
Ratings, A-1
EF3339EN.0.1
Index-2
G P
General Precautions, P-3 Parameter
Ground Fault, 4-3 Descriptions, 3-1
Grounding Types, 3-1
Filter, 1-5 Viewing and Editing, 2-4
General, 1-4 Parameter Checksum Fault, 4-4
Parameter Cross Reference
H by Name, 3-27
Heatsink OvrTmp Fault, 4-3 Parameters
HW OverCurrent Fault, 4-3 Advanced Program Group, 3-13
I Display Group, 3-3
I/O Program Group, 3-8
Wiring, 1-11 PE Ground, 1-5
Wiring Examples, 1-14, 1-17 Phase Short Fault, 4-4
I/O Board Fail Fault, 4-4 Phase to Ground Fault, 4-4
Input Contactor, 1-11 Potentiometer, Wiring, 1-14
Input Fusing, 1-6 Power Cables/Wiring, 1-8
Input Potentiometer, 1-14 Power Conditioning, Input, 1-4
Input Power Conditioning, 1-4 Power Loss Fault, 4-3
Installation, 1-1 Power Unit Fault, 4-4
Integral Keypad, 2-3 Powering Up the Drive, 2-1, 2-2
Interference, EMC/RFI, 1-20 Precautions, General, P-3
Product Selection, B-1
K Program Group Parameters, 3-8
Keypad, 2-3 Programming, 3-1
PTC Analog Input Wiring, 1-14
L
LEDs, 2-3 R
Ratings, A-1
M Reflective Wave Protection, 1-9
Minimum Clearances, 1-2 Removing Cover, 1-1
Motor Cable Length, 1-9 Repeated Start/Stop, 1-11
Motor Overload Fault, 4-3 Repeated Start/Stop Precautions,
Motor Stalled Fault, 4-3 1-11
motor starter, 1-6 RFI, see EMC/RFI
Mounting Options and Clearances, RWR (Reflective Wave Reducer), 1-9
1-2
MOVs, 1-3 S
Safety Ground, 1-5
O Shielded Power Cables, 1-8
Opening the Cover, 1-1 Short Circuit Protection, 1-6
Operating Temperatures, 1-2 Software, 3-1
Operator Interface, 2-3 Start and Speed Reference Selection
OverVoltage Fault, 4-3 and Control, 1-18, 1-19
EF3339EN.0.1
Index-3
Start/Stop, Repeated, 1-11

Start-Up Checklist, 2-1, 2-2
Static Discharge, ESD, P-3
Status LEDs, 2-3
Supply Source, AC, 1-3
SW OverCurrent Fault, 4-4
System Grounding, 1-4
T
Terminal Block
I/O, 1-12
Power, 1-10
Three Wire Control, 1-14, 1-17
Two Wire Control, 1-14, 1-17
U
UnderVoltage Fault, 4-3
Ungrounded Supply, 1-3
Unshielded Power Cables, 1-8
W
Watts Loss, A-4
Wiring, 1-1
Block Diagram, 1-13
I/O, 1-11
I/O Examples, 1-14, 1-17
Potentiometer, 1-14
Power, 1-8
PTC Example, 1-14
EF3339EN.0.1
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters

Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA,Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium,Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong,Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication 22A-UM001F-EN-E – October 2005

Supersedes October 2003
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
EF3339EN.0.1
Square D 9007 C Heavy Duty Limit Switches
Outside Source Information for CPM Part Number 3808600
Limit Switches
9007 C Heavy Duty
Description and Specification
9007 C Heavy Duty - Description and Specification
Traditionally, a limit switch was a basic snap switch in an enclosure with an actuator and was
used to detect the presence of cams, boxes, parts of machines, cars, elevators, etc. A snap
switch is excellent for cyclic applications since the rapid contact transfer caused by the internal
toggle springs reduces arcing and prolongs contact life. However, the toggle springs cannot
exert sufficient force to break even a light contact weld caused by an overcurrent. Therefore,
where the operation of the contacts is critical, as in an emergency end-of-travel application,
direct acting normally closed contacts that are directly forced open by the actuator should be
used.
In the United States the term “Limit Switch” was used to refer to these devices whether they
had snap acting or direct acting contact mechanism. However, the European (CENELEC)
Standards define a “Limit Switch” as having direct acting or positive break contacts and
“Position Switch” is the general term for any switch that detects the position or presence of a
cam, box, etc.
This publication will use the term “Position Switches” as a generic identification for most
switches and the term “Limit Switch” as a specific reference to those devices with direct acting
contacts.
Heavy duty limit switches are metal bodied switches (one device has a plastic body) with heads
that can rotate to any of four directions. Operational sequence can easily be changed from
clockwise to counterclockwise, or both directions. Many different varieties of operating heads
are available, from lever arm styles to plungers, momentary to maintained. Contact blocks for
these devices can range from standard silver, gold flashed, reed type, and are available in snap
acting or slow make/slow break configurations. Single pole and double pole versions are also
available.
The traditional Square D turret head line was introduced in 1980 to replace the former Type B,
introduced in 1964. Twenty different head styles and over 200 different lever arms add to its
versatility. Many different options and forms allow the customer to choose a switch to customize
for his application. Four basic enclosure styles are available, including explosion proof.
Extremely well accepted by automotives and industrials around the country.
Features
Limit Switches
• Type C provides superior electrical / mechanical life along with easy installation and wiring.
• Available in a variety of head and body styles.
• All complete devices are rated NEMA and UL Type 2, 4, 6P and 13 as standard.
• Explosion proof versions are also watertight and submersible.
• Reed contacts available in all head types.
• Ninety degree total travel on lever arm, no shaft breakage due to maladjusted cams.
• Direction of operation on lever types easily converted.
• Many special features and options available.
• Heavy Duty Contact Rating – NEMA A600, on two pole as well as single pole for longer
contact life.
• The Type C passed both major automotive life/load tests.
• UL and CSA Certified
• The Type C should be the first choice for all applications.
Available Literature
Limit Switches from Square D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007BR9401
The Limit Switch Built for the Long Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SM570R1
Proper Application of Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SM444
Competitive Cross Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M311I
Cross Reference of Obsolete Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M425
474
© 1997-2002 Schneider Electric All Rights Reserved 10/02
Source: Schneider Electric.
EF3326EN.0.0 1
2 Square D 9007 C Heavy Duty Limit Switches
Limit Switches
9007 C Heavy Duty
9007 C Heavy Duty - Description and Specifications
General Selection
This part of the selection guide allows you to choose the particular style or model required for
most applications. The Type C will handle the vast majority of the applications encountered
where a mechanical position switch is needed. The Type C is a heavy-duty switch and will
perform as well or better than the Type T, if the load is within contact ratings of the Type C.
This section briefly lists some of the most common position switch selections.
1. Standard 10° Pre-travel Lever Type Switches – will handle about 90% of all
applications.
a. Select Standard CW and CCW Version – will handle most applications with no
conversion necessary. Where CW only or CCW only is required, the switch can be
easily converted by removing the turret head and rotating the guide until the arrow
points to the appropriate operating mode symbol.
b. Select Plug-in Standard Box – the trend is toward plug-in contact blocks because of
easy replacement. Also the standard box is the same size for 1 or 2 poles.
c. The above selection leads you to:
2. Specialty Lever Type Switches
a. Low Differential Type – is generally required where the differential must be small and
should not be selected for the 5° pre-travel feature, except in the case of neutral
position application. Desired trip point can usually be obtained by adjusting the lever
arm and/or cam. Recommended Type – C54A2
b. Light Operating Torque Type – is used where the operating torque of the standard
Lever Arm Type type is too high. Recommended Type – C54N2
c. Gravity Operated Type – is used where extremely light operating torque is required.
Lever arm is returned by gravity. Recommended Type – B54NC2
d. Maintained Contact Type – is used where a memory device is required to
“remember” that a cam has passed. Recommended Type – C54C
3. If a space problem exists where 1 N.O./1 N.C. (or SPDT) is needed, select the compact
box as shown on page 478.
4. If other enclosure types are required, see pages 477 and 478.
Limit Switches
Selection of Lever Arms
1. Standard lever arms for position switches are as follows:
Type C Limit Switches – Type MA-11 Lever Arm, 1.5" (38.1mm) long with a 0.75" (19mm)
diameter, 0.25" (6.35mm) wide roller.
Maintained Contact:
a. Type C. For resetting by same cam, select a Type LA-4 forked lever arm.
b. For resetting by another cam, select Type LA-5 or LA-6.
Type T and FT Position Switch – Type B1 Lever Arm, 1.5" (38.1mm) long with a 0.75"
(19mm) diameter, 0.25" (63.5mm) wide roller.
Type AW Position Switch – Type BA-1 Lever Arm, 1.38" (35mm) long with a 0.63"
(16mm) diameter, 0.25" (6.35mm) wide roller.
2. For other lever arms see catalog listing.
Lever Arm
475
10/02 © 1997-2002 Schneider Electric All Rights Reserved
EF3326EN.0.0
Square D 9007 C Heavy Duty Limit Switches 3
Limit Switches
9007 C Heavy Duty
9007 C Heavy Duty - Description and Specification
Plunger Types
Plunger type switches are used where short, controlled machine movements are present and
where space or mounting does not permit a lever type switch.
Recommended Types:
• Top Roller Plunger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type C54D
• Side Roller Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type C54F
• Top Push Rod Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type C54E
• Side Push Rod Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type C54G
If space does not permit the use of the Type C, use Type XA. Where precise control of the trip
point is required, use Type AW.
Plunger Type Wobble Stick and Cat Whisker Types

These position switches are suitable for application on conveyors to detect or count parts.
Wobble stick and cat whisker switches can be operated from any direction. Cat Whisker
switches are used to detect very light weight parts.
Recommended Types:
• Wobble, Delrin Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type C54J
• Wobble, Wire Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type C54K
• Cat Whisker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type C54L
Cam Design Data

For maximum position switch life, the force applied to the lever arm by a cam should be
perpendicular to the lever arm. This means that the cam angle and lever arm angle should be
the same. The force applied should also be perpendicular to the shaft axis about which the
lever rotates.
Non-Overriding Cams
Limit Switches
Wobble Stick Type

The arrangement shown in Figure 4 is satisfactory only at cam speeds below 50 fpm. At higher
speeds, the impact due to high lever acceleration causes excess roller bounce.
A good recommended cam angle and lever arm angle at moderate cam speeds (up to 90 fpm)
is 45° (see Figure 5).
Here lever acceleration is less and deceleration is also less at the lower cam edge. For cam
speeds greater than 90 fpm, see SM444 “Proper Application of Position Switches” for
recommended cam and lever angles.
Cam Must Not

Advance Beyond
This Point
These Angles Lever Arm
Approximately The Same Initial Position
Trip Point
90 Final Position
Cam Min.
0.13
3
90 60 Max.
0.72 Min.
16 5 Min. OverTravel
Cat Whisker Type
Figure 4 Figure 5
476
EF3326EN.0.0
Limit Switches
9007 C Heavy Duty Industrial
9007 C Heavy Duty Industrial - Single Pole and Two Pole Selection Information
Single Pole and Two Pole Selection Information
All Type C Switches Are Rated NEMA Type And UL Type 6P
Side Plunger Type
Select Lever Arm Type

Turret Standard Low Neutral Position Extra Main- Side Side Side Side
Head Pre- Differ Standard Low Light tained Roller Push Push Push Rod
travel ential Pre- Differ- Operating Contact Plunger Rod Rod Plunger
Select Spring Spring travel ential Torque Spring Plunger Plunger Main-
Basic Return Return Spring Spring Spring Return Spring Adjustable c tained
Switch Return Return Return Vertical Return Spring Contact
Roller j Return
CW (Trip) Type
CW & CW & CW & CW & CW &
CCW
CCW t CCW t CCW CCW CCW t
(Reset)
Contacts Type Type Type Type Type Type Type Type Type Type
1 N.O.
C54B2 C54A2 ... ... C54N2 C54C C54F C54G C54GD C54H
1 N.C.
2 N.O.
Standard C62B2 C62A2 ... ... C62N2 C62C C62F C62G C62GD C62H
2 N.C.
Box
2 N.O. - 2 N.C.
Plug-in ... ... C68T10 C68T5 ... ... ... ... ... ...
Neutral Position
2 N.O. - 2 N.C.
C66B2 C66A2 ... ... C66N2 ... C66F C66G C66GD ...
Two Stage
Compact
1 N.O.
Box C52B2 C52A2 ... ... C52N2 C52C C52F C52G C52GD C52H
1 N.C.
Plug-in
UL Listed 1 N.O.
CR53B2 CR53A2 ... ... CR53N2 CR53C CR53F CR53G CR53GD CR53H
for 1 N.C.
Hazardous 2 N.O.
Location CR61B2 CR61A2 ... ... CR61N2 CR61C CR61F CR61G CR61GD CR61H
2 N.C.
Class I 2 N.O. - 2 N.C.
Groups ... ... CR67T10 CR67T5 ... ... ... ... ... ...
Neutral Position
B,C,D
Class II 2 N.O. - 2 N.C.
Groups CR65B2 CR65A2 ... ... CR65N2 ... CR65F CR65G CR65GD ...
Two Stage
E, F and G
1 N.O.
CF53B2 CF53A2 ... ... CF53N2 CF53C CF53F CF53G ... CF53H
1 N.C.
2 N.O.
CF61B2 CF61A2 ... ... CF61N2 CF61C CF61F CF61G ... CF61H
Flush 2 N.C.
Mounting 2 N.O. - 2 N.C.
... ... CF67T10 CF67T5 ... ... ... ... ... ...
Neutral Position
2 N.O. - 2 N.C.
CF65B2 CF65A2 ... ... CF65N2 ... CF65F CF65G ... ...
Two Stage
Limit Switches
Head Type
B A T10 T5 N C F G GD H
Only Number
Pre-travel 10° 5° 10° 5° 10° 45° 0.08" (2mm) 0.14" (3.6mm)
First
Pre- 10° 5° ... ... 10° ... 0.08" (2mm) ...
Stage
travel
First to
Two
Second 2.5° 1.5° ... ... 2.5° ... 0.02" (0.5mm) ...
Stage
Stage
Total Travel 90° 90° 90° 90° 90° 90° 0.25" (6.3mm) 0.25" (6.3mm)
Nominal Differential 4° 2° 4° 2° 4° ... 0.03" (0.8mm) ...
Operating Reverse
Data 90° 90° 90° 90° 90° ... ... ...
Overtravel
Operating
4 lb-in 4 lb-in 4 lb-in 4 lb-in 25 oz-in 3 lb-in (0.34 7lb-in
Torque/Force — 4 lb-in (0.45 N•m)
(0.45 N•m) (0.45 N•m) (0.45 N•m) (0.45 N•m) (0.18 N•m) N•m) (0.80 N•m)
1 Pole & 2 Pole
Repeat Accuracy
— Linear travel ± 0.002" ± 0.001" ± 0.002" ± 0.002" ± 0.002" ± 0.002" 0.001"
...
of cam (0.05mm) (0.03mm) (0.05mm) (0.05mm) (0.05mm) (0.05mm) (0.03mm)
(1.5" (38) lever arm)
The basic switch and head without the plug-in receptacle can be ordered by substituting the letters “CO” for the first “C” in the type number.
Plug-in Replacement Units
Example: Open type replacement for Type C54B2 is Type CO54B2.
t These devices are factory set to operate the contacts in both the CW and CCW directions. Mode of operation is field convertible to CW only or CCW only. To order factory converted
devices – for CCW only operation, change the “2” at the end of the type number to “1” (Example: C54B2 becomes C54B1) – for CW only operation, delete the “2” at the end of the type
number (Example: C54B2 becomes C54B).
j Can be converted to horizontal roller type in the field. To order horizontal roller version add the letter “H” at the end of the equivalent vertical roller version type
number (Example: C54F would become C54FH).
c To lock the nut in the desired position, crimp the slot near the bottom of the nut.
NOTE: Mode change of lever arm is easily convertible to clockwise, counterclockwise, or both. Simply point the arrow to the letters representing the
desired direction – CW, CCW, or CW/CCW. See photo to the right. All parts are captive.
Acceptable wire sizes: 12-22 AWG. Recommended terminal clamp torque:3 lb-in (0.34 N•m) Selection Mode
Arrow
477
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Heavy duty Turret Head Selection Information
9007 C Heavy Duty Industrial - Heavy Duty Turrent Head Selection Information

Top Plunger Type Wobble Stick Type
Top Top Push Top Push Palm Universal Wobble j Wobble j Wobble j Cat Plug-in Plug-in
Roller Rod Rod Operated † Stick Stick Stick Whisker Unit Receptacl
Select Plunger Plunger Plunger ★ DELRIN Wire Coil Less e
Turret Spring Spring Adjustable ■ Extension Extension Spring Head Only
Head Return Return Spring Return Extension
Select
Basic
Switch
Contacts Type Type Type Type Type Type Type Type Type Type Type
1 N.O.
C54D C54E C54ED C54R ★ C54JKC C54J C54K C54KC C54L CO54 CT54
1 N.C.
2 N.O.
Standard C62D C62E C62ED C62R★ C62JKC C62J C62K C62KC C62L CO62 CT62
2 N.C.
Box
Plug-in 2 N.O. - 2 N.C.
... ... ... ... ... ... ... ... ... CO68 CT62
Neutral Position
2 N.O. - 2 N.C.
C66D C66E C66ED C66R ★ C66JKC C66J C66K C66KC C66L CO66 CT62
Two Stage
Compact
1 N.O.
Box C52D C52E C52ED C52R ★ C52JKC C52J C52K C52KC C52L CO52 CT52
1 N.C.
Plug-in
UL Listed
1 N.O.
for CR53D CR53E CR53ED CR53R ★ CR53JKC CR53J CR53K CR53KC CR53L ... ...
Hazardou 1 N.C.
s
Location 2 N.O.
Class I CR61D CR61E CR61ED CR61R ★ CR61JKC CR61J CR61K CR61KC CR61L ... ...
2 N.C.
Groups
B,C,D
2 N.O. - 2 N.C.
Class II ... ... ... ... ... ... ... ... ... ... ...
Neutral Position
Groups
E, F and
2 N.O. - 2 N.C.
G CR65D CR65E CR65ED CR65R ★ CR65JKC CR65J CR65K CR65KC CR65L ... ...
Two Stage
Head
Type Number D E ED R★ JKC J K KC L ... ...
Only
Pre-travel 0.08" (2mm) 10° (Any Direction) 20° ... ...
First
Pre- 0.08" (2mm) 10° (Any Direction) 20° ... ...
Stage
travel
Two First to
Stage Second 0.01" (0.3mm) 4° 5° ... ...
Limit Switches
Stage
Total Travel 0.25" (6.3mm) 90° 90° ... ...
Nominal
Operatin Differential 0.02" (0.5mm) 3° 6° ... ...
g Reverse
... ... ... ... ...
Data Overtravel
Operating
Torque/ 7 oz-in
3 lb-in (0.34 N•m) 3 lb-in (0.34 N•m) ... ...
Force — 1 Pole (0.05 N•m)
and 2 Pole
Repeat Accuracy
— Linear travel ± 0.001" (0.03mm) ... ... ... ...
of cam
Plug-in Replacement The basic switch and head without plug-in receptacle can be ordered by substituting the letters “CO” for the first “C” in the type number.
Units Example: Open type replacement for Type C54D is Type CO54D.
a Price does not include mushroom button. Must be ordered separately, see page 482.
† Wobble stick extensions are available separately for the universal head or as
replacements for complete devices as follows in the table below:
Description Type
DELRIN extension WJ
Wire extension WK
Coil Spring extension WKC
Acceptable Wire Sizes: 12-22 AWG. Recommended Terminal Clamp Torque: 7 lb-in
Types C File E42259 File LR25490

and CF CCN NKCR CCN 3211 03
Marking
Type CR File E10054 File LR26817

CCN NOIV CCN 3218 02 Compact Box Hazardous Location Standard Box Flush Mounting
478
EF3326EN.0.0
Limit Switches
9007 C Heavy Duty Industrial - Reed Contact Selection Information
Reed Contact Selection Information
Heavy Duty Precision Turret Head Type

Can be used with standard industrial relays and starters to NEMA size 4.
UL Listed for Class I, II and III Division 2 Groups B, C, D, F and G hazardous locations. They can also be used as inputs to intrinsically safe systems.
NOTE:Because Reed switches are operated by a magnet, they should not be installed in areas where strong magnetic fields may be present. The
devices should always be checked for proper operation after installation

Plug-in Plug-in
Lever Arm Type Side Plunger Type Unit Receptacle
Less Only
Extra Side Side Side Side Head
Select Standard
Turret Low Light Roller Push Push Push
Pre-
Head Differential Operating Maintained Plunger Rod Rod Rod
travel
Spring Torque Contact Spring Plunger Plunger Plunger
Spring
Select Return Spring Return Spring Adjustablec Maintained
Return
Basic Return Vertical Return Spring Contact
Switch Roller j Return
CW (Trip) Type
CW & CW & CW &
CCW
CCW t CCW t CCW t
(Reset)
Contacts Type Type Type Type Type Type Type Type Type Type
Standard 1 N.O. C84B2 C84A2 C84N2 C84C C84F C84G C84GD C84H f CT54
Box Reed
Plug-in 1 N.C. C86B2 C86A2 C86N2 C86C C86F C86G C86GD C86H f CT54
Head
Type Number B A N C F G GD H .... ....
Only
Pre-travel 13° 7° 13° 45° 0.110" (2.8mm) 0.14" (3.6) .... ....
Total Travel 90° 90° 90° 90° 0.25" (6.3mm) 0.25" (6.3) .... ....
Differential 7° 4° 7° .... 0.07" (1.8mm) .... .... ....
Nominal Reverse Overtravel 90° 90° 90° .... .... .... .... ....
Operating 4 lb-in 4 lb-in 25 oz-in 3 lb-in 7 lb-in
Data Operating Torque/Force 4 lb-in (0.45 N•m) .... ....
(0.45 N•m) (0.45 N•m) (0.08 N•m) (0.34 N•m) (0.80 N•m)
Repeat Accuracy -
±0.006" ±0.003" ±0.006" ±0.006" ±0.003"
Linear travel of cam .... .... ....
(0.15mm) (0.076mm) (0.15mm) (0.15mm) (0.076mm)
(1.5" (38mm) lever arm)
Top Plunger Type Wobble Stick Type

Select Top Roller Top Push Top Push Palm Universal Wobble u Wobble u Wobble u Cat Plug-in Plug-in
Turret Plunger Rod Rod Plunger Operated u Stick Stick Stick Whisker Unit Receptacle
Head Spring Plunger Adjustable c a DELRIN Wire Coil Less Only
Head
Return Spring Spring Extension Extension Spring
Limit Switches
Return Return Extension
Select
Basic
Switch
Contacts Type Type Type Type Type Type Type Type Type Type Type
Standard 1 N.O. C84D C84E C84ED C84Ra C84JKC C84J C84K C84KC C84L f CT54
Box Reed
Plug-in 1 N.C. C86D C86E C86ED C86Ra C86JKC C86J C86K C86KC C86L f CT54
Head
Type Number D E ED R★ JKC J K KC L ... ...
Only
Pre-travel 0.100" (2.5mm) 13° (Any Direction) 25° .... ....
Total Travel 0.25" (6.3mm) 90° 90° .... ....
Nominal Differential 0.05" (1.3mm) 11° 18° .... ....
Operating Operating 7 lb-in
Data 4 lb-in (0.45 N•m) 3 lb-in (0.34 N•m) .... ....
Torque/Force (0.80 N•m)
Repeat Accuracy
±0.003" (0.076mm) .... .... .... ....
- Linear travel of cam
Plug-in Replacement The basic switch and head without the plug-in receptacle can be ordered by substituting the letters “CO” for the first C in the type number.
Units Example: Open type replacement for Type C84B2 is Type CO84B2.
t These devices are factory set to operate the contacts in both the CW and CCW directions. Mode of operation is field convertible to CW only or CCW only. To order factory converted
devices - for CCW only operation, change the “2” at the end of the type number to “1” (Example: C84B2 becomes C84B1) - for CW only operation, delete the “2” at the end of the type number
(Example: C84B2 becomes C84B).
j Can be converted to horizontal roller type in the field. To order horizontal roller version add the letter “H” at the end of the equivalent vertical roller version type number
(Example: C84F would become C84FH).
a Does not include mushroom button. Must be ordered separately from page 482.
f Plug-in units less head are not available as separate units. Order complete plug-in replacement units instead (include the plug-in unit and head).
u Wobble stick extensions are available separately for the universal head or as replacements for complete devices. See bottom of page 478.
Acceptable Wire Sizes: 12-22 AWG Recommended Terminal Clamp Torque: 7 lb-in (0.80 N•m) File E10054
CCN NOIV Marking
479
EF3326EN.0.0
Limit Switches
Dimensions
9007 C Heavy Duty Industrial - Dimensions
Type C standard box also meets 1.2" (30mm) x 2.4" (60mm) mounting dimensions per UC EN50041E (DIN 43694)
Approximate shipping weight - 1.38 lb (0.62 kg) standard box, 1.13 lb (0.51 kg) compact box.
Lever Arm Type / 1 Pole or 2 Pole Lever Arm Type / 1 Pole Side Push Rod Plunger Side Roller Plunger
Standard Box Compact Box Turret Head Type G Current Head Type F
0.58 2.50
2.50 2.16 2.63 0.78
15 1.72 64 64
0.58 55 1.41 67 1.88 Dia
0.63 0.12 20
44 1.72 0.78
1.24 0.44 15
0.75 Dia 44 36 0.36 Dia. 20 48 3
31 19 11 16
9
1.24 1.24 1.24
(2) 31 0.75 0.75
19 31 31
0.20 0.22 3.14 19
2.35 4.02
5 x 6 (2)10-24 1.47 Dia 80 0.58 0.58
60 HLS 102 TappedHLS 37 0.44
HLSBackMtg 11 1.55 15 1.55 15
(2)
0.21DP 39 39
10-24Tapped 5 Dia.
HLSBackMtg 1 14 0.64 1.17 0.64
1.17 (2) 0.20 30 16
0.29 DP 2 NPT 16 5 1/2 -14NPT 1.79
30 1.55
1.55 7 1.79 HLSFrontMtg. 39 45 Dual Dimensions inches
39 45 mm
Top Push Rod Plunger Top Roller PLunger Adjustable Top Push Rod Plunger Adjustable Side Push Rod Plunger
Turret Head Type E Turret Head Type D Turret Head Type ED Turret Head Type GD
0.78 0.19 Adj. 0.50
0.78 0.63 Hex 2.71 Min
Dia. 0.12 20 5
0.36 Dia. 16 13 69 1.96 0.19
20 3 0.78
9
0.78 50 Min 5 Adj 20
1.72 20
44 2.19 1.88 1.24 Hex
1.88
48 56 48 31 0.50
0.58 0.58 13
1.55 15 0.75 15
1.55
39 0.58 0.58 19 39
15 15
1.55 1.55
39 39
Wobble Stick DELRIN Extension
Side Push Rod Plunger Turret Head Type J
Maintained Contact Coil Spring Extension Turret Head Type KC s Universal Wobble Stick Cat Whisker
Turret Head Type H Wire Extension Turret Head Type K1 Turret Head Type JKC Turret Head Type L
3.12 0.25 Dia 0.25 0.78

79 0.78
1.68 6 Dia 6 0.07 20
1.44 20 2
43
37 5.50 2.16
55 1.80 6.29
1.24 Dia. 140
0.75 3.00 46 2.28 160
31 0.37
19 76 58
9 0.58 0.78
15 20 0.58
0.58 1.55 15
0.78
15 20 39
Wobble Stick DELRIN Extension

Turret Head Type CRJ
Coil Spring Extension Type CRKC s Type CF Type CR
Lever Arm Type Wire Extension Turret Head Type CRK k Approximate shipping weight 1.38 lb. Approximate shipping weight 0.38 lb.
2.79
1.07 2.50 0.96 1.51 Adj 0.19
71 1.09 0.50 Hex
2.72 27 64 1.00 24 38 Mounting 5
28 D65075-171 1.72 Cavity 13 1.07
69 0.75
7
75 1.72
2 25 Min 1.96
Limit Switches
44 0.25 44 27
19
9 0.86 50
6 Dia
2.19 22 1.68
1.68 1.58 2.07
2 56 1.19 2.07
43 40 0.44 53 5.93 6.32 4.28 43 1.58
11 Dia 30 53
151 161
4.88 109 40
(2)1/4-20 4.38 124
6.10 3.45
112 UNC-2B
UNC 2B 3.84 111
3.00 1.55 88
0.27
2 76 97
(2) 7 Dia 0.20 Dia 1.81
5 46 0.16R 1.59
Mtg.Holes 2.00 4 40
Front 0.34
0 51
Mtg 1.50 9 Side Roller Plunger
DP
Holes 38 0.63 1/2 or 1/4 2.08
08 Turret Head Type CRF
16 NPT 53
Side Push Rod Plunger Top Roller Plunger Adjustable Side Push Rod Plunger Top Push Rod Plunger
Turret Head Type CRG Turret Head Type CRD Turret Head Type CRGD Turret Head Type CRE
0.50 Hex 3.24 0.12 2.77
1.07 Adj 0.19 1.07
3 1.07
0.36 Dia 13 62 1.56 1.07 70 1.41 0.36
27 5 27
9 40 27 36 9 Dia 27
1.68 1.19 2.07
Min 2.69 Min 3.08 1.58 1.68 1.19 2.07
2.16 2.55 43 30 53 1.58
68 78 43 30
55 65 40 40 53
0.63
16 Dia
Adjustable Top Push Rod Plunger Universal Wobble Stick Cat Whisker Side Push Rod Plunger
Turret Head Type CRED Turret Head Type CRJKC Turret Head Type CRL Maintained Contact Turret Head Type CRH
0.04
0.12 0.25 Dia 3.12 1.07
1.07 1 Dia
3 0.63 6 27
16 Dia
27
6.72 7.11 1.68 79 1.44 Dia 0.36
181 43 37 9
2.60 171
2.32 2.63 2.24 2.63 2.99 1.68 2.07
67 2.71 66 57 1.97 1.58
59 67
69 76 50
2.36 43 40 53
60
1.07
27 1.07
27
s For coil spring extension, dimension from top mounting hole to end of spring cap is 5.5" (140mm) ( 5.94" (151mm) for Type CR).
k For wire extension, dimension from top mounting hole to end of wire is 13.44" (341mm) (13.88" (353mm) for Type CR). Wire is 0.075" (1.9mm) diameter.
480
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9007 C Heavy Duty Industrial - Factory Modificatin (Forms)
Factory Modifications (Forms)
Special Features e Form

Optional Shaft Equipped With Type T-FT Hub:
Any lever arm Type C, CF or CR switch can be furnished with an optional shaft and hub combination Add S9
which will accept the lever arms normally used with Type T and FT limit (position) switches. To order, as a
add S9 as suffix to the device type number. For example, to order a 9007 C54B2 with this Suffix
modification, order as a 9007 C54B2-S9. For details about switches and lever arms that can be to the
furnished with this modification, see the appropriate Product Catalog. Device
Type
HUB ONLY: Can be field installed on any Type C lever type switch. Number
Class 9007 S9.
LED Pilot Light, 24 to 120 Volts AC or DC on Plug-In Type Switch (Type C52, C54, C62, C64, C66, C68 or ✶):
Addition of LED pilot light in parallel with N.O. contact (light normally on) - - - - - - - - - - - - - - - P5
Form P5 Thru P9 L1 Form P10 L2 Addition of LED pilot light in parallel with N.C. contact (light normally off) - - - - - - - - - - - - - - - P6
L1 Light Normally On L2 *Customer Addition of two LED pilot lights, one in parallel with N.O. contact (light normally on), one in
CR1 Installed parallel with N.C. contact (light normally off)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P7
Jumper CR1
Addition of two LED pilot lights in parallel with N.O. contacts (lights normally on)
B CR2 (Types C62, C64, C66 or C68 only)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P8
CR2
A Addition of two LED pilot lights in parallel with N.C. contacts (lights normally off)
(Types C62, C64, C66, or C68 only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P9
Light Normally Off *Only one of the Jumpers may be used
Addition of one isolated LED pilot light (light on when load is energized)
Pilot Light is ON when load is energized
(Type C54 only. Not available with Y1901.)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - P10
Bleeder circuit must be added to ensure PLC compatibility.
✶ Type C84 and C86 are available with P5 or P6 pilot lights only.
Pre-Wired Receptacle:
Single pole plug-in limit (position) switch furnished with pre-wired mini 5 pin Brad Harrison male connector (or interchangeable Crouse-Hinds connector at our convenience)
No. 41310. For use with Brad Harrison female portable plug No. 41306, 41307, or 41308 (or equal). (Not available with P10 or for hazardous locations.) - - - - - - - - - - - - - - - Y1901
Single Pole – Y1905: Same as Y1901 but with different wire color coding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Y1905
Tamper proof Screws – Complete Switch Only
Single Pole – Same as Y1901 but with tamper proof screws on head and body - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Y1903
Similar to Y1905 except for double pole device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Y19013
Other versions with different wiring diagrams per automotive requirements are available. Contact your local Square D field office.
Wiring Diagrams Form Y190_____
Forms Y1901 and Y1903 Form Y1905
Mating plug and cables available – also see Product Catalog. Orange- 3 4 -Red White- 3 4 -Black
White- 1 2 -Black Orange- 1 2 -Red
Green- Green-
Dust Boot:
Lever type limit (position) switch furnished with a boot around the shaft for additional protection against abrasive dusts, dirt, grit and sand.
Available on all Type C and CR lever type switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Y33
Dust Boot Only:
Can be field installed on any Type C and CR lever type switch. Class 9007 Type BT3.
Potted Limit (Position) Switch Or Plug-In Receptacle Only: i
With Individual Wires
Limit Switches
Single pole plug-in limit (position) switch or receptacle pre-wired with five #16 wires five feet long and wire entry completely sealed with Epoxy Resin - - - - - - - - - - - - - - Y1841
Two pole plug-in limit (position) switch or receptacle pre-wired with nine #16 wires five feet long and wire entry completely sealed with Epoxy Resin - - - - - - - - - - - - - - - - Y1842
With STOWA Cord
Single pole plug-in limit (position) switch or receptacle pre-wired with five conductor #16 STOWA cord eight feet long and wire entry completely sealed with Epoxy Resin Y1851
Single Pole – Y1855: Same as Y1851 but with different wire color coding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Y1855
Two pole plug-in limit (position) switch or receptacle pre-wired with nine conductor #16 STOWA cord eight feet long and wire entry completely sealed with Epoxy Resin Y1852
Two Pole – Y1856: Same as Y1852 but with different wire color coding Y1856
Tamper proof Screws – Complete Switch Only
With Individual Wires
Same as Y1841 but with tamper proof screws on head and body - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Y1843
With STOWA Cord
Other versions with different wiring diagrams per automotive requirements are available. Contact your local Square D field office.
Forms Y1851 and Y1853 Forms Y1852 and Y1854 Forms Y1855 andY 1857 Forms Y1856 and Y1858
Red- 3 4 -Orange Orange- 4 8 -Brown White- 3 4 -Black Yellow- 4 8 -Black

White- 1 2 -Black Orange- 1 2 -Red
Red- 3 7 -Yellow Brown- 3 7 -White
Green- Black- 2 6 -Blue Green- Red- 2 6 -Blue
White- 1 5 -Pink Orange- 1 5 -Pink
Green- Green-
Conduit Seal Only (Field Installable):

Conduit seal fits in conduit entrance and excludes liquids: 5 hole seal – Part # 31032-488-01
9 hole seal – Part # 31032-815-01
e Do not apply to Types CF or CR unless noted. Not field installable, except where noted.
i Not for 9007 CR hazardous location devices.
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Factory Modifications (Forms)
9007 C Heavy Duty Industrial - Factory Modifications (Forms)
Special Features e Form

Manifold Mounting: Form
Receptacle is furnished with a wiring hole and a gasket on the base. Y205-
Available on standard and compact types. Replaces existing Type B installations if new hole is
drilled to match knockout. Supersedes Type C with Form Y205. 0.29 x 0.61
7 x 16 0.36
9
Y2051
A65075-068
Dual Dimensions inches 0.58
mm
15
Special Chemical Resistant Coating (Includes fluorocarbon [VITON] Seals - Y140, and Stainless Steel Head and Body Screws) L3
Low Temperature – Lever Types Only: Limit (Position) switch will operate in an ambient temperature range of -40°F to 185°F (Standard limit switch ambient temperature
range is -20°F to 185°F). Minimum temperature is based on the absence of freezing moisture or water. (Must also specify potted form. See page 482.) Y128
Fluorocarbon (VITON) Gaskets And Seals
Substitution of Fluorocarbon (VITON) gaskets and seals on:
Lever arm type, standard box (Shaft seals on lever arm types are Fluorocarbon (VITON) as standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y140
Lever arm type, compact box (Shaft seals on lever arm types are Fluorocarbon (VITON) as standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y140
Plunger type, standard box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y140
Plunger type, compact box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y140
Substitution of Fluorocarbon (VITON) boot only on plunger type switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Y1401
Note: Fluorocarbon (VITON) has been shown to resist sunlight aging problems.
Direct Acting Contacts:
One pole, normally closed, slow make-slow break, direct acting contact mechanism substituted for standard snap switch on Types C52, C54, CF53 and CR53 devices.
This mechanism was designed for use in emergency overtravel applications. The movable contact of this basic switch unit is acted upon directly by the actuating mechanism
of the limit switch and is not dependent upon the force exerted by a snap switch blade or spring to open the circuit. Because these contacts are slow make-slow break, they
are best suited for applications where they are not actuated during normal operation, but only if abnormal overtravel is encountered.
Note: Direct Acting Contacts described above are supplied on the 9007 CLS1 Hoist Overtravel Switch as standard.
Electrical Contact Ratings

AC – NEMA A600 DC
Max. Current – 35% Power Factor Maximum Current
Volts Make Break Continuous Make or Break Continuous
Carrying Volts Carrying
Amps VA Amps VA Amps Amps VA Amps
120 60 7200 6 720 10 125 1.1/0.55 k 138/69 k 5/2.5 k
240 30 7200 3 720 10
480 15 7200 1.5 720 10 250 0.27 67.5 2.5
Direct Acting
600 12 7200 1.2 720 10 600 0.10 60 2.5
Contact Mechanism
k Type C52 compact unit ratings at 125Vdc — same ratings as C54, CF53 and CR53 at other (Shown without
voltages.
Cover)
Substitution of Direct Acting Contact Unit for Snap Switch of Single Pole Switch Y1561
Limit Switches
Optional Shaft (0.306" (7.8mm) diameter):

To accommodate lever arms from the obsolete Denison C Limit Switches. Available on all 9007C, CF, or CR Limit Switches. Y247
Optional Shaft (0.28" (7.1mm) diameter):
Available on all 9007C, CF, or CR Limit Switches. Y249
e Do not apply to Types CF or CR unless noted. Not field installable, except where noted.
Mushroom Button
For Palm Operated Turret Head
Adapters — Field Installable Also see Type C Palm Operated Switches
Description Class 9007 1.38" Dia. Button 2.25" Dia. Button
Switch with adapter plate permitting substitution of any Type C switch with Color
Form Y147 Type No. Type No.
standard box for any Type T switch with Style B base plate
Adapter Plate Kit only (plate plus mounting screws) for above Type BT1 Black NB-1 PB-1
Adapter plate to allow direct substitution of Type C plunger switches for Type B
plug-in plunger switches –use only if there is a problem in lining up cam tracks
Red NB-2 PB-2
Standard Box Type CT10 j
Compact Box Type CT13 q
Adapter Plate Kit permitting direct substitution of any Type C lever arm switch
Type CT11 Green NB-3 PB-3
with standard box for ANY Type AW lever arm switch
Conduit connection adapter — male 0.5" (12.7mm) NPT on one end, female 20
Type CT12 Yellow NB-5 PB-5
mm on other end
j Dimensions: 0.22"(5.6mm) x 2.94" (75mm) x 1.54" (39mm)
q Dimensions: 0.22" (5.6mm) x 2.07" (53mm) x 1.54" (39mm) Plug and Cable Assemblies
5 Pin Mini Connecting Cables to fit switches with Form Y190.
Part
Description
Number
Plug and 3’ cable BH20-5-3
482
EF3326EN.0.0
Limit Switches
9007 AW and C Heavy Duty Industrial
9007 AW and C Heavy Duty Industrial - Lever Arm Selection Information
Lever Arm Selection Information
.
Cast Zinc Lever Arms

Roller
Length Standard Standard Standard Standard Nylon Nylon Nylon Nylon a
of 0.75"(19) Dia. 0.75" (19)Dia. 0.63" (16) Dia. 0.63" (16) Dia. 0.75" (19) Dia. 0.63" (16) Dia. 0.63" (16) Dia. 1" (25.4) Dia.
Arm 0.25" (6.3) Wide 0.63" (16) Wide 0.25" (6.3) Wide 0.63" (16) Wide 0.25" (6.3) Wide 0.25" (6.3) Wide 0.63" (16) Wide 0.63" (16) Wide
Type Type Type Type Type Type Type Type
0.88" (22) .... .... AA-1 AA-2 .... AA-8 AA-17 ....
1.38" (35)
( ) BA-11 BA-12 BA-1 BA-2 BA-18 BA-8 BA-17 BA-13
1.5" (38)
( ) MA-11 MA-12 MA-1 MA-2 MA-18 MA-8 MA-17 MA-13
2" (51) CA-11 CA-12 CA-1 CA-2 CA-18 CA-8 CA-17 CA-13
2.5" (63.5) DA-11 DA-12 DA-1 DA-2 DA-18 DA-8 DA-17 DA-13
3" (76) EA-11 EA-12 EA-1 EA-2 EA-18 EA-8 EA-17 EA-13
Standard Standard Standard Cable
Standard
0.75" (19) Dia. 0.63" (16) Dia. 0.63" (16) Dia. Operated
Nylon Ball Bearing 0.75" (19) Dia.
Length 0.25" (6.3) Wide 0.25"(6.3) Wide 0.63" (16) Wide Without With Eyebolt
1" (25.4) Dia. 0.69" (17.5) Dia. 0.25" (6.3) Wide
of Roller on Roller on Roller on Roller (0.38" (9.6) I.D.)
0.25" (6.3) Wide 0.25" (6.3) Wide (Countersunk
Arm Opposite Side Opposite Side Opposite Side Instead of
Roller Pin)
to Standard to Standard to Standard Roller
Type Type Type Type Type Type Type Type
0.88" (22) .... AA-9 .... AA-5 AA-6 AA-0 .... ....
1.38" (35) BA-4 BA-9 BA-15 BA-5 BA-6 BA-0 .... ....
1.5" (38) MA-4 MA-9 MA-15 MA-5 MA-6 MA-0 MA-31 MA-22
2" (51) CA-4 CA-9 CA-15 CA-5 CA-6 CA-0 CA-31 ....
2.5" (63.5) DA-4 DA-9 DA-15 DA-5 DA-6 DA-0 DA-31 ....
3" (76) EA-4 EA-9 EA-15 EA-5 EA-6 EA-0 .... ....
Flat Steel Lever Arms

Roller A Dual Dimensions inches
Length Standard Standard Nylon Nylon mm
of 0.63" (16) Dia. 0.63" (16) Dia. 0.75" (19) Dia. 1" (25.4) Dia. None
Arm 0.25" (6.3) Wide 0.63" (16) Wide 0.25"(6.3) Wide 0.25" (6.3) Wide
B
Type Type Type Type Type
0.88" (22) AA-1S AA-2S .... .... AA-0S

1.38" (35) BA-1S BA-2S .... BA-4S BA-0S
C
1.5" (38) .... .... MA-18S .... .... D
2" (51) CA-1S CA-2S .... CA-4S CA-0S
2.5" (63.5) DA-1S DA-2S .... DA-4S DA-0S 0.09
0.156
3" (76) EA-1S EA-2S .... EA-4S EA-0S 3.96 2.29
90° Forked Cast Zinc Lever Arms Cast Lever Arm Dimensions
Standard Standard Nylon Nylon Ball Bearing A = Length of Lever Arm
0.75" (19) Dia. 0.63" (16) Dia. 0.75" (19) Dia. 0.75" (19) Dia. 0.69" (17.5) Dia. B = Roller Diameter
Roller 0.25" (6.3) Wide 0.25" (6.3) Wide 0.25" (6.3) Wide 1" (25.4) Wide 0.25" (6.3) Wide C = Roller Width
Position Rollers Rollers Rollers Rollers Rollers D = C+ 0.31"
Limit Switches
Type Type Type Type Type
See price table for A, B and C dimensions
Rollers on Approximate shipping weights range from
LA-4 LA-1 LA-16 LA-10 LA-7
Same Side 0.13 lb (0.06 kg) to 0.25 lb (0.11 kg)
R.H. Roller on
LA-5 LA-2 LA-17 LA-11 LA-8
Opp. Side
L.H. Roller on
LA-6 LA-3 LA-18 LA-12 LA-9
1.5" (38) Length Opp. Side
One-Way Cast Zinc Roller Lever Arm Offset Type Cast Zinc Lever Arms
1.25" (32) Dia. 0.25" (6.3) Wide Roller Std. Roller
Type
Length Cast Arm Flat Steel Arm Dia. Width
of Arm Type Type 0.63 (16) 0.25 (6.3) KA-1
1.38" (35) BA-3 BA-3S 0.63 (16) 0.63 (16) KA-2
1.5" (38) MA-3 .... 0.75(19) 0.25 (6.3) KA-11
2" (51) CA-3 CA-3S 0.75 (19) 0.63 (16) KA-12
2.5" (63.5) DA-3 DA-3S Ball Bearing
3" (76) EA-3 EA-3S Offset Lever Arm KA-9
0.69 (17.5) 0.25 (6.3)
2" (51) Length
0.44" (11) Offset Nylon
KA-18
One-Way Lever Arms 0.75 (19) 0.25 (6.3) KA-21
Roller 0.75 (19) 1 (25.4)
Length Standard Nylon Ball Bearing Rod Std. Roller
of 0.75" (19) Dia. 0.75" (19) Dia. 0.69" (17.5) Dia. Type Type
1.5" (38) Length Dia. Width
Arm 0.25" (6.3) Wide 0.25" (6.3) Wide 0.25" (6.3) Wide 0.88" (22) Offset
0.75 (19) 0.25 (6.3) KB-11
Type Type Type Type
0.75 (19) 0.25 /(6.3) KB-15 q
1.5" (38) RA-11 RA-18 RA-9 ....
5"(127) .... .... .... FA-2
a Recommended in place of Types BA-7, CA-7, DA-7, EA-7 and MA-7 lever arms with steel rollers.
q Roller inside.
NOTE:Standard roller is hardened oil-impregnated sintered iron. Bold face type numbers indicate the most commonly used lever arms
483
EF3326EN.0.0
Limit Switches
9007 AW and C Heavy Duty Industrial
Lever Arm Selection Information
9007 AW and C Heavy Duty Industrial - Lever Arm Selection Information
Adjustable Length Lever Arms

Adjustable Length Lever Arm
B
Adj. from 0.88" (22mm) to 4"(101mm)
Roller
D
Rubber
Standard Standard Nylon Ball Brg. Nylon a DELRIN® Nylon
E Tire
0.63" (16) 0.63" (16) 0.63" (16) 0.69" (17.5) 1" (25.4) 0.63" (16) 2" (51)
Without 2.13" (54)
A C Description Dia. Dia. Dia. Dia. Dia. Dia. Dia.
0.34 Roller Dia.
F 0.25"(6.3) 0.63" (16) 0.25" (6.3) 0.25" (6.3) 0.63" (16) 0.25" (6.3) 0.25"(6.3)
86 0.5"(12.7)
Wide Wide Wide Wide Wide Wide Wide
Wide
A = Lever Arm Length

Type Type Type Type Type Type Type Type Type
B = Roller Diameter Non-bendable HA-1 HA-2 HA-4 HA-0 HA-24 HA-22 .... .... ....
C = Roller Width
D = 0.84" Bendable HA-5 HA-6 HA-8 HA-9 HA-25 HA-23 HA-20 HA-26 HA-21
A E = 0.38"
F = 1.05" a Recommended in place of Types HA-3 and HA-7 lever arms with steel rollers.
B Dimensions
Arm
Type A B C D E F
C HA-1,4 0.63 (16) 0.19 (4.8) 0.25 (6.3) 0.72 (18) 4.38 (111)
0.88 HA-2 0.88 (22mm) 0.63 (16) 0.38 (9.6) 0.63 (16) 1.09 (28) 4.38 (111)
D F
22 HA-3,22 to 4 (101mm) 1 (25.4) 0.38 (9.6) 0.63 (16) 1.09 (28) 4.38 (111)
E
HA-24 0.69 (17.5) 0.19 (4.8) 0.25 (6.3) 0.72 (18) 4.38 (111)
0.69 HA-5,8 0.63 (16) 0.19 (4.8) 0.25 (6.3) 0.72 (18) 4.75 (121)
17.5 HA-6 0.63 (16) 0.38 (9.6) 0.63 (16) 1.09 (28) 4.75 (121)
0.88 (22mm)
HA-7,23 1 (25.4) 0.38 (9.6) 0.63 (16) 1.09 (28) 4.75 (121)
Approximate shipping weights to 4 (101mm)
HA-25 0.69 (17.5) 0.19 (4.8) 0.25 (6.3) 0.72 (18) 4.75 (121)
range from 0.13 to 0.25 lbs. HA-26 2 (51) 0.19 (4.8) 0.25 (6.3) 0.72 (18) 4.75 (121)
NOTE: Type HA-1 shown in photo.
With arm and clamp in position shown in above dimension drawing, distance from switch shaft to center of arm roller (Dia. A) is adjustable
10.72 from 0.88" (22) to 3.63"(92). By removing arm from clamp, turning clamp upside down and replacing arm, Dimension A is adjustable from
272 1.19
0.41 1.25"(32) to 4"(102).
0.16 30
4 0.52 10
13 360° Angular Adjustable Lever Arms
0.13 Dia.
Roller (Can be changed in the field from roller outside
9.97 Max. 3.3 to roller inside position or vice versa)
253
0.41 Standard Standard Nylon Nylon Ball Bearing
10 Length 0.63" (16) Dia. 0.75" (19) Dia. 0.63" (16) Dia. 0.75" (19) Dia. 0.69" (17.5) Dia.
0.80 of 0.25" (6.3) Wide 0.25" (6.3) Wide 0.25" (6.3) Wide 0.25"(6.3) Wide 0.25" (6.3) Wide
20 Arm
360° Roller Roller Roller Roller Roller Roller
Angular Outside Inside Outside Outside Outside Outside
Type FA1 Adjustable Type Type Type Type Type Type
Lever Arm
0.88" (22) AA-1M AA-5M AA-11M AA-8M AA-18M AA-9M
1.38" (35) BA-1M BA-5M BA-11M BA-8M BA-18M BA-9M
4.31
1.5" (38) MA-1M MA-5M MA-11M MA-8M MA-18M MA-9M
Limit Switches
109
0.75 DIA. 2" (51) CA-1M CA-5M CA-11M CA-8M CA-18M CA-9M
19 2.5" (63.5) DA-1M DA-5M DA-11M DA-8M DA-18M DA-9M
3" (76) EA-1M EA-5M EA-11M EA-8M EA-18M EA-9M
2.56
65
Rod Type Lever Arms
2.5 Rod Type
0.39 63.5 0.66
9.9 17
10" (254) Stainless Steel Rod FA-1
0.72 12" (304) Spring Rod, Steel FA-3
0.78
18 0.41 Rod Type
19.8 12" (304) Spring Rod, DELRIN FA-5
10 Lever Arm
Looped Delrin Rod Arm FA-6
Type LA19 90° Forked Rod
2.5" (63.5) Spring Rods, Steel LA-19
NOTE: Standard roller is hardened oil-impregnated sintered iron. Bold face type numbers indicate the most commonly used lever arms
2.06 Approx. 1.31 12.66

0.52 12.66 1.19
33 1.19 322
52 13 322 30 0.52
30 0.52
0.41 13 0.28 13
10 0.45 (11.4) 0.41 0.41
10 10
12 Max.
305
0.39 0.39
5.5 Approx. 0.41 0.250 DIA.
0.075 9.9 9.9
12.7 0.13 Dia. 10 6.3 0.72
1.9 0.72
3.3 0.80 18 18
20
Dual Dimensions inches

mm
484
EF3326EN.0.0
EF3326EN.0.0
R. Stahl ConSig 8040 Instruções de Operação
Source: R. Stahl, Inc. publication S-BA-8040-pt-02-15/06/2007 204164 8040617300, downloaded May 19, 2011.
EF3431PT.0 1
2 R. Stahl ConSig 8040 Instruções de Operação
EF3431PT.0
R. Stahl ConSig 8040 Instruções de Operação 3
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
EF3431PT.0
Timken® Spherical Roller Bearing Mounting Procedure
Outside Source Information
Source: Timken® Spheircal Roller Bearing Catalog, pages 103–105, © 2007 The Timken Company, downloaded from Timken.com Jan. 8, 2010.
EF3336EN.0.1 1
2 Timken® Spherical Roller Bearing Mounting Procedure
EF3336EN.0.1
Timken® Spherical Roller Bearing Mounting Procedure 3
EF3336EN.0.1
4 Timken® Spherical Roller Bearing Mounting Procedure
EF3336EN.0.1
EC Declaration of conformity
of the machinery
Acc. to 20061421EC - Annex ll, 1, A
CPM-Roskamp Champion
2975 Airline Circle
Waterloo, lowa 50703
U.S.A.
Telephone : 319.232.8444
E-mail : olsonb@cpmroskamp.com
herewith declares that:
Name: 1200-72
Function: Crumbler Mill
Model: CMXl2OO-720S
Type:
Serial number: 442753
Year: 2015
is ín accordance to the following directives
Directive 20061 42lEC (Mach ines)

Directive 2006i9s/EC (Low Voltage)
Directive 94l4lEC (ATEX), Glassification ll 3 D c T 125"G
and (where appropriate) is in conformity with the following standard(s) or other

such specifications:
EN-ISO 12100-1 (Safety of Machinery)

EN-ISO 12100-2 (Safety of Machinery)
EN-|SO 60204ll (Safety of Machinery - Electrical equipment)
Other specifications or certificates

P reduced = N/A
Place: Waterloo, lowa

Date: March 12,2015
Name:
Signature
Function: and Documentation

Manual Triturador CPM

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CPM PAGE ONE ITEMS

SERIAL NUMBER: 442753

QUANTITY PART NUMBER DRAWING PART DESCRIPTION

MAIN DRIVE: ILLUSTRATIONS:

ITEM QUANTITY PART NUMBER PART DESCRIPTION

ITEM QUANTITY PART NUMBER PART DESCRIPTION

ITEM QUANTITY PART NUMBER PART DESCRIPTION

1.00 3817502 Switch,Emergency Stop Stahl

1.00 7202304 Bracket, 'E' Stop Switch

ITEM QUANTITY PART NUMBER PART DESCRIPTION

ITEM QUANTITY PART NUMBER PART DESCRIPTION

025 12.00 3784552 Nut,Panel Lube

030 12.00 3784557 Zerk,Straight 1/4-28 5010

ITEM QUANTITY PART NUMBER PART DESCRIPTION

015 1.00 0630100 Bellows,9-1/4 Lg 1000

025 2.00 3114100 Cotter Pin - 1/8 D. X 1"

030 1.00 3116514 Valve,1/4" 4W XP Dbl Sol 24VDC

060 1.00 3756501 Pin, Clevis 1/2" X 2-1/4"

075 1.00 5325201 Key - 3/16 Sq. X 1" Long

080 1.00 7155000 Washer, Bellows Retainer

ITEM QUANTITY PART NUMBER PART DESCRIPTION

ITEM QUANTITY PART NUMBER PART DESCRIPTION

005 6.00 3016726 Belt,5VX750

010 2.00 3793901 Sheave,Qd 3-5V8.5"Od Sf

015 2.00 3793903 Sheave,QD 3-5V16.0" OD E

020 2.00 73604 Bushing,QD E 60mm

025 2.00 8118301 Base,Motor Single/Top 3 Pair

ITEM QUANTITY PART NUMBER PART DESCRIPTION

1.00 3376600 Sealant,RTV

001 4.00 0605910 Bracket,Pressure Spring

015 8.00 3786600 Bolt,Eye M24 X 3.0 X 75mm

035 4.00 7242610 Plate,Cheek 1000/1200

045 4.00 7243152 Insert,Wear Standard FP

055 4.00 7244304 Pressure Member Rear Cast

060 4.00 7244324 Pressure Member Front Cast

ITEM QUANTITY PART NUMBER PART DESCRIPTION

150 1,000.00 87255 Seal,Trim 3100-B3X1/8A

160 2.00 7315400 Cover,Frnt Slot 12 CMX RH

ITEM QUANTITY PART NUMBER PART DESCRIPTION

4.00 3772800 Handle,Pull

005 1.00 7315000 Plate,Backing - IRD (RH Drive)

ITEM QUANTITY PART NUMBER PART DESCRIPTION

005 2.00 7315270 Door, Maint. - CMX1200-72

ITEM QUANTITY PART NUMBER PART DESCRIPTION

4.00 7244730 Tube,Spacer - Idler Arm

005 4.00 3384800 Spring,Die 2"OD X 1"ID X 6"

020 2.00 3781603 Sheave,TL 3A9.0/B9.4 2517

025 8.00 3783701 Brg,ER35 2-3/16" Bore

035 2.00 3789300 Label,IRD Belt Tension Gauge

050 2.00 7244615 Tension Arm Pivot Bar

065 2.00 7244635 Bolt,Idler Pivot Tension

070 2.00 7244690 Scale,IRD Tension XPB

075 2.00 7244710 Shaft,Main Idler 6-Groove IRD

080 2.00 7244715 Shaft,Idler 6 Groove IRD

ITEM QUANTITY PART NUMBER PART DESCRIPTION

005 2.00 3060900 Collar,Set 1" Steel

010 2.00 3772800 Handle,Pull

015 2.00 3782000 Bearing,FY45FM,45mm 4-B Flange

065 2.00 7316831 Door, Inspection FDR-72

ITEM QUANTITY PART NUMBER PART DESCRIPTION

ITEM QUANTITY PART NUMBER PART DESCRIPTION

035 1.00 3764150 Valve,1/2"Npt Lockout Air

060 4.00 7157701 Collar Thrust Nook Jack

100 2.00 7378505 Back Plate, Roll Adjust Shaft